Utility Systems

Utility Systems – Steam, Power, Hot Water and Chilling Water

Process industries are typically served by utility systems that provides the necessary energy to carry out day-to-day operations. The most common utility systems include steam, electricity and water. PIL delivers a set of operating guidelines, retrofit options and deploys an online monitoring and optimization tool that can substantially reduce your operating cost and carbon emissions.

What are the Issues with Utility Systems?

Very energy intensive

Very Energy Intensive

Utilities, such as steam and electricity, consume a large amount of fuel during production. It is very energy intensive and requires high operating costs.

Frequent Changes in Process Demand

Steam and power demands in processes frequently change that results in variations in utility system operations.

Frequent changes in steam demand
Variable Tariffs

Variable Tariffs

Steam and electricity prices can vary frequently. Therefore, the operations for utility system should be adjusted accordingly.

Rigid Steam Distribution Infrastructure

Some utility sites have a steam grid not flexible enough to accommodate the steam reduction obtained from energy-saving projects. As a result, instead of achieving the desired steam savings, the steam is vented without being efficiently utilized.

Legacy steam distribution infrastructure
Old piping system

Out-of-date Pipeline System

An out-of-date steam pipeline in an old plant has issues such as steam condensation and hammering, which could compromise the safety of the piping system.

PIL’s Offline Engineering Solutions

PIL provides offline solutions that require no CAPEX to maintain optimum operations during steam demand variations. Additionally, we propose roadmaps for implementation of revamp projects, at different time intervals based on clients' resources and future planning.

  • Solutions with No CAPEX Required
  • Solutions with Low to Medium CAPEX Required

Operational Optimization: The following key operational parameters are adjusted in a utility system to bring operational savings (typically between 2-7% per year of existing operating expenditure) without CAPEX:

  • Best Fuel Combination for Boilers and Gas Turbines
  • Optimal Load for Boilers, Gas Turbines, HRSG, Steam Turbines and Heat Recovery Generators
  • Key Temperature for Water
  • Best Steam Distribution across the Steam Pipelines
  • Best Pressures for Headers and Deaerators

Retrofit Optimization: The following revamping opportunities could be implemented to bring utility system operational savings (typically between 5-15% per year of existing operating expenditure) with low to medium CAPEX:

  • Pipeline Revamping
  • Letdown Station Retrofit
  • Heat Exchangers Network Retrofit
  • Driver Selection

PIL’s Online Monitoring and Optimization Tool

PIL provides online monitoring and optimization module that combines with clients' existing Steam Management System. Our solution can continually optimize, and report optimum operating values based on the user-defined system constraints every 10-15 minutes. Operators can adjust the operational set points based on the recommendations from the online optimization tool.