The document summarizes INVISTA's efforts to modernize and simplify steam and HVAC systems at facilities in the UK and US to reduce costs and energy usage. In the UK, the system was upgraded by installing new steam boilers and eliminating an aging hot water system. This provided energy savings of 25-35% along with major maintenance and operational savings. In the US, waste heat recovery, boiler upgrades, and steam header simplification reduced energy usage by 25% and costs by eliminating staffing needs. Future plans include modernizing other utility systems for greater efficiency and automation.

1. FMA Future Facilities Summit:
INVISTA Utilities Systems Transformation
Mark Niehaus
October 22,2019

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Outline
• New Boilers / HVAC Systems in the UK
• Summary of Existing System and issues
• Alternatives studied
• Final System Design
• Benefits of the system
• Steam System Energy Savings and Simplification in the US
• Summary of existing system and issues
• Heat Recovery Project
• Steam System Simplification

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UK Synthetic Fiber Site – Heat/HVAC Infrastructure in 2016
• Synthetic fiber spinning site includes spinning, packing, warehouse, and support facilities.
• High Pressure Hot Water (HPHW) System
• Space Heat for spinning (1 large and 3 small HVAC units), and warehouse (piping and unit heaters).
• Two High Pressure Hot Water fire-tube boilers operating at 150 deg. C.
• Two circulation pumps and extensive piping distribution system.
• Oversized for remaining operation. (Piping losses equal 30-50% of HPHW energy consumption.)
• Piping system age results in frequent leaks, particularly if system is shut down and restarted.
• Leaks are expensive to repair due to asbestos insulation.
• Steam System
• Heat for process and some smaller HVAC systems.
• Three 250 psig, firetube steam boilers.
• Existing boilers require continuous monitoring by licensed boilermen per UK regulation.
• Common reliability and maintenance issues:
• All five boilers have shell cracking problems from decades of cyclic duty.
• Boiler burners are obsolete and parts are no longer available causing reliability losses.

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INVISTA UK Heating System - Alternatives Studied
• Base Case: Replace burners and controls and continue to repair existing boilers.
• Resolves the near-term reliability issues, but defers shell cracking issue.
• Little energy savings, little maintenance savings, no operations savings.
• Option 1: Replace existing with two new steam boilers and two steam heated HPHW exchangers.
• Option 2: Replace existing boilers with two new steam boilers and two new HPHW boilers.
• Option 3: Replace existing boilers with two new steam boilers and one new HPHW boiler.
• Option 4: Eliminate the HPHW system and install two new steam boilers – Selected Option
• Highest maintenance savings, highest energy savings, highest operations savings.
• 20% more capital than option 3.
• Approval to proceed with purchasing two new steam boilers in November 2015.
• Full funding was approved in February 2016.
• All systems operational in January 2017.

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INVISTA UK Heating System Final Design
• Steam System Modernization:
• Two new fire-tube, 250 psig boilers to replace three existing steam boilers.
• Fully automatic burner safety, start/stop, combustion, and blowdown controls.
Old Boilers
New Boilers

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INVISTA UK Heating System Final Design
Gas Burner
• HPHW Elimination:
• Electric heat tracing on selected fire
protection headers to replace warehouse
heating.
• Convert 3 existing smaller HVAC unit hot
water coils to steam.
• Convert lab hot water heating system to
electric heat.
• Replace hot water unit heaters in shops with
electric unit heaters.
• Convert one large process HVAC unit from
hot water to direct fired natural gas.

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• Simple Payback: 3 years
• Energy Savings: (25% of savings)
– Eliminate heat losses from HPHW piping distribution system and boilers.
– Eliminate pumping energy in HPHW distribution system and reduced boiler fan horsepower.
– Increased boiler efficiency.
– Direct fired natural gas heating is more efficient than steam or HPHW heating.
– We consistently see between 25 and 35% gas savings!
• Operations and Maintenance Savings: (75% of savings)
– New boiler controls meet regulatory requirements to allow operation without 24/7 coverage by licenced boiler
operators.
– Significant reduction in routine overhaul cost for two new versus five old boilers.
– Elimination of frequent repairs to boiler shells.
– Elimination of frequent repairs to HPHW distribution piping (including asbestos work).
– Improved reliability results in fewer repairs and production losses.
INVISTA UK Heating System - Results

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US Steam Plant Energy and Infrastructure Savings
Summary of Existing Steam System Infrastructure:
• One large field erected, 850 psig boiler of 1968 vintage.
• Converted to natural gas in 2011, with SCR, CEMS and aqueous ammonia system.
• High pressure feedwater pumps – two need overhauls.
• Oversized ID fan and fluid drive with vibration and foundation issues.
• High maintenance cost.
• One 1950s vintage 5.5 MW, 850/300/40 psig turbine generator – to be abandoned.
• One 1968 vintage, 2 stage, 4000 hp turbine driven air compressor – to be abandoned.
• Aging 850 psig steam distribution system (50-70 years old).
• HP to LP feedwater pressure reducing station.
• Two 850/300 psig pressure reducing stations, two 850/40 psig pressure reducing stations.
• Three small 300 psig, package boilers, installed in 2014.
• Two low pressure feedwater pumps installed in 2014.
• One 300/40 psig pressure reducing station.
• Average steam demand has been declining due to energy program.
• Peak winter loads were above to the system “firm capacity”. (4th boiler is needed for spare.)
Synthetic fiber site includes polymer production, spinning, packing, warehouse, and support facilities

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0%
50%
100%
150%
200%
250%
Total Capacity Firm Capacity
Boiler Capacity as Percentof FirmCapacity
Boiler #3 Boiler #6 Boiler #7 Boiler #8
US Steam Plant Energy and Infrastructure Savings
Firm Capacity =
Capacity with largest
unit out of service.

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US Steam Plant Energy and Infrastructure Savings – Step 1
Recent History (Energy and maintenance cost reductions):
• 2015 – 4000 hp Steam Turbine Driven air compressor replaced with 2000 hp electric
compressor.
• 2016 – 1500 Ton 20-year old absorption chiller replaced with new 1500 ton electric chiller.
• 2017 – 2800 ton 1968 vintage electric chiller and 1200 ton, 1998 absorption chiller replaced
with one 3000 ton electric chiller.
• In all three above projects the savings were roughly 50% energy and 50% maintenance
related.
• 2017 – Eliminate redundant steam header.
• 2017 – Return air utilization on drive room HVAC to reduce winter steam demand.
• 2018 – Continuous Polymerization unit heat recovery.

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US Steam Plant Energy and Infrastructure Savings –Step 2
Waste Heat Recovery Project Scope ($1.5MM):
• Use hot cooling tower water (110 deg. F) from process heat exchangers in polymer area to
heat process HVAC in spinning building.
• Approximately 1500 feet of piping, control valves for HVAC units, and controls.
• Cross-tie between cooling tower water and chilled water systems.
• Change to water treatment system since chilled water and cooling tower will be mixed in the
winter.
• Startup in January 2019.
Waste Heat Recovery Project Benefits:
• Saves $450k/year of fuel.
• Reduces peak winter steam demand by 25%.
• Two of the three package boilers can meet winter steam demand.
• Switch boiler #3 to “harvest mode”:
• Reduces sustaining capital by $600k one time.
• Only expect to run 1 or 2 months/year during overhauls.
• Reduces maintenance by $90k/year.

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0%
20%
40%
60%
80%
100%
2014 2015 2016 2017 2018 2019
Boiler Load as percentof firm boiler capacity
Annual Average Load Peak Month Average Load Peak Winter Hour
US Steam Plant – Boiler load versus firm capacity
Warm
Winter
Peak Demand below
67% of firm capacity
allows permanent
shutdown of the large
field erected boiler.
Annual average
Peak Winter hour
Peak Month Average

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US Steam Plant Energy and Infrastructure Savings –Step 3
Simplify Steam Generation System Scope:
• Permanently blank boiler #3, SCR, Ammonia, and CEMS systems.
• Permanently isolate 5.5 MW generator and 4000 Hp turbine driven compressor.
• Permanently isolate 850 psig steam distribution system.
• Permanently isolate high-pressure feedwater system.
• Eliminate four steam pressure reducing stations and one feedwater pressure reducing
station.
• Install one new 300/40 psig pressure reducing station.
• Install one new low-pressure feedwater pump with auto start.
• Automate startup on makeup water and other small pumps.
• Relocate boiler control interface for package boilers to another existing control room.
Simplify Steam Generation System Benefits:
• Saves $100k/year of fuel and electricity.
• Eliminates one manned control room.
• Reduces maintenance and operations cost by $500k/year.
• Reduces sustaining capital by $600k one-time by eliminating need to upgrade controls.
• Construction underway.
• Scheduled completion in April 2020.

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0%
50%
100%
150%
200%
250%
300%
350%
400%
1970-2010 2011 2014 2020
Total Boiler Capacity as % of 2020 Plan
Boiler #1 Boiler #2 Boiler #3 Boiler #4 Boiler #6 Boiler #7 Boiler #8
100% Gas
100% Coal
Coal
Coal
Gas
100% Gas
US Steam Plant Infrastructure Reduction
75% availability 95% availability

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Next Steps – Duplicate steam system improvements in other systems:
High Temperature Heat Transfer System Modernization:
• New PLC Burner Management System/variable speed fan drives
• Remote monitoring of pump temperature and other equipment via wireless sensors
• Scheduled completion in 2020.
• Benefits:
• Improved reliability
• Allows remote and automatic burner start/stop – no routine field operator duties
• Operations and maintenance savings
• Energy savings
Compressed Air System Modernization:
• Eliminate one of the three pressure levels to eliminate two compressors.
• Upgrade compressor machine controls on remaining compressors.
• Upgrade compressor system controls for two remaining headers.
• Scheduled completion in 2021.
• Benefits:
• Improved reliability.
• Eliminates operator intervention to adjust compressors – eliminating need to be in control room.
• Energy savings

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Key Points:
• Most energy projects require multiple drivers (energy savings, maintenance
savings, operations savings, reliability improvement) to compete for resources
and capital versus production improvements at an industrial site.
• A long-term goal such as a 20% reduction in energy intensity, or a single site
control room, helps to expand our thinking and see a bigger picture.
Significant reduction in energy intensity enables simplification of infrastructure,
improved reliability, and automation at a lower investment.
• Current controls technology combined with reliable equipment allows
significantly reduced maintenance and operations staffing versus historical
legacy industrial energy systems.
• We need to shift to a “utilities technician” model to perform higher value tasks
such as PMs and improvements rather than a “utilities operator” who monitors
equipment and adjusts controls that could be automated.