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The DHT upgrades consisted of:
" installing variable speed drives (VSDs) on the 2,250-hp primary feed pump
and 700-hp product pump
" replacing the internal elements on the 2,250-hp secondary feed pump and
a 400-hp power recovery turbine (PRT)
. changing operating procedures for the main 5,000-hp and 4,000-hp
backup pumps.
The upgrade project began when Planergy Services, Inc.-a nationwide energy
services company and a Motor Challenge Allied Partner-responded to a request
for proposals from Pacific Gas & Electric Company (PG&E) for energy conservation
and generation projects. PG&E contracted with Planergy to reduce industrial con-
sumption by 23 million kWh per year. In early 1995, with that goal in mind,
Planergy approached Chevron's Moffitt with an offer to provide VSDs and pump
upgrades at no cost to Chevron. Moffitt relayed information on Planergy's offer
to Lubcyik at the Richmond refinery. After an initial candidate project was deter-
mined to be unfeasible, Mares recommended the DHT project.
"It's a 'win-win-win' situation," says Moffitt, "we save money, we save energy, and we
conserve natural resources." The DHT's operators are constantly reminded of the
effect the VSDs have on the plant's operating costs. A sign on the 700-hp VSD con-
trol units says, "RUNNING THIS PUMP WITH VSD SAVES $120,000 PER YEAR IN
ELECTRICAL SAVINGS." Another sign on the 2,250-hp VSD states, "RUNNING
THIS PUMP WITH VSD & PRT SAVES $220,000/YR IN ELECTRICAL SAVINGS."
Appropriately, there are dollar signs at the corners of the sign.Chevron paid no up-front capital costs for the DHT upgrade project. Instead,
Planergy installed the equipment at no cost to Chevron in return for a share of the
savings resulting from the project. Energy consumption was reduced by 1 million
kWh a month, resulting in $700,000 cost savings annually. In addition, Chevron is
no longer levied a demand charge on the DHT's operation. Two other winning
aspects of the upgrade project were improved equipment reliability and improved
process control.
To complete the project by the May 1, 1997, deadline, Lubcyik assembled a project
team that included Mares; Anne Broughton, Project Engineering; Jay Lindstrom,
D&R Project Operator; Bill Kane, Control Engineer; and Alroy Barker, Instrument &
Electrical Shop. Lubcyik's team was joined by personnel from Allen-Bradley, manu-
facturer of the VSDs, and Ingersoll-Dresser, which assisted with the pump rerates.
Chevron decided to let Planergy contract out the work in an effort to minimize the
labor impact on the D&R unit. In April of 1997, the project was completed.Motor Challenge, administered by
the Office of Industrial Technologies,
is a voluntary partnership program
with U.S. industry to promote the
use of energy-efficient electric motor
systems. Thousands of industrial
partners have joined Motor Challenge
and are improving their competitiveness
and efficiency and, in turn, the
Nation's.
Motor Challenge assists the
petroleum industry and other
OIT Industries of the Future by
identifying near-term gains in
energy efficiency these industries
can achieve by adopting existing
technologies.
PROJECT PARTNERS
Chevron Refinery
Richmond, CA
Planergy Services, Inc.
Richmond, CA
Allen-Bradley
Milwaukee, WI
Ingersoll-Dresser Pump Company
Liberty Corner, NJ
FOR ADDITIONAL INFORMATION,
PLEASE CONTACT:
The OIT Information Clearinghouse
Phone: (800) 862-2086
Fax: (360) 586-8303
http://www.motor.doe.gov
Visit our home page at
www.oit.doe.gov
Please send any comments,
questions, or suggestions to
webmaster.oit@ee.doe.gov
Office of Industrial Technologies
Energy Efficiency
and Renewable Energy
U.S. Department of Energy
Washington, D.C. 20585
DOE/GO-10099-734
January 1999
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Ericksen, E. Petroleum--Project Fact Sheet: A Motor Challenge Success Story, book, January 27, 1999; Golden, Colorado. (https://digital.library.unt.edu/ark:/67531/metadc694771/m1/2/: accessed April 23, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.