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MONITORING REPORT
Petrotemex Energy Integration Project
1
Grupo Petrotemex S.A. de C.V.
Verification Plus
Monitoring Report
of
Petrotemex Energy Integration Project UNFCCC Number: 1453
Version 04
22/12/2008
Monitoring period 20/11/2007 to 4/05/2008
Project location Grupo Petrotemex, S.A. de C.V.
Belisario Domínguez 2002, Colonia Obispado
Nuevo León, Mexico
http://www.alfa.com.mx
Prepared by MGM International Group LLC
501 Brickell Key Dr, Suite 202
Miami, FL 33131
http://www.mgminter.com
2
TABLE OF CONTENTS
TABLE OF CONTENTS ........................................................................................ 2
1 INTRODUCTION ........................................................................................... 3
2 REFERENCE .................................................................................................. 3
3 GENERAL DESCRIPTION OF THE PROJECT ACTIVITY ..................... 3
3.1 OBJECTIVES OF THE PROJECT............................................................ 3
3.2 PROJECT PARTICIPANTS ...................................................................... 4
3.3 TECHNICAL DESCRIPTION OF THE PROJECT ................................. 5
4 PROJECT LOCATION .................................................................................. 6
5 CURRENT STATUS OF THE PROJECT ..................................................... 6
6 MONITORING PLAN .................................................................................... 6
6.1 DATA MONITORED .................................................................................. 6
6.2 QUALITY CONTROL (QC) AND QUALITY ASSURANCE (QA) ........12
6.3 FIXED PARAMETERS .............................................................................12
6.4 OPERATIONAL AND MANAGEMENT STRUCTURE .........................12
6.5 MEASURING INSTRUMENTS ................................................................14
6.6 CALIBRATION EQUIPMENT .................................................................15
6.7 MAINTENANCE PROCEDURES ............................................................17
6.8 SPREADSHEET MODELS .......................................................................17
7 ENVIRONMENTAL IMPACT .....................................................................19
8 EQUATIONS USED FOR CALCULATION OF EMISSION
REDUCTIONS .......................................................................................................19
9 EMISSION REDUCTION CALCULATION................................................23
MONITORING REPORT
Petrotemex Energy Integration Project
3
1 INTRODUCTION
The objective of this Monitoring Report is to show the calculation of the emission reductions
achieved by the project activity under the Voluntary Market and verified by a Designated
Operational Entity.
The monitoring period is from 20/11/2007 to 4/05/2008 (both days included).
The report also shows the Monitoring and Verification Plan for data collection and auditing
followed by the project developer in order to determine real and credible emission reductions.
2 REFERENCE
The monitoring plan is in accordance with the registered project design document of
Petrotemex Energy Integration Project, Version 10 of 08/02/20081, that uses existing baseline
and monitoring methodologies (AM0018/Version01.1 of 06/12/2004 and
ACM0004/Version02 of 03/03/2006), which have been approved and made publicly available
by the CDM Executive Board. The methodologies are designated “Methodology for steam
optimization systems” and “Consolidated methodology for waste gas and/or heat and/or
pressure for power generation”.
According to the methodology ACM0004/Version02, the emission factor of the grid is
determined using the methodology ACM0002/Version06 of 19/05/2006.
3 GENERAL DESCRIPTION OF THE PROJECT ACTIVITY
3.1 OBJECTIVES OF THE PROJECT
The project activity aims at reducing GHG emissions (mainly carbon dioxide and, to a lesser
extent, methane and nitrous oxide) through the implementation of a series of mitigation
measures that involve fuel and electricity savings as well as the installation of new electricity
self-generation equipment.
These goals will be achieved through a process of energy integration, leading to lower
consumption of steam from boilers and lower electricity demand to the national grid, thus
reducing overall fuel usage. Besides, additional power will be generated using remaining low-
quality steam produced from waste heat of the production process.
Petrotemex will lead this project activity that involves its production plants of Pure
Terephthalic Acid (PTA), located at Cosoleacaque and Altamira, in Mexico.
Petrotemex is a business of Alpek Group, subsidiary of Alfa, oriented to the production of
raw materials for polyester yarn, Polyethylene terephthalate (PET) and other products.
The project activity generates the inherent benefits of fuel and electricity savings, and clean
self-generation:
� Petrotemex technical staff has carried out studies in order to design the best option for
energy saving for each plant, which involves adaptation and transference of efficient
and clean technology to the productive sector.
1 http://cdm.unfccc.int/UserManagement/FileStorage/TYH8ELFNEMX7K4OBCQ93I48HVDE078
MONITORING REPORT
Petrotemex Energy Integration Project
4
� As a result of the project activity, there is an improvement in plant efficiency in a
thermodynamic sense, reducing fuel burning at the plant site, and reducing electricity
purchases, thus decreasing electricity generation outside the industrial facility.
� The energy savings obtained through the project activity contributes to the sustainable
use of natural resources, and to improve the environment by reducing emission of
pollutants and particulate matter in the air.
� The project activity generates economic benefits related to CDM and Voluntary
Market revenues. The benefit obtained by selling CERs and VERs will allow
Petrotemex to invest in further research and development and to cover part of the
initial investment and the unexpected costs of project implementation and operation.
� The project activity improves de air quality and the cleanliness of the work site, thus,
improving the labor and health conditions of the employees.
� The project activity provides job opportunities during the construction phase of the
project. About 100 new work positions are needed during this phase.
Thus, the project activity involves social, environmental, and economic benefits, contributing
to the sustainable development objectives of Mexican Federal and State authorities, in
accordance with the development plans of:
� Mexico (Plan Nacional de Desarrollo 2001-20062),
� Veracruz State (Plan Veracruzano de Desarrollo 2005-20103), and
� Tamaulipas State (Plan Estatal de Desarrollo 2005- 20104).
The project proponent has obtained the written approval of the Mexican DNA, confirming
that the project supports sustainable development.
3.2 PROJECT PARTICIPANTS
Organization: Grupo Petrotemex, S.A. de C.V.
Street/P.O.Box: Belisario Domínguez 2002, Colonia
Obispado
City: Nuevo León
Postfix/ZIP: 64060
Country: Mexico
Telephone: 52 81 8748-1355
FAX: 52 81 8748-2525
2 http://www.economia.gob.mx/pics/p/p1376/PLAN1.pdf
3 http://portal.veracruz.gob.mx/portal/page?_pageid=273,3913793&_dad=portal&_schema=PORTAL 4 http://www.tamaulipas.gob.mx/gobierno/plan_estatal/plan%20estatal%20de%20desarrollo.pdf)
MONITORING REPORT
Petrotemex Energy Integration Project
5
URL: http://www.alfa.com.mx
Name of the person in
charge Roberto Blanco Sánchez
Personal E-Mail: rblanco@alfa.com.mx
3.3 TECHNICAL DESCRIPTION OF THE PROJECT
The project activity involves the two PTA production plants of Petrotemex, one located in
Cosoleacaque and the other one in Altamira.
Cosoleacaque Plant
The project activity involves the reduction of overheated steam generation in boilers by
switching from the existing turbo-compressors to a new high-efficiency turbo-compressor.
The new turbine of such compressor will utilize surplus low-pressure steam from PTA
production process, instead of the overheated steam used by the existing compressors.
The project also involves the reduction of low-pressure steam consumption from the PTA
production process by increasing of low-pressure steam generation using waste heat from
such process. In order to achieve that, the following mitigation measures were carried out:
• Switching from binary distillation to azeotropic distillation in dehydration columns.
• Incorporation of a new process of thermo-compression of the steam used in the
reboiler of the dehydration tower.
• Switching the current dehydration columns’ condensers to new condensers that
generate low-pressure steam.
• Installation of new systems generating low-pressure steam using the heat released by
the oxidation reaction of p-xylene.
In addition, steam consumption is reduced by shutting down the low-pressure steam turbine
connected to turbo-compressor.
Due to the availability of the low-pressure steam flows mentioned above, the generated
energy surpasses the requirements of the new turbo-compressor. Thus, the project also
involves the installation of an electricity generator integrated to the new compression train to
obtain the complete use of energy.
Additionally, the project activity also involves changes in electricity consumption due to the
shutting down of the condenser fans of the dehydration towers, the moto-compressor, among
other equipment, and the installation of more-efficient new equipment like motors and pumps
(actually, there are electricity savings due to the project activity, but they are not considered
in the calculation of emission reductions as a conservative assumption).
Altamira Plant
The project activity involves the reduction of low-pressure steam consumption used as means
of heating the reboilers in dehydration column, by switching from binary to azeotropic
distillation. The more-efficient low- pressure steam generated by azeotropic distillation will
be used to generate electricity in a new turbo-generator, in order to obtain the complete use of
energy resulting from the availability of low-pressure steam flow mentioned above.
MONITORING REPORT
Petrotemex Energy Integration Project
6
The project activity also involves taking advantage of the additional energy benefits obtained
when expanding plant capacity to 900,000 tPTA/year in 2007, generating more steam that can
be used in the turbo-generator to produce additional power output. The proposed project
activity already considers such an expansion so as to capture these future benefits with no
additional investment.
4 PROJECT LOCATION
The project activity was implemented at the production facilities of Petrotemex, located in
Cosoleacaque and Altamira, in the States of Veracruz and Tamaulipas, respectively.
The exact coordinates of the project sites are 18° 1’ 56” North and 94° 35’ 43” West for
Cosoleacaque plant, and 22° 22’ 44’’ North and 97° 53’ 32’’ West for Altamira plant.
5 CURRENT STATUS OF THE PROJECT
In Cosoleacaque plant, the project activity started operating in the lately months of 2005 and
reach its stable operation on March 2006, while in Altamira plant, the project activity started
operating on January 2008.
The Petrotemex Energy Integration Project started operating in the lately months of 2005. A
first VER verification was done on 19/11/2007 under the VSC version 1.
The first voluntary crediting period started on 01/11/2005.
The CERs generation began on 05/05/2008, when the project was registered as a CDM
project activity.
6 MONITORING PLAN
6.1 DATA MONITORED
Since the monitoring plan of the proposed CDM project was not completely implemented
until the project was registered as CDM, the data used to determine the emission reductions
obtained from 20/11/2007 to 4/5/2008 was collected by Petrotemex’ staff following a
monitoring plan with some differences, comparing to the requirement of the methodologies
applied to the CDM project. In order to explain these minor differences, the registered
monitoring plan and the monitoring plan used in this monitoring period are shown in the
following tables.
MONITORING REPORT
Petrotemex Energy Integration Project
7
Cosoleacaque Plant
# Data
variable Data unit
Recording frequency
(registered
PDD)
Comment
(registered PDD)
Monitoring plan used in the monitoring period from
20/11/2007 to 4/5/2008
1 PTA
production tonne
every shift
PTA production in
Cosoleacaque plant.
Value determined by
mass balance based on
solids concentration and
flow rate feed to the purification reactors
(CR-202-A/B) of
Cosoleacaque plant.
Each reactor feed
pipeline have one Micro
Motion flow meter
(CWT-110 and CWT-
112A2). A third Micro
Motion (CWIC-201)
measures the solid
concentration in the
slurry drum (CD-101).
Value determined by mass
balance based on solids concentration and flow rate feed
to the purification reactors (CR-
202-A/B) of Cosoleacaque
plant.
Recording frequency: daily
2 Steam
consumption tonne every shift
Steam consumption by the compression room of
Cosoleacaque plant.
It is measured by orifice
plates (AFE-131, AFE-
4131, and AFE-1103)
and transmitters (AFT-
131, AFT-4131, and AFT-1103) installed at
the turbine inlet 42
kg/cm2 steam pipelines
of each turbo-compressor
(ACT-101, ACT-103,
and ACT-104) of
Cosoleacaque plant.
For the new turbo-compressor,
the steam flow meters are BFI-
1140, BFIR-960B, and
AFIR_360 (BFE-1140 turbine
inlet, BFE-960B second
pressure reduction valve, and AFIR-360 first pressure
reduction valve).
For the existing turbo-compressors, it is measured by
orifice plates (AFE-131, AFE-
4131, and AFE-1103) and
transmitters (AFT-131, AFT-
4131, and AFT-1103) installed
at the turbine inlet 42 kg/cm2
steam pipelines of each turbo-
compressor (ACT-101, ACT-
103, and ACT-104) of
Cosoleacaque plant.
Recording frequency: every
shift
MONITORING REPORT
Petrotemex Energy Integration Project
8
# Data
variable Data unit
Recording frequency
(registered
PDD)
Comment
(registered PDD)
Monitoring plan used in the
monitoring period from
20/11/2007 to 4/5/2008
3 Steam
temperature ºC
every shift
Temperature of the steam generated at the boiler
room of Cosoleacaque
plant.
This value is used to
determine the steam
enthalpy.
It is measured by thermo
couples installed at each
boiler exit pipeline
(ATE-336-A/B/D and
ATE-309-C) of
Cosoleacaque plant.
In this case, a unique value of
steam enthalpy is used, which is obtained according to design
conditions provided by AMOCO
(temperature and pressure) of
the generated steam. These
conditions are significantly
constant during the operation of
the plant.
Recording frequency: unique
value
4 Steam
pressure kg/cm
2
every shift
Pressure of the steam generated at the boiler
room of Cosoleacaque
plant.
This value is used to
determine the steam
enthalpy.
It is measured by
pressure transmitters
installed at each boiler
exit pipeline (APT-311-
A and APT-310-B/C/D)
of Cosoleacaque plant.
In this case, a unique value of steam enthalpy is used, which is
obtained according to design
conditions provided by AMOCO
(temperature and pressure) of
the generated steam. These
conditions are significantly
constant during the operation of
the plant.
Recording frequency: unique
value
5 Feed water
temperature ºC
every shift
Temperature of the water
feed to the boiler room of
Cosoleacaque plant.
This value is used to
determine the feed water
enthalpy.
It is measured by
temperature indicators
(before de-aerator and
economizer) at the end of
each shift in
Cosoleacaque plant.
In this case, a unique value of
feed water enthalpy is used,
which is obtained according to
design conditions provided by
AMOCO (temperature) of the
feed water. This condition is
significantly constant during the
operation of the plant.
Recording frequency: unique
value
MONITORING REPORT
Petrotemex Energy Integration Project
9
# Data
variable Data unit
Recording frequency
(registered
PDD)
Comment
(registered PDD)
Monitoring plan used in the
monitoring period from
20/11/2007 to 4/5/2008
6 Steam
generation tonne daily
Steam generation by the boiler room of
Cosoleacaque plant.
It is measured by orifice
plates and transmitters
installed at each boiler
exit pipeline (AFE-309-
A/B/C/D and AFT-309-
A/B/C/D) of Cosoleacaque plant, and
the total steam generated
is determined by an
algorithms configured in
the DCS (AFQI-
301ABC).
It is measured by orifice plates
and transmitters installed at each
boiler exit pipeline (AFE-309-
A/B/C/D and AFT-309-A/B/C/D) of Cosoleacaque
plant, and the total steam
generated is determined by an
algorithms configured in the
DCS (AFQI-301ABC).
Recording frequency: daily
7 Fuel
consumption m
3 daily
Consumption of each
fuel in the boiler room of
Cosoleacaque plant.
It is measured by orifice
plates and transmitters installed at each boiler
natural gas pipeline
(AFE-306-A/B/C/D and
AFT-306-A/B/C/D) and
Micro Motion flow
meters installed at each
boiler fuel oil pipeline
(AFT-306-A2/B2 and
AFT-305).
The natural gas consumption is measured by flow meters
installed at each boiler natural
gas pipeline (AFIR-306A.SQR
in boiler AB-301A, AFIR-
306B.SQR in boiler AB-301B,
AFR-306C.SQR in boiler AB-
301C, and AFR-306D in boiler
AB-301D).
The fuel oil consumption is
measured by flow meters
installed at each boiler fuel oil
pipeline (AFIR-306A2 in boiler
AB-301A, AFIR-306B2 in
boiler AB-301B, and AFR-305D
in boiler AB-301D).
Recording frequency: daily
8
Lower heating
value of
fuels
MMBtu/m3
with every delivery of
fuel
Lower heating value of
each fuel consumed at
the boiler room of
Cosoleacaque plant.
Determined by fuel oil
analysis made by the
supplier laboratory for
each delivery and by an
external laboratory as
required.
For the natural gas, this
analysis results can be
consulted as needed in
supplier’s Web site and
can be validated by an external laboratory as
required.
A unique value of lower heating value obtained through
laboratory analysis of each fuel
is considered.
Recording frequency: unique
value
MONITORING REPORT
Petrotemex Energy Integration Project
10
# Data
variable Data unit
Recording frequency
(registered
PDD)
Comment
(registered PDD)
Monitoring plan used in the
monitoring period from
20/11/2007 to 4/5/2008
9 Fuel
composition %
with every
delivery of
fuel
Composition of each fuel consumed at the boiler
room of Cosoleacaque
plant, on weight basis.
Determined by fuel oil
analysis made by the
supplier laboratory for
each delivery and by an
external laboratory as
required.
For the natural gas, this
analysis results can be
consulted as needed in
supplier’s Web site and
can be validated by an
external laboratory as
required.
Composition of each fuel
consumed at the boiler room of
Cosoleacaque plant, on weight
basis.
Determined by fuel oil analysis
made by the supplier laboratory for each delivery and by an
external laboratory as required.
For the natural gas, this analysis results can be consulted as
needed in supplier’s Web site
and can be validated by an
external laboratory as required.
Recording frequency: unique
value
10 Retrofit NA when occurs
Future retrofitting within
the project boundary, at
Cosoleacaque plant.
The enhanced steam
saving due to the impact of a retrofit should be
estimated and deducted
from claimed emission
reductions.
N/A
11 Electricity
generation MWh monthly
Electricity generation at
Cosoleacaque plant.
Value measured. Using
the generated voltage and
the current signals from the electric generator, a
transducer converts
continuously to power
signal (BXI-124)
Value measured. Using the
generated voltage and the
current signals from the electric
generator, a transducer converts
continuously to power signal
(BXI-124).
Recording frequency: monthly
12
Auxiliary
electricity
consumption
MWh monthly
Auxiliary electricity used
by power generating
equipment at
Cosoleacaque plant.
Electricity consumption
is measured continuously
by power meters.
Only the control panel of the
generation equipment consumes
electricity. In this case, the electricity consumption is not
measured, but estimated
according to data from the
provider of the control panel.
Recording frequency: monthly
MONITORING REPORT
Petrotemex Energy Integration Project
11
Altamira Plant
# Data
variable Data unit
Recording
frequency
(registered
PDD)
Comment
(registered PDD)
Monitoring plan used in the monitoring period from
20/11/2007 to 4/5/2008
13 Electricity
generation MWh monthly
Electricity generation at
Altamira plant.
Value measured. Using the generated voltage and
the current signals from
the electric generator, a
transducer converts
continuously to power
signal (AXI-310).
Value measured. Using the
generated voltage and the
current signals from the electric
generator, a transducer converts
continuously to power signal
(AXI-310).
Recording frequency: monthly
14
Auxiliary electricity
consumption
MWh monthly
Auxiliary electricity used by power generating
equipment at Altamira
plant.
Electricity consumption
is measured continuously
by power meters.
Electricity consumption is estimated in a conservative
manner using equipment
specifications.
Recording frequency: monthly
In addition, emissions of NOx, COx, SOx, and particulate matter will be measured in order to
detect environmental impacts of the project and to ensure compliance with environmental
regulations.
As part of the routine of Petrotemex, perimeter noise measurements and medical
examinations to all the personnel are carried out in Cosoleacaque and Altamira plants.
In Altamira plant, the perimeter noise is monitored in an annual basis and control measures
are established in accordance with the results. Complete medical examinations of the
personnel are carried out on an annual basis, including the administrative personnel.
Additionally, the Altamira plant has a continue communication with the local community,
through meetings that are included within the annual training program for the community
schools about preventing contamination. Mini-Olympics activities are included as a part of
this activity and, through answer addressing exercises, Altamira plant can get close to the
authorities and organize meetings with them.
In Cosoleacaque plant, the medical examinations (clinical analysis, radiographies, ocular
analysis, and audiometry) are carried out annually to all the personnel, and the perimeter noise
is monitored according to the Mexican norms.
All the monitored data, including data related to sustainability indicators, will be registered
and stored according to the procedures developed by the company.
Additionally, all the data monitored will be filed until two years after finishing the crediting
period.
MONITORING REPORT
Petrotemex Energy Integration Project
12
6.2 QUALITY CONTROL (QC) AND QUALITY ASSURANCE (QA)
All the measuring instrument signals are connected to the Distributed Control System (DCS)
and their data are exported and stored in the database of the PI system.
Additionally, the value of PTA production determined by mass balance is verified daily by
silos inventories and the product shipment.
6.3 FIXED PARAMETERS
The following table shows the fixed parameters that will not be monitored and that will be
used in calculation of emission reductions.
Parameter Value Source
Emission factor of residual fuel
oil
0.08166 tCO2/MMBtu
and 77.40 tCO2/TJ
2006 IPCC Guidelines for National Greenhouse
Gas Inventories, Chapter 1, Table 1.4, Page 1.23
Emission factor of natural gas 0.05919 tCO2/MMBtu
and 56.10 tCO2/TJ
2006 IPCC Guidelines for National Greenhouse
Gas Inventories, Chapter 1, Table 1.4, Page 1.24
Emission factor of diesel 74.10 tCO2/TJ 2006 IPCC Guidelines for National Greenhouse
Gas Inventories, Chapter 1, Table 1.4, Page 1.23
Emission factor of coal 94.60 tCO2/TJ 2006 IPCC Guidelines for National Greenhouse
Gas Inventories, Chapter 1, Table 1.4, Page 1.23
Oxidation factor of residual fuel
oil 0.990 IPCC Guidelines for National Greenhouse Gas
Inventories, Reference Manual, Volume 3 (1996),
Table 1-6, Page 1.29. Oil and Oil Products: 0.99.
Oxidation factor of natural gas 0.995 IPCC Guidelines for National Greenhouse Gas
Inventories, Reference Manual, Volume 3 (1996), Table 1-6, Page 1.29. Gas: 0.995.
Oxidation factor of diesel 0.990
IPCC Guidelines for National Greenhouse Gas
Inventories, Reference Manual, Volume 3 (1996),
Table 1-6, Page 1.29. Oil and Oil Products: 0.99.
Oxidation factor of coal 0.980 IPCC Guidelines for National Greenhouse Gas Inventories, Reference Manual, Volume 3 (1996),
Table 1-6, Page 1.29. Coal: 0.98.
Global Warming Potential (CH4) GWP (CH4)
21 IPCC, Climate Change 1995: The Science of Climate Change (Cambridge, UK: Cambridge
University Press, 1996).
Global Warming Potencial GWP (N2O)
310 IPCC, Climate Change 1995: The Science of Climate Change (Cambridge, UK: Cambridge
University Press, 1996).
6.4 OPERATIONAL AND MANAGEMENT STRUCTURE
Measurements in the levels of fuel and steam consumption as well as electricity and steam
generation after the project implementation is made by the production departments of the respective plants. The structure that the company will implement for the monitoring process is
showed through the following tables:
MONITORING REPORT
Petrotemex Energy Integration Project
13
Cosoleacaque Plant
Department Responsibility Monitoring Methodology
Raw Material Fernando Vásquez Daily Inventory consumption Physical tanks level measurement and
balance in-out
TA/PTA production
José Luis Sosa Valencia
PTA production Mass balance based on solids concentration
and flow rate feed to the purification
reactors (DCS, PI, and meter calibration)
OSBL
production
(utilities)
Fredy
Valenzuela
Zarrabal Steam consumption
Orifice plates and transmitters installed at
the turbine inlet 42 kg/cm2 steam pipelines
of each turbo-compressors (DCS, PI, and
meter calibration)
OSBL
production
(utilities)
Fredy
Valenzuela
Zarrabal Steam generation
Orifice plates and transmitters installed at
each boiler exit pipeline (DCS, PI, and
meter calibration)
OSBL
production (utilities)
Fredy
Valenzuela Zarrabal
Fuel flow measurement on line to the boilers
Orifice plates and transmitters installed at
each boiler natural gas pipeline and Micro
Motion flow meters installed at each boiler fuel oil pipeline (DCS, PI, and meter
calibration)
OSBL production
(utilities)
Fredy Valenzuela
Zarrabal Electricity generation
Transducer that converts the generated voltage and the current signals to power
signal (DCS, PI, and meter calibration)
Instruments
Maintenance Juan Alonso Iparrea
Medellín
Quality assurance for low uncertainties in the measurement
instruments ISO-9001 Instructions, procedures, and
planning maintenance
Environmental Carlos Roberto Vergara Herrera
Emissions of NOx, COx, SOx, and particulate matter
For third party inspection (external company)
Altamira Plant
Department Responsibility Monitoring Methodology
Operations Eduardo Anaya
Núñez de
Cáceres
Electricity generation Transducer that converts the generated
voltage and the current signals to power
signal (DCS, PI, and meter calibration)
Maintenance
Manuel
Vázquez
Zúñiga
Quality assurance for low
uncertainties in the measurement
instruments ISO-9001 Instructions, procedures, and
planning maintenance
Security and
Ecology Ernesto Flores
Emissions of NOx, COx, SOx,
and particulate matter For third party inspection (external
company)
MONITORING REPORT
Petrotemex Energy Integration Project
14
6.5 MEASURING INSTRUMENTS
The following tables show principal characteristics of measuring instruments to be used by
the company:
Cosoleacaque Plant
Instruction
number
Identification
number5
Variable Instrument Manufacturer Model Accuracy Range
CWIC-201* Solid
concentration
Controller
indicator
ABB MOD-
300
+/- 0.1 % 0-35 %
GMT-I-061 CWT-112A2 Solid
concentration
Flow
transmitter
MICROMOTION RFT9712 +/- 0.2 % 0-35 %
GMT-I-061 CWT-110 Solid
concentration
Flow
transmitter
MICROMOTION 9739 +/- 0.2 % 0-35 %
GMT-I-004 AFT-131 Steam
consumption
Flow
transmitter
YOKOGAWA EJA110 +/- 0.2 % 0-8,000
m3/hr
GMT-I-004 AFT-4131 Steam
consumption
Flow
transmitter YOKOGAWA EJA110 +/- 0.2 % tonne/hr
GMT-I-004 AFT-1103 Steam
consumption
Flow
transmitter YOKOGAWA EJA110 +/- 0.2 % tonne/hr
GMT-I-062 ATE-336A Steam
temperature
Temperature
element
MINCO +/- 0.2 %
GMT-I-062 ATE-336B Steam
temperature Temperature
element MINCO +/- 0.2 %
GMT-I-062 ATE-336D Steam
temperature Temperature
element MINCO +/- 0.2 %
GMT-I-062 ATE-309C Steam
temperature Temperature
element MINCO +/- 0.2 %
GMT-I-004 APT-311A Steam
pressure
Pressure
transmitter
YOKOGAWA EJA530A +/- 0.2 %
GMT-I-004 APT-310B Steam
pressure Pressure
transmitter YOKOGAWA EJA530A +/- 0.2 %
GMT-I-004 APT-310C Steam
pressure Pressure
transmitter YOKOGAWA EJA430A +/- 0.2 %
GMT-I-004 APT-310D Steam
pressure Pressure
transmitter YOKOGAWA YA43F +/- 0.2 %
GMT-I-004 AFT-309A Steam
generation
Flow
transmitter
YOKOGAWA EJA110 +/- 0.2 % 0-100
tonne/hr
GMT-I-004 AFT-309B Steam
generation Flow
transmitter YOKOGAWA EJA110 +/- 0.2 % 0-100
tonne/hr
GMT-I-004 AFT-309C Steam
generation Flow
transmitter YOKOGAWA EJA110 +/- 0.2 % 0-85
tonne/hr
5 The differences between the identification numbers shown in the registered monitoring plan and the
monitoring plan used from 20/11/2007 to 4/5/2008 are detailed in Section 6.1.
MONITORING REPORT
Petrotemex Energy Integration Project
15
Instruction
number
Identification
number5
Variable Instrument Manufacturer Model Accuracy Range
GMT-I-004 AFT-309D Steam
generation Flow
transmitter YOKOGAWA YA11F +/- 0.2 % 0-115
tonne/hr
GMT-I-004 AFT-306A Natural gas
consumption
Flow
transmitter
YOKOGAWA EJA110 +/- 0.2 % 0-8,000
m3/hr
GMT-I-004 AFT-306B Natural gas
consumption
Flow
transmitter YOKOGAWA EJA110 +/- 0.2 % 0-8,500
m3/hr
GMT-I-004 AFT-306C Natural gas consumption
Flow
transmitter YOKOGAWA EJA110 +/- 0.2 % 0-7,000
m3/hr
GMT-I-004 AFT-306D Natural gas
consumption
Flow
transmitter YOKOGAWA EJA110 +/- 0.2 % 0-8,981
m3/hr
GMT-I-061 AFT-306A2 Fuel oil consumption
Flow transmitter
MICROMOTION +/- 0.2 % 0-8,500 lt/hr
GMT-I-061 AFT-306B2 Fuel oil
consumption
Flow
transmitter
MICROMOTION +/- 0.2 % 0-8,500
lt/hr
GMT-I-061 AFT-305 Fuel oil consumption
Flow transmitter
MICROMOTION +/- 0.2 % 0-8,500 lt/hr
BXI-124 Power
generation
Transducer 0-11.6
MWh
Altamira Plant
Instruction
number
Identification
number6
Variable Instrument Manufacturer Model Accuracy Range
AXI-310 Power
generation Multifunction ABB
MGE
144
+/- 0.25
%
0-14.3
MWh
6.6 CALIBRATION EQUIPMENT
The calibration procedures implemented for the project are similar to those currently
implemented in Cosoleacaque and Altamira plants, because despite the project is an innovate
technological development, the equipment, recipients and instruments are of the same type
than those currently installed in the plants.
Petrotemex developed a specific Calibration Program for the equipment that is involved in the
CDM project. The maintenance management is in charge of the follow up of this program
through instruments department.
6 The differences between the identification numbers shown in the registered monitoring plan and the
monitoring plan used from 20/11/2007 to 4/5/2008 are detailed in Section 6.1.
MONITORING REPORT
Petrotemex Energy Integration Project
16
The calibration of the equipment is done as it is established in the tables below:
Cosoleacaque Plant
Instruction number
Identification number7
Variable Instrument Calibration
CWIC-201* Solid concentration
Controller indicator Internal calibration twice a year
GMT-I-061 CWT-112A2 Solid concentration
Flow transmitter Internal calibration twice a year
GMT-I-061 CWT-110 Solid concentration
Flow transmitter Internal calibration twice a year
GMT-I-004 AFT-131 Steam consumption
Flow transmitter Internal calibration once a year
GMT-I-004 AFT-4131 Steam consumption
Flow transmitter Internal calibration once a year
GMT-I-004 AFT-1103 Steam consumption
Flow transmitter Internal calibration once a year
GMT-I-062 ATE-336A Steam temperature Temperature element Internal calibration once a year
GMT-I-062 ATE-336B Steam temperature Temperature element Internal calibration once a year
GMT-I-062 ATE-336D Steam temperature Temperature element Internal calibration once a year
GMT-I-062 ATE-309C Steam temperature Temperature element Internal calibration once a year
GMT-I-004 APT-311A Steam pressure Pressure transmitter Internal calibration once a year
GMT-I-004 APT-310B Steam pressure Pressure transmitter Internal calibration once a year
GMT-I-004 APT-310C Steam pressure Pressure transmitter Internal calibration once a year
GMT-I-004 APT-310D Steam pressure Pressure transmitter Internal calibration once a year
GMT-I-004 AFT-309A Steam generation Flow transmitter Internal calibration once a year
GMT-I-004 AFT-309B Steam generation Flow transmitter Internal calibration once a year
GMT-I-004 AFT-309C Steam generation Flow transmitter Internal calibration once a year
GMT-I-004 AFT-309D Steam generation Flow transmitter Internal calibration once a year
GMT-I-004 AFT-306A Natural gas consumption
Flow transmitter Internal calibration once a year
GMT-I-004 AFT-306B Natural gas consumption
Flow transmitter Internal calibration once a year
GMT-I-004 AFT-306C Natural gas consumption
Flow transmitter Internal calibration once a year
7 The differences between the identification numbers shown in the registered monitoring plan and the
monitoring plan used from 20/11/2007 to 4/5/2008 are detailed in Section 6.1.
MONITORING REPORT
Petrotemex Energy Integration Project
17
Instruction
number
Identification
number7
Variable Instrument Calibration
GMT-I-004 AFT-306D Natural gas
consumption
Flow transmitter Internal calibration once a year
GMT-I-061 AFT-306A2 Fuel oil
consumption
Flow transmitter Internal calibration once a year
GMT-I-061 AFT-306B2 Fuel oil
consumption
Flow transmitter Internal calibration once a year
GMT-I-061 AFT-305 Fuel oil consumption
Flow transmitter Internal calibration once a year
BXI-124 Power generation Transducer Internal calibration once a year
Altamira Plant
Instruction
number
Identification
number8
Variable Instrument Calibration
AXI-310 Power generation Multifunction Calibration once a year
Petrotemex developed specific Calibration Procedures that are follow up by the specialized
personal to secure that the equipment of inspection, measurement and test stays calibrated,
controlled and in conditions of operation to demonstrate the product conformity according to
their requirements, as well as, to assure that the calibration of the instrument is within the rank
of exactitude specified by the manufacturer.
6.7 MAINTENANCE PROCEDURES
The maintenance procedures implemented for the project are similar to those currently
implemented in Cosoleacaque and Altamira plants, because despite the project is an innovate
technological development, the equipment, recipients and instruments are of the same type
than those currently installed in the plants.
These procedures were available during the verification.
6.8 SPREADSHEET MODELS
For this project, the monitoring methodology is applied through spreadsheet models. The
spreadsheets automatically provide the total GHG emission reductions achieved through the
project.
8 The differences between the identification numbers shown in the registered monitoring plan and the
monitoring plan used from 20/11/2007 to 4/5/2008 are detailed in Section 6.1.
MONITORING REPORT
Petrotemex Energy Integration Project
18
The models contain a series of worksheets with different functions, as follows:
Data entry sheets Function
Cosoleacaque Plant
The input data is entered in these sheets to
estimate parameters used in the emissions
reduction calculations.
PTA production
Steam Consumption
Steam Generation
Fuel Consumption
Lower Heating Value
Steam Enthalpy
Feed Water Enthalpy
Electricity Generation
Altamira Plant
Electricity Generation
Calculation sheets Function
Cosoleacaque Plant
These sheets use the data entered in the data entry
sheets.
Fuel Proportion
Net Enthalpy
Representative PTA Production
Representative Steam Consumption
Project SSCR
Efficiency
ER Steam Savings
ER Electricity Generation
Result sheet Function
Cosoleacaque Plant
This final sheet shows the emissions reductions calculated on an annual basis.
Total Emission Reductions
Altamira Plant
Emission Reductions
Additionally, there are some cells that show fixed parameters required for the calculations and
references for these parameters.
A color-coded key is used to facilitate data input. The key for the code is as follows:
• Input Fields: Pale yellow fields indicate cells where project operators are required to
supply data input, as is needed to run the model;
MONITORING REPORT
Petrotemex Energy Integration Project
19
• Result Fields: Green fields display key result lines as calculated by the model.
7 ENVIRONMENTAL IMPACT
The activities involved in this energy integration project have positive environmental impacts
on several grounds.
As a consequence of steam saving, the project activity will reduce emissions of particulate
matter and pollutant gases like SO2 and NOx from combustion of petroleum fuels in boilers,
reducing local negative environmental impact and improving air quality in the regions.
In addition, by reducing electricity demand from the Electricity Federal Commission
(Commission Federal de Electricidad – CFE), the project will reduce emissions from
electricity generation of the power plants connected to the grid. Thus there will be a reduction
of the local negative effects of such emissions.
In the case of this project activity, it is not necessary to modify the environmental impact
study required by the Environmental and Natural Resources Secretariat of Mexico, due to the
modifications that will be carried out by Petrotemex will not change the PTA production
process.
In addition, it is considered that the construction process will not have any negative
environmental impact.
8 EQUATIONS USED FOR CALCULATION OF EMISSION REDUCTIONS
Baseline emissions BEEG related to
avoided grid electricity generation due to
the waste heat recovery for power self-
generation in Cosoleacaque and Altamira
plants
BEEG = EG × EFgrid
where
EG Net quantity of electricity generated (MWh/year). It is
obtaining by subtracting the quantity of electricity
required by the power generation equipment to the
total electricity generation.
EFgrid CO2 baseline emission factor for the electricity
displaced due to the project activity (tCO2/MWh). It
is determined using the methodology
ACM0002/Version06 as a combined margin emission
factor, consisting of the combination of the operating
margin and the build margin factors. It is calculated
ex-ante and considered fixed along the crediting
period.
CO2 baseline emission factor for the
electricity displaced due to the project
activity
EFgrid = wOM × EFOM + wBM × EFBM
where
EFOM Operating margin emission factor (tCO2/MWh).
EFBM Build margin emission factor (tCO2/MWh).
wOM and
wBM
Relative weights assumed to be equal to 0.5,
according to the default value provided by the
methodology ACM0002/Version06.
MONITORING REPORT
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20
Operating margin emission factor EFOM = (Σkp Fkp × COEFkp) / (Σp GENp)
where the sum over k extends to all the fuels used by the power sources p, and the sum over p extends to all power sources
delivering electricity to the grid, not including low-operating cost
and must-run power plants, and including imports to the grid, and:
Fkp Quantity of fuel k consumed by the power source p
(TJ).
COEFkp CO2 emission coefficient of fuel k (tCO2 /TJ).
GENp Electricity generation delivered to the grid by the
power source p (MWh).
CO2 emission coefficient of fuel k COEFkp = CEFk × OXIDk
where
CEFk Carbon dioxide emission factor per unit energy of
fuel k (tCO2/TJ). IPCC default values are used.
OXIDk Oxidation factor of fuel k. IPCC default values are
used.
Build margin emission factor EFBM EFBM = (Σkq Fkq × COEFkq) / (Σq GENq)
where the sum over k extends to all the fuels used by the power
sources q, and:
Fkq Quantity of fuel k consumed by the power source q
(TJ).
COEFkq CO2 emission coefficient of fuel k (tCO2 /TJ). It is
obtained through equation showed above.
GENq Electricity generation delivered to the grid by the
power source q (MWh).
Project emissions PEEG and leakage
LEEG related to avoided grid electricity
generation due to the waste heat
recovery for power self-generation in
Cosoleacaque and Altamira plants
According to the methodology ACM0004/Version02, no leakage is
considered. In addition, no project emissions are considered, since
there are not fuels fired in the project scenario for electricity
generation start-up, in emergencies, or to provide additional heat
gain. Thus, PEEG = 0 and LEEG = 0.
Emission reductions EREG related to
avoided grid electricity generation due to the waste heat recovery for power self-
generation in Cosoleacaque and Altamira
plants
EREG = BEEG – PEEG – LEEG = BEEG
Emission reductions ERFS related to
boiler steam optimization
ERFS = Σ Cernet = Σ [Cer – (Cer1 + Cer2)] = Σ Cer
where the sum extends to all the days in a given year, and
Cernet Emission reductions per day (tCO2e/day).
Cer Emission reductions per day related to fuel savings due
to the boiler steam optimization in Casoleacaque plant
(tCO2e/day).
Cer1 Emissions related to captive generation (tCO2e/day).
Cer2 Emissions related to external grid supply (tCO2e/day).
According to the methodology AM0018/Version01.1, no leakage is
considered. There are not additional electrical load that may result
from the project activity (actually, there are electricity savings due to
the project activity, but they are not considered in the calculation of
emission reductions as a conservative assumption). Thus, Cer1 = 0
and Cer2 = 0.
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Emission reductions per day related to
fuel savings due to the boiler steam
optimization in Cosoleacaque plant
Cer = Ein × Σ(Ffuel × %Hfuel)
where the sum extends to all fuels consumed in the boiler room, and:
Ein Energy input in the boiler room during the day
(MMBtu/day).
Ffuel Carbon dioxide emission factor per unit of energy of
fuel (tCO2/MMBtu).
%Hfuel % of hours per day for each type of fuel. It is
obtained from the actual consumption of fuels by the
boiler room9. Thus, the % of hours per day for each
type of fuel is equivalent to the proportion of fuel
consumed in the boiler room during the day (%).
Energy input in the boiler room during
the day Ein = Enet / ηb
where
Enet Net reduction in steam energy consumption during the
day (MMBtu/day).
ηb Efficiency of the boiler room (%).
Efficiency of the boiler room ηb = Eo / Ei
where
Eo Output energy of steam (MMBtu/month).
Ei Input energy of fuel (MMBtu/month).
Output energy of steam Eo = Es × S
where
Es Net enthalpy of steam (MMBtu/tonne).
S Steam generation by the boiler room (tonnes/month).
Net enthalpy of steam Es = Etot – Efw
where
Etot Enthalpy of steam at the boiler room outlet
(MMBtu/tonne).
Efw Enthalpy of feed water (MMBtu/tonne).
The steam enthalpy is obtained by using steam tables for enthalpy at
given pressures and temperatures.
The enthalpy of feed water is estimated by multiplying the feed
water temperature by the water specific heat (1 kcal/kg ºC).
NOTE: for this verification period, design values provided by
AMOCO for pressure and temperature of the steam and feed water temperature were used.
Input energy of fuel Ei = NCVfuel × F
where
NCVfuel Net calorific value of fuel (MMBtu/m3).
F Quantity of fuel consumed at the boiler room
(m3/month).
9 According to the methodology, under direct method of boiler efficiency estimation, fuel
metering/measurement facility is available. Thus, the % of fuel is derived by actual consumption of
respective fuel.
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Net reduction in steam energy
consumption during the day Enet = Snet × Es
where
Snet Net reduction in steam consumption during the day
(tonnes/day).
Es Net enthalpy of steam (MMBtu/tonne). It is estimated
through equation showed above.
Net reduction in steam consumption
during the day Snet = SSCRdiff ×××× Pact
where
SSCRdiff Difference in SSCR (Specific Steam Consumption
Ratio) of baseline and project scenarios during the day (tonne steam/tonne PTA).
Pact Actual PTA production during the day (tonne
PTA/day).
Difference in SSCR SSCRdiff = SSCR – SSCR1
where
SSCR SSCR of baseline scenario (tonne steam/tonne PTA).
SSCR1 SSCR of project scenario during the day (tonne steam/tonne PTA).
The SSCR of baseline scenario is calculated ex-ante and considered
fixed along the crediting period. It is determined using the same
formulae than the SSCR of project scenario.
SSCR of project scenario during the day SSCR1 = S1 / P1
where
S1 Representative steam consumption during the day
(tonne steam/day).
P1 Representative PTA production during the day (tonne
PTA/day).
Representative PTA production during
the day Prep1 = (P1 + P2…..+ Pm) × A / m
where
P1, P2,….Pm PTA production during the shift 1, 2,….m (tonne
PTA/shift).
A Total number of shifts per day.
The representative PTA production for the day is determined by
selecting and averaging the representative PTA production values
(i.e. within the normal production range). A “normal” production
range can be defined based on the relationship between production
rates and energy consumption. Based on general experience the
energy consumption per unit of production is not significantly
sensitive up to +/- 5% of the normal production. The normal
production range can be defined as the range in which production
levels are 5% above or below the normal production. If production
fluctuates beyond this normal production range, these specific values
can be excluded to derive a representative production level of the day.
NOTE: for this verification period there is only one data per day.
MONITORING REPORT
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23
Representative steam consumption
during the day Srep1 = (S1 + S2…..+ Sm) × A / m
where
S1, S2,….Sm Steam consumption corresponding to the PTA
production during the shift 1, 2,….m (tonne
steam/shift).
A Total number of shifts per day.
The representative steam consumption for the day is determined by
selecting and averaging the steam consumption values corresponding
to the PTA production values included in the calculation of the
representative PTA production for this day.
NOTE: for this verification period there is only one data per day.
Total emission reduction ER of the
project activity ER = EREG + ERFS = BEEG + Σ Cer
where BEEG and Cer are determined as explained above.
There are not identified sources of project emissions PE and leakage
LE associated to the proposed project activity. Then, PE = 0 and LE
= 0.
Thus, the total annual emission reductions ER of the project activity
result to be:
ER = BE – PE – LE = BE
Thus, emission reductions are equal to baseline emissions that
include (i) CO2 emission from fuels that would have been used at the
boiler room of Cosoleacaque plant in order to generate the quantity
of steam saved by the proposed project activity, and (ii) CO2
emissions from fuels that would have been used by the operation of
grid-connected power plants and by the addition of new generation
sources, in order to generate the quantity of electricity self-generated by Cosoleacaque and Altamira plants following project
implementation. Then:
ER = BE = BEEG + Σ Cer
9 EMISSION REDUCTION CALCULATION
The total emission reductions achieved by the project activity through the monitoring period is equal to 59,13458,065 tCO2e.
The following tables summarize the values measured during the monitoring period.
Cosoleacaque Plant
Period
Total PTA
production
(tonnes)
Total Steam
Consumption
(tonnes)
Total Steam
Generation
(tonnes)
Total Residual Fuel
Oil
Consumption
(m3)
Total Natural Gas
Consumption
(m3)
From November 20th
, 2007
15,913 10,474 25,096 23.28 2,144,950
December 2007 51,998 20,689 61,308 63.85 5.023,765
January 2008 52,032 22,067 65,311 62.45 5,471,830
February 2008 43,325 21,262 65,002 59.42 5,501,642
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March 2008 49,450 24,330 79,535 63.80 6,958,237
April 2008 47,963 22,767 66,737 22.58 5,884,496
To May 4th
, 2008 4,634 4,562 11,094 0.10 995,494
TOTAL 265,314 126,151 374,083 295.48 31,980,415
Cosoleacaque Plant
Period
LHV of Residual Fuel
Oil
(MMBtu/m3)
LHV of Natural Gas
(MMBtu/m3)
Steam Enthalpy
(MMBtu/tonne)
Feed Water Enthalpy
(MMBtu/tonne)
From November 20th
, 2007 to May 4
th, 2008
38,89 0.0352 3.0376 0.4808
MONITORING REPORT
Petrotemex Energy Integration Project
25
Cosoleacaque Plant
Period
Total Electricity
Generation
(MWh)
Total Auxiliary
Electricity Used
(MWh)
From November 20th, 2007 265 0.02385
December 2007 1,045 0.06727
January 2008 1,063 0.06727
February 2008 665 .06290
March 2008 1,060 0.06724
April 2008 1,040 0.06501
To May 4th, 2008 97 0.00868
TOTAL 5,234 0.36222
Altamira Plant
Period
Total Electricity
Generation
(MWh)
Total Auxiliary Electricity Used
(MWh)
From November 20th,
2007
December 2007
January 2008 1,968 194.00
February 2008 1,272 108.00
March 2008 2,914 194.00
April 2008 4,573 280.00
To May 4th
, 2008 401 33.00
TOTAL 11,128 809
MONITORING REPORT
Petrotemex Energy Integration Project
26
In addition, the following table shows the parameters calculated ex-ante and considered fixed
along the crediting period.
Baseline SSCR 1.5242 tsteam/tPTA For further information please see the registered
PDD of Petrotemex Energy Integration Project,
Version 10 of 08/02/2008. Grid Emission Factor 0.5133 tCO2/MWh
Finally, the following tables show the emission reductions obtained during the monitoring
period.
Period
Cosoleacaque Plant
Total Emission
Reduction from
Steam Savings
(tCO2e)
Emission Reduction from
Electricity
Generation
(tCO2e)
From November 20th, 2007 2,497 136 2,632
December 2007 10,193 536 10,729
January 2008 10,168 545 10,713
February 2008 8,028 341 8,368
March 2008 9,435 544 9,978
April 2008 9,301 534 9,834
To May 4th, 2008 467 50 517
TOTAL 50,089 2,686 52,771
Period
Altamira Plant
Emission Reduction
from Electricity
Generation
(tCO2e)
From November 20th
, 2007
December 2007
January 2008 910
February 2008 597
March 2008 1,396
April 2008 2,203
To May 4th, 2008 188
TOTAL 5,294
MONITORING REPORT
Petrotemex Energy Integration Project
27
Total Emission Reductions during the monitoring period for Cosoleacaque Plant (tCO2e)
52,771
Total Emission Reductions during the monitoring period for Altamira plant (tCO2e)
5,294
Total Emission Reductions during the monitoring period for Cosoleacaque and Altamira plants
(tCO2e)
58,065
For further details see the monitoring spreadsheets “MGM_MVP_Altamira_ VERs_1Jan08
to 4May08” and “MGM_MVP_Cosoleacaque_VERs_20Nov07 to 4May08”.
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