PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
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CLEAN DEVELOPMENT MECHANISM
PROJECT DESIGN DOCUMENT FORM (CDM-PDD)
Version 02 - in effect as of: 1 July 2004)
CONTENTS
A.
General description of project activity
B.
Application of a baseline methodology
C.
Duration of the project activity / Crediting period
D.
Application of a monitoring methodology and plan
E.
Estimation of GHG emissions by sources
F.
Environmental impacts
G.
Stakeholders’ comments
Annexes
Annex 1: Contact information on participants in the project activity
Annex 2: Information regarding public funding
Annex 3: Baseline information
Annex 4: Monitoring plan
Annex 5: List of Abbreviations
Annex 6: List of References
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SECTION A. General description of project activity
A.1
Title of the project activity:
>>
GHG emission reduction through the installation of energy efficient vacuum creating system in the
vacuum distillation column of petroleum refinery
Version No.: 01
Date: 03-03-2006
A.2.
Description of the project activity:
>>
 Purpose
The main objective of the project activity is to optimize steam utilization in the vacuum distillation
column of the Vacuum Distillation Unit (VDU) of the petroleum refinery of Essar Oil Limited through
installation of an energy efficient vacuum creating system. This energy efficient vacuum creating system
will result in lower energy consumption than the steam jet ejector system which is traditionally used for
generating vacuum in the vacuum distillation column.
The net energy savings in terms of reduced refinery fuel consumption achieved through this project
activity will contribute to reduced GHG emissions from the refinery.

Salient Features:
The present system of creating vacuum in vacuum distillation column of petroleum refinery (as per
the original design):
The present system as adopted by EOL (the project proponent) for creating vacuum in vacuum
distillation column is the use of steam-jet ejector system. The vacuum distillation column of EOL is
originally designed with steam-jet ejector which maintains a vacuum of 12 mm of Hg in the column.
Steam-jet ejector uses steam as a motive fluid and use steam flow through a convergent-divergent nozzle
to create vacuum.
Steam-jet ejector system entails high amount of motive steam as well as cooling water requirement for
the inter stage condensers.
Project activity for energy efficiency improvement:
The project activity will involve re-engineering of the originally designed vacuum creating system by
installation of a higher energy efficient vacuum creating system viz. Vacuum Hydrocirculating (VHC)
system through retro-fitment. VHC system would replace the steam-jet ejector system in vacuum
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distillation column. VHC technology uses one of the process streams (like diesel or vacuum gas oil) as
the motive fluid which is re-circulated in a closed loop.
In absence of the project activity, the project proponent would be continuing with the originally designed
steam –jet ejector system as vacuum creating device in the vacuum distillation column of the refinery.
This VHC unit will result in lower overall energy consumption (due to reduced steam and cooling water
requirement) compared to the conventional steam-jet ejector system. Thus, the project activity will
contribute to reduced GHG emissions due to lower energy consumption than the baseline scenario.
The net impact of this project activity will be the reduction of 136274.8 tCO2 per annum which in
absence of the project activity would have been emitted for meeting energy requirement for the
conventional steam-jet ejector system.
Project’s Contribution to Sustainable Development
The project activity’s contribution to “Sustainable Development of India” is discussed under the three
pillars of sustainable development:
Social well-being: By creating a demand for some skilled jobs for the construction of the unit as well as
operation and the maintenance of the installed equipments, the project activity has the potential to
generate both direct as well as indirect employment. The skill set of the people will be enhanced with a
pioneering technology transfer process. The project activity may also help to create a business
opportunity for local stakeholders such as bankers / consultants, suppliers / manufacturers, contractors
etc.
Economic well-being: Through lower fossil fuel consumption for the process, the project activity will
contribute to the conservation of non-renewable natural resources like petroleum oil. Moreover, the
project activity will increase productivity of the process through reduced energy consumption.
Environmental well-being: The project activity will ultimately result in the reduction of fuel oil
consumption for energy generation. Thus emissions of CO2 and other pollutants like NOx associated with
the combustion of fuel oil will be greatly reduced.
Technological well-being: The proposed technology for the project activity is the first of its kind in
India and the proprietary right of the technology lies only with the foreign technology licensor. A vital
part of the project activity will be to impart proper technical and managerial training to the managerial
and operational staffs of the refinery for proper functioning of the system. An intensive in-house
knowledge base should be developed to build up scientific and technical expertise for running the new
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vacuum creating system. Adoption of this novel technology will also help in capacity building of
employees by better exposure to modern technological development in refining industry. Moreover, this
technology can be replicated to other petroleum refineries in India leading to higher reduction of GHG
emissions.
A.3.
Project Participants:
>>
Name of the Party Private and/or public entity(ies)
involved
Project participants (as applicable)
((host) indicates a
host party)
Government of India
Ministry of
Environment and
Forests (MoEF)
(Host)
A.4.
Essar Oil Limited - EOL is a public
limited company
Kindly indicate if
the Party involved
wishes to be
considered as
project participant
(Yes/No)
No
Technical description of the project activity:
A.4.1.
>> India
Location of the project activity:
A.4.1.1. Host Party(ies):
>> India
A.4.1.2. Region/State/Province etc.:
>> Gujarat
A.4.1.3. City/Town/Community etc:
>> Vadinar, Jamnagar
A.4.1.4.
Detail of physical location, including information allowing the unique
identification of this project activity (maximum one page):
The project activity has been implemented in the greenfield refinery of EOL, located on the west coast of
India at Vadinar, Gujarat .The refinery site is around 40 kms from Jamnagar city and is connected with
other places through well-established network of railway, state highway and port. The site is connected
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to the Kandla-Bhatinda petroleum product pipeline, providing the project proponent an easy access to the
key markets of the north India and other potential markets of petroleum products the proposed central
India pipeline will transport its products to the western and central parts of India cost-effectively.
Vadiner port allows the low-cost coastal movement of products to the Eastern and Southern parts of
India. Moreover, the nearby location of the port also provides substantial advantage to EOL in terms of
import of crude oil.
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Khambalia Post
Vadinar
Map not to scale
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A.4.2. Category(ies) of project activity:
>>
The project activity is steam optimization project in petroleum refinery where aggregate energy savings
of the project exceeds the equivalent of 15 GWh per annum. The baseline and monitoring methodology
has been adopted as per approved methodology AM0018. The project activity may principally be
categorized in Category 3- Energy demand according to the scope of the project activities enlisted in the
‘list of sectoral scopes and approved baseline and monitoring methodologies’ on the UNFCCC website
for accreditation of Designated Operational Entities1.
A.4.3. Technology to be employed by the project activity:
>>
VHC unit consists of four major components – jet type vacuum creating device, centrifugal pump,
separator and cooler. In this system one of the process liquid streams (e.g. diesel or vacuum gas oil)
which meets the requirement of physical and chemical characteristics can be used as motive liquid.
Motive liquid is delivered to the jet vacuum creating device (referred to as J-1 in the diagram describing
project boundary) with the help of the pump (referred to as P-1 in the diagram describing project
boundary) The suction gas from the process unit i.e. the vacuum distillation column goes to the jet
vacuum creating device J-1 inlet where it is compressed up-to the design pressure due to high energy of
the motive liquid stream and convergent-divergent design of the vacuum creating device. The continuous
suction from the vacuum distillation column creates and maintains the desired vacuum at the column.
The liquid gas mixture generated at J-1 goes to the separator device (referred to as S-1 in the diagram
describing project boundary) where the separation of gaseous and liquid phase takes place. The gas
compressed to the design pressure is discharged from the system for further utilization. The motive liquid
thus recovered is cooled in the cooler device (referred to as C-1 in the diagram describing project
boundary) and re-circulated into the system through P-1. At the inlet of P-1 arrangement is made for
fresh motive liquid for the fill-up and motive liquid renovation. Excess motive liquid is discharged from
the VHC unit and finds its utilization as product stream. (Refer to the diagram provided in the
description of the project boundary in section B.4).
The technology to be employed under the project activity for installation of this energy efficient vacuum
creating device is developed by M/s TECHNOVACUUM of Russia. This project concept for energy
efficiency as developed by M/s TECHNOVACUUM is a very innovative and crystallized after technical
1
http://cdm.unfccc.int/DOE/scopes.html
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analysis of process profile for a long time. The technology is pioneering and first of its kind in India for
which the technology partner is M/s TECHNOVACUUM of Russia.
A.4.4. Brief explanation of how the anthropogenic emissions of anthropogenic greenhouse
gas (GHGs) by sources are to be reduced by the proposed CDM project activity, including
why the emission reductions would not occur in the absence of the proposed project
activity, taking into account national and/or sectoral policies and circumstances:
>>
Without this project, EOL would continue to generate additional steam (3.5 kg/cm2(g) Low Pressure
steam) of approximately 56 MT /hr which would have been required for the steam-jet ejector system
with which the vacuum distillation column is originally designed. This project activity would reduce
steam consumption in the process and thus lower the firing of refinery fuel in the boilers for generating
equivalent amount of steam. Reduction in the consumption of refinery fuel would lead to a reduction in
GHG emissions from the baseline scenario.
Perceived technical and financial risks to petroleum refining industry in adopting innovative as well as
unproved energy saving technologies are very high in India because of complexity of the refining
technology and inter-dependence of the individual processes. Any failure of the project activity may
upset the overall refinery process leading to shutdown of some other downstream units thereby resulting
in associated production loss. Moreover, fear that a new technology might be unreliable inhibits industry
from adopting new energy saving technologies. Despite these inhibiting factors, it is commendable that
EOL has taken up the initiative in adopting this innovative technology for the first time in India. With
success of this project the replication potential of this technology would be widened since the same can
be adopted by other petroleum refineries in India.
A.4.4.1.
Estimated amount of emission reductions over the chosen crediting period:
>>
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Years
2007-08
Annual estimation of
Emission Reductions in
tonnes of CO2 e
136274.8
2008-09
136274.8
2009-10
136274.8
2010-11
136274.8
2011-12
136274.8
2012-13
136274.8
2013-14
136274.8
2014-15
136274.8
2015-16
136274.8
2016-17
136274.8
Total estimated reductions (tonnes of CO2 e)
1362748
Total number of crediting years
10
Annual average over the crediting period of estimated reductions 136274.8
(tonnes of CO2 e)
A.4.5. Public funding of the project activity:
>>
No public funding from parties included in Annex I is available to this project.
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SECTION B. Application of a baseline methodology
B.1.
Title and reference of the approved baseline methodology applied to the project activity:
>>
Title: Baseline methodology for steam optimization systems
Reference: AM00018, website: http://:www.unfccc.int
B.1.1. Justification of the choice of the methodology and why it is applicable to the project
activity:
>>
As per the Kyoto Protocol (KP) baseline should be in accordance with the additionality criteria of article
12, paragraph 5(c), which states that the project activity must reduce emissions that are additional to any
that, would occur in the absence of the certified project activity.
Justification for why is the baseline methodology applicable to project activity.
The project is about optimization of steam utilization in one of the petroleum refining processes. Under
the project activity, the system in use would be replaced by the new system. Therefore, the emission
would be compared with the historical emission. The applicability criteria laid down by the approved
methodology AM0018, therefore are suitable for demonstration of additionality, selection of baseline and
quantification of emission reductions from the project activity.
As per the applicability criteria of AM0018:“This methodology is applicable to steam optimization
projects in production processes with homogeneous and relatively constant outputs with continuous
monitoring of steam output.”
The project activity will involve installation of VHC system in the vacuum distillation column of the
refinery of EOL. The project activity optimizes the steam utilization in the vacuum distillation column of
the refinery. ‘Outputs’ (which is the mm Hg of vacuum generated by the vacuum creating system) will
remain constant and homogeneous. Also, the steam output from the boiler will be continuously
monitored.
Moreover, as per AM0018, the steam must have some use inside the plant premise. In this case, the steam
in the baseline scenario is determined to be used for vacuum generation through steam jet ejector system.
Both the scenarios before and after the implementation of the project activity are as follows:
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Scenario 1
Non-project option: In the business-as-usual scenario, EOL would continue to consume energy and emit
CO2 for generating steam which would be used in the steam-jet ejector system with which the vacuum
distillation column is originally designed.
Scenario 2
CDM Project option: In the project activity scenario, new energy efficient ejector system would be in
place, resulting in lower energy consumption in the system thereby leading to reduction in CO2
emissions.
There is a direct comparison of emissions available with the project proponent based on the real time
data. Before implementation of the project activity the facility would be emitting the additional CO2 due
to combustion of refinery fuel in the boiler for generation of additional steam to be used in steam-jet
ejector of the vacuum distillation column.
Moreover, the project activity is the first of its kind in Indian petroleum refining industry; therefore any
other project activity is not available for comparison. On the basis of this, it can be justified that most
suitable baseline methodology for this application would be based on “Existing actual or historical
emissions”.
B.2.
Description of how the methodology is applied in the context of the project activity:
>>
The methodology uses four-point approach. In this approach, actual data are collected for direct
comparison of baseline and project specific steam consumption and thus estimating reduction in CO2
emissions.
1. Baseline Determination: Baseline for the project activity is the existing vacuum creating system viz.
steam-jet ejector system the vacuum distillation column is originally designed with. In the after
project scenario the VHC system would replace the steam-jet ejector system through retro-fit measure
in the vacuum distillation column.
2. Baseline Fixation: Baseline for the project is fixed by calculating specific steam consumption (tph of
steam/ mm Hg of vacuum created) in the vacuum creating system of the vacuum distillation column.
The vacuum is created through continuous removal of hydrocarbon from the vacuum distillation
column. The data required for this calculation would be taken from the data documented in the
previous record sheets of VDU running on steam-jet ejector system. The value of “vacuum created”
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used in this context is the average representative value of normal range2 of output3 (vacuum
generated) measured in a day. The steam consumption values corresponding to the values of “vacuum
created” selected above needs to be identified and the average representative value required to be
calculated (refer section-D for details).
3. Estimation of Specific Steam Consumption After Project Implementation: In the project
scenario, specific steam consumption (tph of steam/ mm Hg of vacuum created) in the vacuum
creating system of the vacuum distillation column is calculated based on the ratio of average
representative values of steam consumed (in tph) in the vacuum creating system the and the amount of
vacuum created (in mm of Hg) in the vacuum distillation column. The method for estimating
representative data of output and steam consumption is same as in case of baseline scenario (refer
section D for details).
4. Estimation of Net Increase in Power Consumption after Project Implementation: In the project
scenario there would be additional electricity load under operation due to motive liquid circulation
pump etc. The net increase in emissions due to additional electrical load is taken into account while
estimating emission reductions. In case the unavailability of facility of measurement/recording of
actual electrical power consumed by motor, the rated power of motors is taken as fixed load, which is
the maximum limit of their consumption.
5. Estimation of Emission Reduction: Total reduction in steam consumption in project scenario is
calculated by multiplying the reduction in specific steam consumption by the vacuum created in the
project scenario. The reduction in emission is calculated by estimating the fuel required for the
generation of additional steam in the boiler and deducting from it the emissions due to additional
electrical loads to be operated under the project activity. The efficiency of the boiler, net enthalpy of
steam will be monitored to estimate the saving in refinery fuel at the boiler end.
2
Normal range is the range in which the plant output takes place most of the time. It is 95% confidence interval. This
is based on the rated plant capacity and internally acceptable deviations ( 5% of rated plant capacity).
3
Output here is defined as the main outcome of process/system for which process/system is designed and where the
steam generated by using fossil fuel is utilized. Therefore, in case of EOL, output of the process is the quantity of
CO2 produced per hour (in kg or Tons) and accounted through the monitoring system.
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B.3.
Description of how the anthropogenic emissions of GHG by sources are reduced below
those that would have occurred in the absence of the registered CDM project activity:
>>
As per the decision 17/cp.7 Para 43, a CDM project activity is additional if anthropogenic emissions of
greenhouse gases by sources are reduced below those that would have occurred in absence of the
registered CDM project activity.
The proposed project activity is energy efficiency improvement activity and results into net reduction in
CO2 emissions of facility.
Following steps of additionality test are followed with respect to the steam optimisation project of EOL
for demonstration of additionality
Step 0. Preliminary screening of projects started after 1 January 2000 and prior to 31 December
2005
The procurement for the project started after 1 January 2000. The project will be commissioned in July
2007. The CDM fund was seriously being considered before starting the planning of the project. There
are sufficient evidences available in the form of documentation that shows that the CDM incentive
played an important role in the decision-making. Following are the evidences available:
1. Approval from the top-management for investing in the project activity
Step 1: Identification of alternatives to the project activity (steam optimisation project) consistent with
current laws and regulations
Define realistic and credible alternative scenarios to the CDM project activity that can be (part of) the
baseline scenario through the following sub-steps:
Sub-step 1a. Define alternatives to the project activity:
The alternatives to the proposed project activity are following, which also has potential of substantial
energy savings.
Alternative 1
Non-project option: In the business-as-usual scenario, EOL would continue to consume steam for
vacuum generation through the steam-jet ejector system.
Alternative 2
CDM Project option: In the project activity scenario, new energy efficient ejector system i.e. VHC
system will be in place, resulting in lower steam consumption in the system thereby leading to reduction
in CO2 emissions.
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Sub-step 1b. Enforcement with applicable laws and regulations:
For steam optimisation projects, there is no legal mandate applicable for the project proponent. But the
project complies with all good and safe engineering practices.
Step 2. Investment Analysis
EOL does not follow this step to demonstrate additionality of the project activity, but follows step-3 for
barrier analysis.
Step 3. Barrier Analysis
If this step is used, determine whether the proposed project activity faces barriers that:
(a) Prevent a wide spread implementation of this activity and thus preventing the baseline scenarios from
occurring; and
(b) Do not prevent a wide spread implementation of at least one of the alternatives.
Use the following sub-steps:
Sub-step 3a. Identify barriers that would prevent a wide spread implementation of the proposed project
activity:
Following are the barriers that would prevent the proposed project activity from being implemented if the
project was not registered as a CDM activity.
Barrier due to prevailing practice:
The project is not the prevailing practice in petroleum refining industry in India (and even other
countries) with similar technologies. Therefore EOL lacks the familiarity with such project. The internal
documents are available regarding risks associated with the project activity implementation and
operation.
The project is the “first of a kind”
The project activity is the ‘first of its own kind’ in the Indian petroleum refining industry. The energy
efficient technology is imported from M/s TECHNOVACUUM who is the leader in the development of
vacuum hydrocirculating (VHC) system. This state-of-the-art technology is new to Indian refining
industry and would be achieved and implemented for the very first time for a petroleum refinery in India.
M/s TECHNOVACUUM has selective credentials primarily in Russian petroleum refineries. EOL has
taken substantial efforts and also decided to bear all the technical as well as operational risks in
implementing the project activity. Since the technology is new and an ejector system is of critical
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importance in the vacuum distillation column of a refinery the failure of the ejector system may severely
affect the operation of the column.
Although the reliability of VHC system has not yet been established in Indian petroleum refining
industry, EOL has decided to cross the associated barriers and go ahead with the CDM project activity.
Success of this project activity would generate good replication potential across the petroleum refining
industry, particularly where M/s TECHNOVACUUM is pursuing to supply the technology. Therefore it
would ensure that greater amount of CO2 emission reduction will take place across the globe wherein this
technology would be successfully applied.
The high risk of the new technology therefore prevents widespread implementation of the project
activity.
Technological barriers
Since the implementation of VHC system is entirely new in India, the risks associated with the
unforeseen circumstances are not yet fully perceived. The technical people of EOL are not trained in
handling the operational risks. Some of the potential technical and operational risks identified by the
project proponent are as follows:
1. In all the petroleum refineries in India operation of steam jet ejector for creating vacuum in the
vacuum distillation column is a common as well as a favourable practice due to the high
reliability of conventional ejector system. This is because of the fact that during power failure in
a refinery the supply of LP steam would continue since the turbine by-pass valve will open
facilitating let down of HHP steam to LP level through Pressure Reducing and De-superheating
Station (PRDS). This can keep the steam-jet ejector running for sometime to allow for smooth
shutdown of the unit. However, in the vacuum hydrocirculating (VHC) system the motive liquid,
which is nothing but one of the product streams of vacuum distillation column, would be
circulated through electricity driven pumps. Therefore, power failure situation in the refinery
would bring the VHC system into immediate halt due to tripping of the pump. This situation
would tend to destabilize the process parameters of vacuum distillation column and result in
deterioration of product quality due to inefficient separation of hydrocarbons. Therefore, from
the reliability point of view VHC system is less favourable than the conventional steam-jet
ejector system.
Furthermore, vacuum distillation column serves as the feed preparation unit for the downstream
secondary processing units like Fluidized Catalytic Cracking Unit (FCCU) which uses vacuum
gas oil (VGO) as input feedstock. Failure of the VHC system would affect the distillate output
from the vacuum distillation column thereby inhibiting the supply of VGO to FCCU. As a
consequence the FCCU has to be brought under immediate shut-down which would result in its
associated production loss.
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2. The motive liquid in the vacuum creating device of VHC system is one of the process streams
that meets the requirement of the physical and chemical characteristics. The selection of motive
liquid for VHC system is a critical parameter because the suction media mixes with the motive
liquid and some components of the suction gas is also dissolved in the motive liquid. It is
essential to define such motive liquid which can be saturated with the suction gas components
without negative consequences for the overall process, e.g. in case of VHC unit the common
motive liquid is the petroleum fraction (i.e. diesel or gas oil fraction) that goes into downstream
units for reprocessing. However, no such difficulty exists in case of conventional steam-jet
ejector system where steam is the motive liquid and acts as a very good solvent for the
hydrocarbon fractions.
3. The feed of a vacuum distillation column is heated in a furnace before introducing it to the flash
zone of vacuum distillation column. In the furnace usually dilution steam is used to prevent
heater coil coking. When steam jet ejector system is in place as a vacuum creating device in the
vacuum distillation column the use of steam as dilution medium in the heater coil is favourable.
However, if dry vacuum creating system such as VHC is in place in the vacuum distillation
column, usually steam is not preferred be used in the heater coil of the furnace. Therefore,
installation of VHC system increases the chance of choking in the heater coil of the furnace
which is placed in the upstream of the vacuum distillation column.
4. The conventional steam-jet ejector system uses steam as the motive liquid and steam is the
cheapest utility in the refinery. Sacrificing this system with the new VHC system where one of
the hydrocarbon product streams acts as motive liquid would add to the operational cost of the
unit.
Other Barriers:
Lack of adequate experience about the operation of VHC system:
The technology supplier for the project activity i.e. M/s TECHNOVACUUM is a Russian agency who
has the credentials for implementing VHC system mostly in the Russian refineries only. Therefore, the
international technology licensors of the major process units of EOL refinery are apprehensive about the
reliability of operation of VHC system and the compatibility of VHC system with the major process units
of the refinery. This is quite evident from a communication with IFP France which is the technology
supplier for Diesel Hydro-desulphurization (DHDS) unit for EOL. The essence of the communication is
given below:
EOL management thought of installing VHC system in the DHDS unit and regarding that they had
invited the opinion of IFP France. However, IFP France expressed their concern about the reliability of
such a vacuum creating system with which they do not have any prior experience at all and they declared
that they would not shoulder the risk of any adverse effect on the performance of DHDS if this new
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vacuum creating system is installed in the DHDS unit. IFP France which is a world renowned technology
supplier in petroleum and petrochemical industry showed their strong confidence on the higher reliability
of conventional steam-jet ejector as vacuum creating system.
The similar risk issues pertaining to the reliability of the VHC system would be relevant for installation
of VHC system in VDU as well.
In-spite of all these barriers EOL would implement the project activity considering the GHG emission
reduction potential of the new vacuum creating system.
Sub-step 3 b. Show that the identified barriers would not prevent a wide spread implementation of at
least one of the alternatives (excepted the proposed project activity already considered in step 3a):
The alternative of VHC system (i.e. conventional steam-jet ejector system) is relatively more common
practices, more reliable and less risky, as it is proven across the world as well as in the Indian petroleum
refining sector. The same was considered earlier, however not taken up as CDM project activity as this
project alternative does not contribute to GHG emission reductions. The barriers as mentioned above do
not prevent the wide spread implementation of the project alternative.
Step 4. Common Practice Analysis
Sub-step 4a. Analyse other activities similar to the proposed project:
There is no activity similar to the proposed project activity in India, as evident from the letter of the
technology supplier.
Sub-step 4b. Discuss any similar options that are occurring:
Not applicable
Step 5. Impact of CDM Registration
As stated earlier, during the conceptualization of the proposed CDM project activity the potential CDM
revenue that would flow to the project activity had been seriously considered. Following impacts of
CDM fund are identified from the point of view of mitigation of risks and barriers discussed above.
 CDM fund will provide additional coverage to the risks associated with the project activity and help
in mitigating the other technical risk factors as mentioned above.
 CDM funds will provide the training support to EOL employees in understanding operational
accuracies and troubleshooting measures during operational problems.
 The fund will stimulate R&D efforts in EOL to find methods of mitigating risks and enhance
replication of such energy efficiency projects or process optimization schemes in petroleum refining
industry, to promote GHG abatement.
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 18
B.4.
Description of how the definition of the project boundary related to the baseline
methodology selected is applied to the project activity:
>>
Project Boundaries
As per definition of project boundary as given in glossary of terms, “it will encompass all anthropogenic
emissions by sources of Green House Gases (GHGs) under the control of project participants that are
significant and reasonably attributable to the CDM project activity.”
Based on the definition, the project boundary covers the new vacuum hydrocirculating system installed in
the vacuum distillation column.
The following components VHC system would be covered in project boundary.
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 19
PROJECT BOUNDARY
Suction
gas
J-1
Compressed gas to
further utilization
S-1
Motive
liquid excess
Make-up motive
liquid
C-1
P-1
VHC
Project
System
Boundary
Electricity supply
source
Steam generation
source
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board




page 20
Jet vacuum creating device J-1
The motive liquid circulating pump P-1
The separator S-1 which separates gaseous and liquid phases
The cooler C-1
Boiler for steam generation
The actual baseline CO2 emissions take place in the main steam generation boiler.
Electricity supply source
The source of electricity (i.e. turbo-generator) is the part of project boundary.
B.5.
Details of baseline information, including the date of completion of the baseline study and
the name of person (s)/entity (ies) determining the baseline:
>>
Date of completing the final draft of this baseline section:
01/2005
Name of person/entity determining the baseline:
EOL is the project participant.
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 21
SECTION C. Duration of the project activity / Crediting period
C.1
Duration of the project activity:
C.1.1. Starting date of the project activity:
>>
May 2007.
C.1.2. Expected operational lifetime of the project activity:
>>
Expected lifetime: 20 years
C.2
Choice of the crediting period and related information:
C.2.1. Renewable crediting period
C.2.1.1.
Starting date of the first crediting period:
C.2.1.2.
Length of the first crediting period:
>>
Not opted
>>
Not opted
C.2.2. Fixed crediting period:
C.2.2.1.
Starting date:
C.2.2.2.
Length:
>>
01/07/2007
>>
10 years
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 22
SECTION D. Application of a monitoring methodology and plan
D.1.
Name and reference of approved monitoring methodology applied to the project activity:
>>
Title: Monitoring methodology for steam optimization systems
Reference: AM0018, UNFCCC website
D.2.
Justification of the choice of the methodology and why it is applicable to the project
activity:
>>
The PDD is prepared in line with the approved methodology AM0018. As per approved monitoring
methodology, the CO2 emission of proposed CDM project activities is monitored. The baseline is fixed
on the basis of historical emissions. As indicated earlier, the CO2 emission baseline of non-project
scenario is fixed in terms of steam consumption / mm Hg of vacuum created in the vacuum distillation
column with steam-jet ejector as vacuum creating system and emission due to fuel combustion in boiler
to generate equivalent amount of steam. The monitoring is done for the retrofits in the plant.
The monitoring of project activity is in line with approved monitoring methodology. Approved
monitoring methodology covers all the data variables used in the calculation of emission reduction.
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 23
D.2. 1. Option 1: Monitoring of the emissions in the project scenario and the baseline scenario
D.2.1.1. Data to be collected in order to monitor emissions from the project activity, and how this data will be archived:
ID number
Data
Source of
Data unit
Measured
(Please use
variable
Data
(m),
numbers to
calculated (c)
ease crossor estimated
referencing
(e)
to D.3)
Parameters related to specific steam consumption ration (SSCR)
D.2.1.1
Output rate
Vacuum
mm Hg
Measured
created by
every shift
VHC system
D.2.1.2
Steam
rate
D.2.1.3
Additional
electricity
consumption
flow LP Steam flow tph
to VHC system
kWh
Electricity
consumption
in the
motive
liquid
circulation
Recording
frequency
Proportion
of data to
be
monitored
How will the
data be
archived?
(electronic/
paper)
For how long
is archived
data to be
kept?
Every
Shift
Total
Electronic/
Paper
Crediting
Period +
years
Measured every Every
Shift
shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Measured
every shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Every
Shift
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
Comment
2
Measured in the plant
premises to the best
accuracy with the help of
pressure gauge and will be
recorded shift-wise through
DCS. The instrument will
be calibrated by accredited
agency.
Measured in the plant
premises to the best accuracy
with the help of orifice meter
and will be recorded shiftwise through DCS. The
instrument will be calibrated
by accredited agency.
Measured in the plant
premises to the best
accuracy with the help of
energy meter and will be
monitored
shift-wise
through
DCS.
The
instrument
will
be
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
ID number
(Please use
numbers to
ease crossreferencing
to D.3)
Data
variable
page 24
Source of
Data
Data unit
Measured
(m),
calculated (c)
or estimated
(e)
Recording
frequency
Proportion
of data to
be
monitored
How will the
data be
archived?
(electronic/
paper)
For how long
is archived
data to be
kept?
calibrated
agency.
pumps of
VHC unit
Parameters related to steam enthalpy
D.2.1.4
Steam
Temperature of Degree C
temperature LP steam to
VHC system
Measured every Every
Shift
shift
Total
Electronic/
Paper
Crediting
Period + 2
years
D.2.1.5
Steam
pressure
Measured
Every
Shift
Total
Electronic/
Paper
Crediting
Period + 2
years
D.2.1.6
Feed
water Boiler
F.W. Deg C
temperature temperature
per shift
Measured
Every
Shift
Total
Electronic/
Paper
Crediting
Period + 2
years
D.2.1.7
Feed
flow
Measured
Every
Shift
Total
Electronic/
Paper
Crediting
Period + 2
Pressure of LP Kg/cm2(g)
steam to VHC
system
water Boiler
F.W tph
flow per shift
Comment
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
by
accredited
Measured in the plant
premises to the best accuracy
with the help of temperature
gauge and will be monitored
shift-wise through DCS. The
instrument will be calibrated
by accredited agency.
Measured in the plant
premises to the best
accuracy with the help of
pressure gauge and will be
monitored
shift-wise
through
DCS.
The
instrument
will
be
calibrated by accredited
agency.
Measured in the plant
premises to the best
accuracy with the help of
temperature gauge and will
be monitored shift-wise
through
DCS.
The
instrument
will
be
calibrated by accredited
agency.
Measured in the plant
premises to the best
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
ID number
(Please use
numbers to
ease crossreferencing
to D.3)
Data
variable
page 25
Source of
Data
Data unit
Measured
(m),
calculated (c)
or estimated
(e)
Parameters related to determination of Boiler efficiency by Direct Method
Measured
D.2.1.8
Steam
High
High tph
generation of pressure (HHP)
boiler
Steam
generation in
the
boiler
equivalent to
LP
steam
utilization in
the steam-jet
ejector system
Measured
D.2.1.9
Fuel
Fuel Flow for tph
consumption refinery
fuel
used in the
boiler
equivalent to
the LP steam
used in steamjet
ejector
system
Fuel related parameters
Measured
D.2.1.10
Net calorific Gross and
kcal/kg
Recording
frequency
Proportion
of data to
be
monitored
How will the
data be
archived?
(electronic/
paper)
For how long
is archived
data to be
kept?
Comment
years
accuracy with the help of
orifice meter and will be
monitored
shift-wise
through
DCS.
The
instrument
will
be
calibrated by accredited
agency.
Every Shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Measured in the plant
premises to the best accuracy
with the help of orifice meter
and will be monitored shiftwise through DCS. The
instrument will be calibrated
by accredited agency.
Every shift
Total
Electronic/Paper
Crediting
Period + 2
years
Measured in the plant
premises to the best accuracy
with the help of orifice meter
and will be monitored shiftwise through DCS. The
instrument will be calibrated
by accredited agency.
Electronic/
Crediting
Measured
With every Total
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
by
laboratory
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
ID number
(Please use
numbers to
ease crossreferencing
to D.3)
page 26
Data
variable
Source of
Data
value of fuel
Net Calorific
value of
refinery fuel
used in the
boiler
Data unit
Measured
(m),
calculated (c)
or estimated
(e)
Other parameters
D.2.1.11
Boiler
efficiency
Boiler
efficiency
%
Estimated
D.2.1.12
Retrofit
Event
-
Measured
D.2.1.13
Cooling
water
consumption
Cooling water
consumption
in the steamjet ejector
system
m3/hr
Measured
Recording
frequency
Proportion
of data to
be
monitored
How will the
data be
archived?
(electronic/
paper)
For how long
is archived
data to be
kept?
Comment
delivery of
fuel. (Refer
guidelines
on
boiler
efficiency
monitoring)
Paper
Period + 2
years
analysis
Total
Monthly
(Refer
guidelines
on
boiler
efficiency
monitoring)
As and
Total
when
occurs.
As and
Total
when
occurs.
Electronic/
Paper
Crediting
Period + 2
years
Direct efficiency of boiler is
to be estimated..(Refer to the
methodology for guidelines
on
boiler
efficiency
monitoring)
Electronic/
Paper
Crediting
Period + 2
years
Crediting
Period + 2
years
Follow Retrofit Monitoring
Test as given in this
methodology
Measured in the plant
premises to the best
accuracy with the help of
temperature gauge and will
be monitored shift-wise
through
DCS.
The
instrument
will
be
calibrated by accredited
agency.
Electronic/
Paper
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 27
D.2.1.2. Description of formulae used to estimate project emissions (for each gas, source, formulae/algorithm, emissions units of CO2
equ.)
>>
1. Emissions due to internal steam Consumption in VHC system
The source of greenhouse gas emissions in the project activity is due to steam consumption in the VHC system resulting in CO2 emissions from refinery
fuel fired in the service boiler for generating steam.
Step-1: Estimate vacuum generated by the VHC system (Output of the system)
Vacuum generated by the VHC system will be measured by the column-top pressure of the vacuum distillation column.
Step-2: Estimate Representative Value of vacuum generated by VHC system
Based upon capacity of the VHC system all values of vacuum generated (P1, P2, P3 etc.) under normal range of plant capacity to be measured and
averaged out to find the representative value denoted as Prep
Step-3: Estimate steam consumption for representative output values
The steam consumption (consumption per shift) values corresponding to representative vacuum generation values are selected and the average of the
same is calculated.
Sr = (S1+S2+….Sn)/n
S1…Sn = Values of steam consumption per hr (tph).
S r = Representative steam consumption for the day (corresponding to representative production of the day)
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 28
No. operating hours per day = n
Step-4: Calculate Specific Steam Consumption (tph/mm Hg vacuum)
The steam consumption values corresponding to vacuum generated stated above, to be identified and average representative value (Sr) to be worked out.
Ss = Sr / Prep
Where,
Ss = Specific Steam Consumption (tph/mm Hg vacuum generated)
Sr = Representative Steam Consumption Rate (tph)
Step – 5: Net Reduction in specific steam consumption (tph/ mm Hg of vacuum created)
Sr1 = Ss1-Ss
Where:
Sr1 = Net Reduction in specific steam consumption (tph/mm Hg of vacuum created)
Ss1 = Specific steam consumption in baseline scenario (tph/mm Hg vacuum created)
Ss = Specific Steam Consumption in project scenario (tph/mm Hg vacuum created)
Step – 6: Calculate reduction in hourly steam consumption due to project activity (tph)
Snet = Sr1 x PVHC
Where:
Snet = Net reduction in steam due to project activity (tph)
Sr1 = Net Reduction in specific steam consumption (tph/mm Hg vacuum created)
PVHC= actual value of vacuum created by VHC system (mm Hg vacuum created)
Step 7: Estimate the net daily reduction in energy due to reduction in steam consumption:
Enet = Snet x Es
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
Enet = Net reduction in steam energy consumption per hour (kCal/hr)
Snet = Net reduction in steam consumption per day (tph)
Es = Net enthalpy of steam being supplied in boiler (kCal/tonnes).
Es = Etot - Efw
Es = Net enthalpy of steam being supplied in boiler (kCal/tonnes). (To be monitored)
Etot = Total enthalpy of steam at the boiler outlet (kCal/tonnes)
Efw = Heat content of feed water (kCal/tonnes)
Step 8: Estimate daily reduction in input energy to the boiler
Ein = Enet/ b
Where,
Ein = Net reduction in energy input in boiler
Enet = Net reduction in steam energy consumption per hour (kCal/tonnes)
b= Efficiency of boiler, to be monitored periodically by direct or indirect method (as specified in the methodology).
Step-9: Calculate CO2 emissions reduction (tph)
Ce1 = (Ein / NCV of fuel used)*(C% of fuel used)*44/12
Where
Ce1 = CO2 emissions reduction per day due to fuel combustion in boiler to produce steam required for VHC system (tph)
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
page 29
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 30
Ein = Net reduction in energy input in the boiler
2. Net effect on Emissions due to Electrical Energy Consumption
The emission is resulted due to additional operation of motive liquid circulation pump. Net increase in emissions due to change of operation of motors,
the formulae used are as follows.
Step-1: Estimate net increase in electrical energy consumption (KWH)
The net increase in electrical energy consumption in the VHC system compared to the steam-jet ejector system (considering the electrical loads in
motive liquid circulation pump, cooling water circulation pump, cooling water fan etc.) is denoted by En
En = En1 – En2
En1 = Electrical energy consumption of VHC system (kWh)
En2 = Electrical energy consumption of steam-jet ejector (kWh)
Step-2 : Calculate Increase in CO2 emission due combustion of refinery fuel for net increase in power consumption (tph)
Ce2 = En x Ff / (1000 x  g )
Where
Ce2 = Increase in CO2 emission due to increase in power consumption (tph)
En = Net effect on energy consumption (GJ/h)
Ff = Emission factor of the refinery fuel used for power generation (tonnes / GJ)
 g = Minimum efficiency of electricity generating system based on historical data (assumed constant)
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 31
D.2.1.3. Relevant data necessary for determining the baseline of anthropogenic emissions by sources of GHGs within the project
boundary and how such data will be collected and archived :
ID number
Data
Source of
Data unit
Measured
(Please use
variable
data
(m),
numbers to
calculated (c)
ease crossor estimated
referencing
(e)
to D.3)
Parameters related to specific steam consumption ration (SSCR)
D.2.3.1
Output rate
Vacuum
mm Hg
Measured
created by
every shift
steam-jet
ejector
system
D.2.3.2
Steam
rate
D.2.3.3
Electricity
consumption
flow LP Steam flow tph
to
steam-jet
ejector
kWh
Electricity
consumption
in the pumps
Recording
frequency
Proportion
of data to
be
monitored
How will the
data be
archived?
(electronic/
paper)
For how long
is archived
data to be
kept?
Every
Shift
Total
Electronic/
Paper
Crediting
Period +
years
Measured every Every
Shift
shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Measured
every shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Every
Shift
Parameters related to steam enthalpy
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
Comment
2
Measured in the plant
premises to the best
accuracy with the help of
pressure gauge and will be
recorded shift-wise through
DCS. The instrument will
be calibrated by accredited
agency.
Measured in the plant
premises to the best accuracy
with the help of orifice meter
and will be recorded shiftwise through DCS. The
instrument will be calibrated
by accredited agency.
Measured in the plant
premises to the best
accuracy with the help of
energy meter and will be
monitored shift-wise
through DCS. The
instrument will be
calibrated by accredited
agency.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
ID number
(Please use
numbers to
ease crossreferencing
to D.3)
D.2.3.4
page 32
Data
variable
Source of
data
Data unit
Steam
temperature
Temperature of Degree C
LP steam to
steam-jet
ejector system
D.2.3.5
Steam
pressure
Pressure of LP Kg/cm2(g)
steam to steamjet
ejector
system
D.2.3.6
D.2.3.7
Proportion
of data to
be
monitored
How will the
data be
archived?
(electronic/
paper)
For how long
is archived
data to be
kept?
Comment
Measured every Every
Shift
shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Measured
Every
Shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Feed
water Boiler
F.W. Deg C
temperature temperature
per shift
Measured
Every
Shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Feed
flow
Measured
Every
Shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Measured in the plant
premises to the best accuracy
with the help of temperature
gauge and will be monitored
shift-wise through DCS. The
instrument will be calibrated
by accredited agency.
Measured in the plant
premises to the best accuracy
with the help of pressure
gauge and will be monitored
shift-wise through DCS. The
instrument will be calibrated
by accredited agency.
Measured in the plant
premises to the best accuracy
with the help of temperature
gauge and will be monitored
shift-wise through DCS. The
instrument will be calibrated
by accredited agency.
Measured in the plant
premises to the best accuracy
with the help of orifice meter
and will be monitored shiftwise through DCS. The
instrument will be calibrated
by accredited agency.
water Boiler
F.W tph
flow per shift
Measured
(m),
calculated (c)
or estimated
(e)
Recording
frequency
Parameters related to determination of Boiler efficiency by Direct Method
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
ID number
(Please use
numbers to
ease crossreferencing
to D.3)
D.2.3.8
Data
variable
page 33
Source of
data
Steam
High
High
generation of pressure (HHP)
boiler
Steam
generation in
the
boiler
equivalent to
LP
steam
utilization in
the steam-jet
ejector system
D.2.3.9
Fuel
Fuel Flow for
consumption refinery
fuel
used in the
boiler
equivalent to
the LP steam
used in steamjet
ejector
system
Fuel related parameters
D.2.3.10
Net calorific Gross and
Net Calorific
value of fuel
value of
SRFT used in
the boiler
Data unit
Measured
(m),
calculated (c)
or estimated
(e)
Recording
frequency
Proportion
of data to
be
monitored
How will the
data be
archived?
(electronic/
paper)
For how long
is archived
data to be
kept?
Comment
kg/shift
Measured
Every Shift
Total
Electronic/
Paper
Crediting
Period + 2
years
Monitored by steam flow
recording meter.
For SRFT
tph
Estimated
Total
Monthly
(Refer
guidelines
on
boiler
efficiency
monitoring)
Electronic/Paper
Crediting
Period + 2
years
Measured in the plant
premises to the best accuracy
with the help of orifice meter
and will be monitored shiftwise through DCS. The
instrument will be calibrated
by accredited agency.
kcal/kg
Measured
With every Total
delivery of
fuel. (Refer
guidelines
on
boiler
efficiency
monitoring)
Electronic/
Paper
Crediting
Period + 2
years
Measured
analysis
Other parameters
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
by
laboratory
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
ID number
(Please use
numbers to
ease crossreferencing
to D.3)
D.2.3.11
page 34
Data
variable
Source of
data
Data unit
Measured
(m),
calculated (c)
or estimated
(e)
Recording
frequency
Proportion
of data to
be
monitored
Boiler
efficiency
Boiler
efficiency
%
Estimated
D.2.3.12
Retrofit
Event
-
Measured
D.2.3.13
Cooling
water
consumption
Cooling water
consumption
in the steamjet ejector
system
M3/hr
Measured
Total
Monthly
(Refer
guidelines
on
boiler
efficiency
monitoring)
As and
Total
when
occurs.
As and
Total
when
occurs.
How will the
data be
archived?
(electronic/
paper)
For how long
is archived
data to be
kept?
Comment
Electronic/
Paper
Crediting
Period + 2
years
Direct efficiency of boiler is
to be estimated.(Refer to the
methodology for guidelines
on
boiler
efficiency
monitoring)
Electronic/
Paper
Crediting
Period + 2
years
Crediting
Period + 2
years
Follow Retrofit Monitoring
Test as given in this
methodology
Measured in the plant
premises to the best
accuracy with the help of
temperature gauge and will
be monitored shift-wise
through
DCS.
The
instrument
will
be
calibrated by accredited
agency.
Electronic/
Paper
D.2.1.4. Description of formulae used to estimate baseline emissions (for each gas, source, formulae/algorithm, emissions units of CO2 equ.)
>>
The specific steam consumption (in tph) in the steam-jet ejector of vacuum creating system for per mm Hg of vacuum created is derived for base
case scenario. This figure of specific steam consumption is used for all future project scenarios to compare the emissions of project scenario and
likely emissions of baseline scenario.
This template shall not be altered. It shall be completed without modifying/adding headings or logo, format or font.
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 35
Emissions due to steam Consumption in the steam-jet ejector
The source of greenhouse gas emissions in the project activity is due to steam consumption in the steam-jet ejector system resulting into CO2 emitted
from refinery fuel fired boiler for generating steam.
The historical one-month data on shift-wise output of vacuum created is analysed and representative output value (Prep) is calculated. While
calculating daily average, the extreme values are segregated from the available values of output rate (shift output). This is because the specific steam
consumption in a plant reduces with increased production rates. Based on our experience, the energy-production relationship is not significantly
sensitive up to +/-5% of normal rated production. Therefore +/- 5% range is taken as ‘normal production range’ for this purpose. If production
fluctuates (from shift to shift) beyond normal production range, these specific values are segregated to derive average production of the day.
Similarly steam consumption value corresponding to such production is also segregated.
1. Emissions due to internal steam consumption in the steam-jet ejector system
The source of greenhouse gas emissions in the project activity is due to steam consumption in the steam-jet ejector system resulting in CO2
emissions from refinery fuel fired in the boiler for generating steam.
Step-1: Estimate vacuum generated by the steam-jet ejector system
Vacuum generated by the steam-jet ejector system will be measured by the column-top pressure of the vacuum distillation column.
Step-2: Estimate Representative Value of vacuum generated by steam-jet ejector system
Based upon capacity of the steam-jet ejector system all values of vacuum created (P1, P2, P3 etc.) under normal range of plant capacity to be measured
and averaged out to find out representative value denoted as Prep
Step-3: Estimate steam consumption for steam-jet ejector system for representative output values
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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page 36
The steam consumption (consumption per shift) values corresponding to representative vacuum generation values are selected and the average of the
same is calculated.
Sr = (S1+S2+….Sn)/n
S1…Sn = Values of steam consumption per hr (tph).
S r = Representative steam consumption (corresponding to representative output)
No. operating hours per day = n
Step-4: Calculate Specific Steam Consumption for steam-jet ejector system (tph/mm Hg vacuum)
The steam consumption values corresponding to vacuum generated stated above, to be identified and average representative value (Sr) to be worked
out.
Ss = Sr / Prep
Where,
Ss
= Specific Steam Consumption (tph/mm Hg vacuum generated)
Sr
= Representative Steam Consumption Rate (tph)
D. 2.2. Option 2: Direct monitoring of emission reductions from the project activity (values should be consistent with those in section E).
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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page 37
D.2.2.1. Data to be collected in order to monitor emissions from the project activity, and how this data will be archived:
ID number
(Please use
numbers to
ease crossreferencing
to table
D.3)
Data
variable
Source of
data
Data
unit
Measured (m),
calculated (c),
estimated (e),
Recording
frequency
Proportion
of data to
be
monitored
How will the data
be archived?
(electronic/
paper)
Comment
D.2.2.2. Description of formulae used to calculate project emissions (for each gas, source, formulae/algorithm, emissions units of
CO2 equ.):
>> Not applicable in this case.
D.2.3. Treatment of leakage in the monitoring plan
D.2.3.1. If applicable, please describe the data and information that will be collected in order to monitor leakage effects of the
project activity
ID number
(Please use
numbers to
ease crossreferencing
to table
D.3)
Data
variable
Source of
data
Data
unit
Measured (m),
calculated (c)
or estimated (e)
Recording
frequency
Proportion
of data to
be
monitored
How will the data
be archived?
(electronic/
paper)
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Comment
PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 38
D.2.3.2. Description of formulae used to estimate leakage (for each gas, source, formulae/algorithm, emissions units of CO2 equ.)
>>
There are no potential significant sources of leakages.
D.2.4. Description of formulae used to estimate emission reductions for the project activity (for each gas, source, formulae/algorithm,
emissions units of CO2 equ.)
>>
Emission reduction = Baseline emissions – project activity emissions
D.3.
ID No.
Quality control (QC) and quality assurance (QA) procedures are being undertaken for data monitored
Explain QA/QC procedures planned for these data, or why such procedures are not necessary.
D.2.1.1
Uncertainty level of data
(High/Medium/Low)
Low
D.2.1.2
Low
D.2.1.3
Low
The QA procedure needs to be planned because the monitoring and selection of data corresponding to
representative output is important for accurate emission reduction calculations.
The QA procedure needs to be planned because the monitoring and selection of reliable data
corresponding to emission factor due to electricity consumption is important for accurate emission
reduction calculations.
D.2.1.4
Low
There is no procedure required for the measurement of temperature of steam.
D.2.1.5
Low
There is no procedure required for the measurement of pressure of steam.
D.2.1.6
Low
There is no procedure required for the measurement of temperature of feed water.
D.2.1.7
Low
There is no procedure required for the measurement of flow of feed water
D.2.1.8
Low
There is no procedure required for the measurement of flow of steam
D.2.1.9
Low
There is no procedure required for the measurement of flow of fuel. For calibration of refinery fuel flow meter
procedure is defined.
D.2.1.10
Low
The calorific value of refinery fuel is tested in the in-house laboratory.
The QA procedure needs to be planned because the monitoring and selection of representative data
from total data is important for accurate emission reduction calculations.
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page 39
D.2.1.11
Low
The estimation of boiler efficiency based on measured parameters is very critical parameter for estimation of
emission reduction. Procedure is required.
D.2.1.12
Low
For retrofit monitoring retrofit test should be followed as given in section D.2.1.1.
D.2.1.13
Low
There is no procedure required for the measurement of cooling water flow rate.
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page 40
D.4
Please describe the operational and management structure that the project operator will implement in order to monitor emission reductions
and any leakage effects, generated by the project activity
>>
General Manager (Process)
Manager (Technical Cell)
Shift in charge
Operator
D.5
Name of person/entity determining the monitoring methodology:
>>
EOL, their associated experts and consultants (indicate if the person/ entity is also a project participant)
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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page 41
SECTION E. Estimation of GHG emissions by sources
E.1.
Estimate of GHG emissions by sources:
>>
Calculation for Project Scenario (Emission Reduction due to Steam Optimisation)
Steps
Description
Unit
Value
Step-1
Average value of representative data of vacuum
generated
mm Hg of
vacuum
12
Average value of representative data of vacuum
generated
mm Hg of 12
vacuum
Step-2
Representative value of HHP steam generated at the
boiler end equivalent to the LP steam used in VHC
system
tph
Step-3
Sp. Steam consumption used in VHC system
tph/mm Hg 82.25
of vacuum
Step-4
Net reduction in sp. Steam consumption (as compared tph/mm Hg 4.667
to baseline case)
of vacuum
Step-5
Calculate reduction in steam consumption due to
project activity
tph
56
Step-6
Calculate net reduction in energy consumption due to
steam reduction(tph)
kcal/hr
38286080
Step-7
Net reduction in cooling water requirement (as
compared to baseline case)
m3/hr
5858
987
PROJECT SCENARIO (INCREASED EMISSIONS DUE TO ADDITIONAL ELECTRICAL
CONSUMPTION)
DESCRIPTION
UNIT
VALUE
Step-1
Step-2
Average value of daily energy consumption of motive MWh
liquid circulation pump of the VHC system(for
representative scenario of mm Hg of vacuum
generated)
Net increase in daily energy consumption
MWh
Calculate CO2 emission (based on the steam : fuel ratio tph
and steam : power ratio of the captive power plant of
the refinery)
1.7
1.3524
818.57
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page 42
E.2.
Estimated leakage:
>>
There are no potential significant sources of leakages.
E.3.
The sum of E.1 and E.2 representing the project activity emissions:
>>
Operating Years GHG
Emissions
by
sources Leakage
Project emissions
(tCO2/annum)
(tCO2/annum)
(tCO2/annum)
2007-08
740.1
0
740.1
2008-09
740.1
0
740.1
2009-10
740.1
0
740.1
2010-11
740.1
0
740.1
2011-12
740.1
0
740.1
2012-13
740.1
0
740.1
2013-14
740.1
0
740.1
2014-15
740.1
0
740.1
2015-16
740.1
0
740.1
2016-17
740.1
0
740.1
Total
7401
0
7401
E.4.
>>
Estimated anthropogenic emissions by sources of greenhouse gases of the baseline:
BASE LINE CASE (Sample Calculation)
STEPS
DESCRIPTION
UNIT
Step-1
Average value of representative data of vacuum
generated
mm Hg of 12
vacuum
created
Average value of representative data of vacuum
generated
mm Hg of 12
vacuum
created
Representative value of HHP steam generated in the
boiler end equivalent to the LP steam consumed in
steam-jet ejector system
tph
Step-2
BASED ON VALUES
OF JUNE 2003
1043
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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Step-3
page 43
Sp. Steam consumption in steam-jet ejector system
tph/ mm of 86.92
Hg vacuum
generated
E.5.
Difference between E.4 and E.3 representing the emission reductions of the project
activity:
>>
DESCRIPTION
UNIT
Net emission reduction (emission reduction due to steam
tph
optimisation – emission increase due to additional electricity
consumption)
Annual net emission reduction in CO2
Tons/year
17.21
136274.8
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E.6.
>>
page 44
Table providing values obtained when applying formulae above:
Years
Estimation of Estimation of Estimation
of Estimation
of
Project
Baseline
leakage (tonnes of emission reductions
Activity
Emission
CO2 e)
(tonnes of CO2 e)
Emission
reductions
reductions
(tonnes
(tonnes
of
of CO2 e)
CO2 e)
2007-08
740.1
137014.9
0
136274.8
2008-09
740.1
137014.9
0
136274.8
2009-10
740.1
137014.9
0
136274.8
2010-11
740.1
137014.9
0
136274.8
2011-12
740.1
137014.9
0
136274.8
2012-13
740.1
137014.9
0
136274.8
2013-14
740.1
137014.9
0
136274.8
2014-15
740.1
137014.9
0
136274.8
2015-16
740.1
137014.9
0
136274.8
2016-17
740.1
137014.9
0
136274.8
Total
7401
1370149
0
1362748
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 45
SECTION F. Environmental impacts
F.1.
Documentation on the analysis of the environmental impacts, including transboundary
impacts:
>>
The only environmental impacts from this work are positive-reductions in refinery fuel use and
associated pollution. There are no negative environmental impacts from the installation of this project
activity. The technology is easily transportable and installation does not require any major construction
equipment. This project does not require an environmental impact assessment (EIA) under Indian law.
F.2.
If environmental impacts are considered significant by the project participants or the host
Party, please provide conclusions and all references to support documentation of an environmental
impact assessment undertaken in accordance with the procedures as required by the host Party:
>>
NA
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page 46
SECTION G. Stakeholders’ comments
>>
G.1.
>>
Brief description how comments by local stakeholders have been invited and compiled:
Identification of stakeholders:
EOL will be implementing steam optimization project in the vacuum distillation column of the refinery.
Some of the key stakeholders identified for the project are as under:
 Elected body of representatives administering the local area (village Panchayt)
 Employees of EOL
 The technology supplier – M/s TECHNOVACUUM
EOL is in the process of communicating to the relevant stakeholders to get their comments on the project
activity.
Further, as part of registration process, public comments will be invited by appointed DOE.
G.2. Summary of the comments received:
>>
The comments received from M/s TECHNOVACUUM stating about the uniqueness of the project
activity. There are no negative stakeholder comments received so far on this project.
G.3. Report on how due account was taken of any comments received:
>>
There is no negative stakeholder comment received so far on the project activity. The relevant comments
and important clauses mentioned in the project documents/clearances like Detailed Project Report
(DPR), environmental clearances, local clearance etc. were considered while preparation of CDM project
design document.
As per UNFCCC requirement this Project Design Document (PDD) will be published at the validator’s
web site for public comments.
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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page 47
Annex 1
CONTACT INFORMATION ON PARTICIPANTS IN THE PROJECT ACTIVITY
Organization:
Essar Oil Limited
Street/P.O.Box:
P.O Box No -12
Building:
-
City:
Vadinar
State/Region:
Gujarat
Postfix/ZIP:
361 305
Country:
India
Telephone:
91-2833-241127
FAX:
91-2833-241414
E-Mail:
bkm@essar.com
URL:
www.essar.com
Represented by:
Mr. B.K. Mukherjee
Title:
Head of Refinery
Salutation:
Mr.
Last Name:
Mukherjee
Middle Name:
Kumar
First Name:
Bimal
Department:
Mobile:
-
Direct FAX:
-
Direct tel:
-
Personal E-Mail:
-
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page 48
Annex 2
INFORMATION REGARDING PUBLIC FUNDING
No public funding for this project.
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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page 49
Annex 3
BASELINE INFORMATION
Baseline for the project activity is the present system i.e. steam-jet ejector system adopted by the
project proponent for vacuum creation in VDU.
Sl. No.
Parameter/data type
1
Vacuum created in the
VDU by steam-jet ejector
system
2
Average LP steam
consumption in steam-jet
ejector system
3
Average HHP steam
consumption at the boiler
end corresponding to LP
steam consumption at
steam-jet ejector system
4
Temperature of HHP steam
at boiler outlet
5
Pressure of HHP steam at
boiler outlet
6
Boiler feed water
temperature
7
Boiler feed water pressure
8
Specific steam consumption
for steam-jet ejector system
9
Power consumption in the
steam-jet ejector system
10 Cooling water consumption
in steam-jet ejector system
11 Steam:Fuel ratio
12
Steam:Power ratio
13
14
Boiler efficiency
Calorific value of the fuel
(SRFT)used in the boiler
Carbon % of the fuel used
in the boiler
15
Unit
mm Hg
Data
Source
12
EOL source
tph
63.1
EOL source
tph
1043
EOL source
Degree C
465
EOL source
Bar absolute
63
EOL source
Degree C
106
EOL source
Bar absolute
tph/ mm Hg of
vacuum
kWh
90
86.92
EOL source
EOL source
347.6
EOL source
tph
6888
EOL source
Kg of steam/kg
of fuel
Tonnes of
steam/MWh of
power
%
kcal/kg
3.98
EOL source
12
EOL source
80%
10,000
EOL source
EOL source
%
90
EOL source
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Annex 4
MONITORING PLAN
Description of the Monitoring Plan
The Monitoring and Verification (M&V) procedures define a project-specific standard (baseline of
historical emissions) against which the project's performance (i.e. GHG reductions) and conformance
with all relevant criteria will be monitored and verified. It includes developing suitable data collection
methods and data interpretation techniques for monitoring and verification of GHG emissions with
specific focus on specific energy consumption parameters. It also allows scope for review, scrutinize and
benchmark all this information against reports pertaining to M & V protocols.
The M&V protocol provides a range of data measurement, estimation and collection options/techniques
in each case indicating preferred options consistent with good practices to allow project managers and
operational staff, auditors, and verifiers to apply the most practical and cost-effective measurement
approaches to the project. The aim is to enable this project have a clear, credible, and accurate set of
monitoring, evaluation and verification procedures. The purpose of these procedures would be to direct
and support continuous monitoring of project performance/key project indicators to determine project
outcomes, greenhouse gas (GHG) emission reductions.
The project employs latest state of art monitoring and control equipment that measure, record, and
control various key parameters.
Parameters monitored will be as follows.
1. The monitoring of vacuum created
2. The monitoring of quantity of steam used in the vacuum creating system in the baseline as well as in
the project scenario
3. Monitoring of temperature and pressure of steam used in the vacuum creating system in the baseline
as well as in the project scenario
4. Monitoring of boiler efficiency and steam enthalpy parameters and estimation of boiler efficiency by
direct method.
5. Monitoring of retrofits in the plant for change in baseline and project emissions.
The instrumentation system installed for the project is Distributed Control System (DCS) of reputed
make, with shift-wise recording and feedback facility with desired level of accuracy. All instruments will
be calibrated and marked at regular intervals so that the accuracy of measurement can be ensured all the
time.
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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page 51
GHG SOURCES
Direct On-Site Emissions
Direct on-site emissions after implementation of the CDM project arise from the following sources.
Net emissions due to increased load of the motive liquid circulation pump of VHC system
As discussed above, these emissions are monitored and taken into account while estimating net emission
reductions of project.
Direct Off-Site Emissions
There is no off-site emission due to the project activity.
Indirect On-Site Emissions
There is no indirect on-site emission due to the project activity.
Indirect Off-Site Emissions
No indirect off-site emissions could occur due to CDM project.
Project Parameters affecting Emission Reduction
Monitoring Approach
The general monitoring principles are based on:
 Frequency
 Reliability
 Registration and reporting
As the emission reduction units from the project are determined by the reduction in steam quantity and
subsequent reduction in consumption of refinery fuels in the boiler and net change in electrical energy
consumption, it is important to discuss the monitoring principles in the context of monitoring these
parameters.
Frequency of monitoring
The project developer has installed all metering facilities within the plant premises. The measurement is,
monitored and controlled through DCS on continuous basis and recorded shift-wise (8-hours shift) in log
sheets by operator, duly authenticated by head of plant
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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page 52
Reliability
The amount of emission reduction units is proportional to the net energy reduction due to project. Thus
the steam meter reading is of crucial value. All measurement devices will be of digital type meters with
on-line DCS (Distributed Control System), having best accuracy and will be procured from reputed
manufacturers. Since the reliability of the monitoring system is governed by the accuracy of the
measurement system and the quality of the equipment for reproducibility, all instruments must be
calibrated once a year for ensuring reliability of the system. All instruments carry tag plates, which
indicate the date of calibration and the date of next calibration. Therefore it ensures the monitoring
system is highly reliable.
Registration and reporting
Registration is done on the basis of shift-wise data logging in computer. Daily, weekly and monthly
reports are prepared stating the steam consumption reduction and electrical consumption.
The following reports will be generated for monitoring and controlling emissions.
The daily report of hourly data of steam consumption in vacuum creating system, hourly generation of
vacuum would be prepared. The steam consumption per unit of vacuum created in the vacuum distillation
column is worked out. The net reduction in steam consumption is thus estimated by multiplying
difference in specific steam consumption and amount of vacuum created in the project scenario.
Furthermore, daily report on cooling water consumption for the vacuum creating system would also be
prepared.
Daily report has to be maintained for the electrical energy consumption in the motive liquid circulation
pump of the VHC system.
Verification
The reduction in steam consumption leads to the CO2 emission reductions. The project control system
comprises sophisticated monitoring system like on-line display meters and Distributed Control Systems
(DCS) which measures, collects the information about various process parameters, monitors and controls
on a continuous basis and records on two hourly basis. Fully functional management information is built,
which is generated through DCS in pre-decided daily reports formats so that accessing and verification of
actual data are possible at any point of time. A computerised MIS can be generated and distributed
among decision makers of the project. The major activities to be verified are as under

Verification of various measurement and monitoring methods

Verification of instrument calibration methods

Verification of data generated through on-line meters and DCS

Verification of measurement accuracy
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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page 53
Monitoring of boiler efficiency
Following guidelines are to be used to decide the periodicity for monitoring and estimation of boiler
efficiency by direct method.
1.
The fuel test certificate including calorific value and carbon percentage of the refinery fuel supplied
in the boiler would be provided by the reputed laboratory
2.
The generated steam enthalpy parameters (steam temperature, pressure and quantity) is continually
monitored and entered in log-book at periodic intervals in every shift.
3.
The fuel meters are available for refinery fuels which record the fuel flow to the boiler on continual
basis
4.
The efficiency is estimated on monthly basis by direct method.
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
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page 54
Annex 5
List of Abbreviations
CC
CDM
CER
CO
CO2
CP
Cum
DCS
DOE
DPR
DM
EB
EIA
EOL
GHG
GJ
GOI
GPCB
GWh
HP
HHP
HR or hr
HV
IPCC
KP
km
KV
KW
KWh
LP
1 Lakh
MkWh
MT
MW
NG
Climate Change
Clean Development Mechanism
Certified Emission Reductions
Carbon Monoxide
Carbon di-oxide
Credit Period
Cubic Meter
Distributed Control System
Designated Operational Entity
Detailed Project Report
De-Mineralised
Executive Board
Environmental Impact Assessment
Essar Oil Limited
Green House Gas/es
Gega Joules
Government of India
Gujarat Pollution Control Board
Gega Watt hour
High Pressure
High High Pressure
Hour
High Voltage
Intra-governmental Panel for Climate Change
Kyoto Protocol
kilo meter
Kilo Volts
Kilo Watt
Kilo Watt hour
Low Pressure
1,00,000
Million Kilo Watt hour
Metric Ton
Mega Watt
Natural Gas
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NOC
p.a.
PDD
PFD
PLF
PIN
SSCR
TJ
TPH
UNFCCC
VHC
VDU
page 55
No Objection Certificate
Per annum
Project Design Document
Process Flow Diagram
Plant Load Factor
Project Idea Note
Specific Steam Consumption Ratio
Trillion Joules
Tones Per Hour
United Nations Framework Convention on Climate Change
Vacuum Hydrocirculating System
Vacuum Distillation Unit
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PROJECT DESIGN DOCUMENT FORM (CDM PDD) - Version 02
CDM – Executive Board
page 56
ANNEX 6
LIST OF REFERENCES
Sr.No
Particulars of the references
Kyoto Protocol / UNFCCC Related
1.
Kyoto Protocol to the United Nations Framework Convention on Climate Change
2.
Website of United Nations Framework Convention on Climate Change (UNFCCC),
http://unfccc.int
3.
UNFCCC Decision 17/CP.7 : Modalities and procedures for a clean development
mechanism as defined in article 12 of the Kyoto Protocol.
4. UNFCCC document, Clean Development Mechanism-Project Design Document
(CDM-PDD) version 01(in effect as of: August 29, 2002)
5. UNFCCC document : Annex B to attachment 3 Indicative simplified baseline and
monitoring methodologies for selected small scale CDM project activity categories
ver 01, January 21, 2003.
6. Intergovernmental Panel on Climate Change (IPCC) Document on emission factors.
IPCC-1996-Rev.
7. British Standard BS-845-1987 for Indirect Boiler Efficiency Calculations
8. Steam tables to determine enthalpy of steam
9. Phychrometric charts to determine moisture in air based on wet bulb and dry bulb
temperatures.
10. National Document to refer fuel emission factor, if any.
Project Related
11. Project scheme documents and records from EOL records
12. Design data of M/s TECHNOVACUUM
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