Energy Management
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Transcript of Energy Management
Energy ManagementBuilding your Foundation with Energy Measurement
Joel LemkeFlow Specialist
[File Name or Event]Emerson Confidential27-Jun-01, Slide 2
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Implement Site Management
Optimize Unit Processes
The Energy Improvement Process
Survey and Measure
Fix Devices and Loops
Address Equipment
Begin
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Proper Flow Metering is Part of All Energy Management Actions
Metering Needs:
Optimized Combustion Control to
reduce excess O2
Enhanced Compressor
Control
Reduce Pressure Losses
Flexible Fuel – Maximize use of Low Cost
Loading Balance – Run
the Most Efficient
Equipment Fix Insulation Issues
Increase Condensate
Returns
Repair Leaks
Steam Trap Maintenance
More accurate & repeatable Fuel/Air (mass) flows
Flexible metering technology Balance/know energy consumption
by use point Mass balance of utilities Output flow measurement for each
boiler, compressor, chiller
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What is Included in a Good Energy Measurement Plan?
Accurately Measure All
Utilities
Establish Benchmarks for Energy In vs. Energy
Out
Automate Data
Collection
BTUs
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Balance & Benchmark
Objective: Benchmarking to identify areas for energy
improvement
To benchmark, must energy balance first
Energy In = Energy Out
All energy (used or else) must be accounted for
If data is not reliable, it won’t be used
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Types of Energy
Energy consuming systems & processes use:
Electricity, Fuel, Compressed Air, Steam, water
Each Energy System needs to be analyzed to
identify opportunities for improvement
Each Process Unit needs to be analyzed to
identify opportunities for improvement
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Balance & Benchmark Start by listing:
All major systems All major processes/usage areas
Then develop Energy Envelopes for each Boilers / steam Electrical (includes lighting, motors, drives, controls) CW systems HVAC Compressed air Major Process Units
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Energy Balance Major process units
– Pulp & Paper• Paper machine, • Coating• Pulp mill
– Refining• Cat cracker• Coker• Hydrocracker
– Steel Mill• Coke plant• BF• BOF• Caster• HSM
Energy In = Energy OutElectricalSteamChilled waterCompressed airGasAdditional Utilities
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Energy Management
“If you want to Manage it you have to Measure it”
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Application FluidProperties
Performance Installation EconomicFactors
Environmental& Safety
MeterSelected
Liquid, Gas, SteamConductivityMulti-phaseViscosityPressureTemperatureWetted parts
AccuracyRepeatabilityTemperature EffectResponse Time
Line SizeVibrationPipe RunsSubmergence
CostInstallationReliabilityMaintenance
EmissionsHazardous Waste Leak PotentialShut Down System?
ControlMonitorIndicateBatchingCustody Transfer
Flow Solutions
CoriolisDP FlowMagneticVortexOther
Select the Right Flowmeter for the Application
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Energy Management Best PracticesMinimize Pressure Loss
Save on EnergyOptimize Performance
Correct Flowmeter Installation
Automate Data Collection
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Energy Management Best PracticesMinimize Pressure Loss
Save on EnergyOptimize Performance
Correct Flowmeter Installation
Automate Data Collection
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3 sources of error make traditional flow measurement inaccurate in Gas and Steam applications
Source #1: P&T Variation
Pressure & Temperature variation in Gas & Steam
Source #2: Primary ElementFlow Coefficients not constant
Source #3: Transmitter
Installed performance of transmitter over flow range
Mass Flow in Gas, Steam & Unstable Liquids
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Measure Mass Flow40.9 gal(154.8 L)
42.0 gal(159.0 L)
60º F (15.6º C)20º F (-6.7º C)
342 lb (155.1 kg)
342 lb (155.1 kg)
2.7%
0.0%
Mass (Energy) is Conserved,Volume is not
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* Per Crane Handbook
Measure Mass Flow in Gas When Density Changes
20 ft
Manufacturer’s Specification
20 ft pipe2 elbows
Typical variation
0.55 psi 1.0%
0.44 psi 1.1%
0.5 psi 0.9%
Total 1.49 psi 3.0%
Max Variation
RegulatorP = 40 psi
P = 39.08 ± 1.05 psi
RegulatorDroop
PipeFriction*
BarometricVariation
% Error
Pressure at the source does not equal pressure at the destination
Density compensation improves flow performance
Natural Gas Example:2 inch pipeFlow rate = 10,000 SCFH
3.0%
1.5%
<0.1%
Flow = K * DP * r
Flow = V * Constant ρflow
SQRT is to the 1/2 power
Pressure and Temperature Variation CompensationMultiVariable
Uncompensated DP
Uncompensated Velocity
0 1 2 3 4
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Multivariable Mass Flow for Natural Gas, Steam, Air & other gases
WE CALCULATE:• Density• Viscosity• Velocity• Beta Ratio• Enthalpy
• Gas Expansion• Discharge Coefficient• Velocity of Approach• Reynolds Number• Compressibility Factor
YOU ENTER:• Process Fluid• Primary Element• Line Size
• Mass Flow• Energy Flow
• Volumetric Flow• Totalized Flow
• Process Temperature• Differential Pressure
• Static Pressure
YOU RECEIVE:
WE MEASURE:• Differential Pressure• Static Pressure• Process Temperature
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Challenge– Fuel gas composition varied
considerably.– Fixed F/A ratio led to hot spots &
NOx when fuel Btu rose.– Reduced production to 80%
capacity to prevent the hot spots & NOx.
– Overall plant capacity reduced due to less steam production.
Solution– Coriolis direct mass meter
installed on main fuel line.
Outcome– Better measurement enabled
automatic cascade control.– Production increased to nearly
100% capacity.– Hot spots and NOx reduced greatly.
Gas MeasurementBoosting Combustion Control
Coriolis Elite Mass Flow Meters
NGRFG
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Energy Management Best PracticesMinimize Pressure Loss
Save on EnergyOptimize Performance
Correct Flowmeter Installation
Automate Data Collection
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Correct Installation of the Flowmeter is Critical for Accuracy
VS
Eliminate Impulse LinesAdequate Straight Pipe RunOrifice Plate Alignment & Pipe ID UncertaintyProper steam conditioning
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Typical DP Flow Straight Run Requirements
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5
10 Diameters Upstream5 Diameters Downstream
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Required Straight Pipe for O-Plates
Measurement of fluid flow in pipes using orifice, nozzle, and venturi
ASME MFC-3M-2004
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Ideal for both new and retrofit DP flow applications Requires only 2D of straight pipe upstream and 2D
downstream from any flow disturbance– Up to 90% reduction of piping from standard orifice installations
Rosemount Conditioning Orifice Technology
Geometry conditions the flow profile across the entire pipe
The four orifice holes act as a flow conditioner and primary element in
one device
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Conditioning Plate for Short Run Applications
Typical air to fuel ratio of 10:1
4” gas line typically has a 12 or 14” air line
After elbow, 60 pipe diameters (60 feet) required for a 0.6 beta o-
plate
Performance degradation rule of thumb:
– Installed perf. = Perf. / % of recommended straight pipe
– 2% device has 50% of recommended straight pipe
– Installed perf. = 2% / 0.50 = 4%
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Direct Mounting Reduces Maintenance…and Improves Consistency & Accuracy
Eliminates inaccuraciesConsistent installationsReduced complexityLeak points reducedNo leak testing
Traditional Installation DP Flowmeter Installation
Instrument Tubing is 10 to 20 feet long, plus several elbows Increased potential leak points and plugging
Transmitter is direct-mounted less than 1 foot from the pipe, with straight connections Reduces potential leak points and plugging
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Removing Leak Points Saves Time and Money Direct Mounting Reduces Leak Points
All but 2 potential leak points factory leak-checked.
$1214/year energy* per leak PLUS:• Value of lost process fluid• Personal safety and risk• Environmental cost, impact• Cost of inaccurate measurement• Maintenance cost of repairing leaks
*U.S. Dept. of Energy Office of Industrial Technologieswww.oit.doe.gov/bestpractices
*75 psig steam;1/16” diameter leak;$10 per 1000 lb steam
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3000 applications over 3 years resulted in only 6 work orders
90% reduction in work orders
46% reduction in total maintenance cost
* Copy of study available from Rosemount. Document 00802-0100-2071
3-Year User-Study* Finds Implementing Direct Mount Technology Pays Off
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Flow meters designed for single-phase (liquid or gas, not both)
Condensate in steam reduces effective pipe area
Water hammer possible if too much liquid build up
Water heat transfer terrible compared to steam!
Why is Condensate Drainage Important?
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Aluminum Recycler Flow Meter Audit
¼” water leg imbalance = 12.5% flow rate error at 1 inH2O DP
DP xmtr
Background: North Plant reverbs 1, 2, 7 & 8 2 burners/reverb Air & gas flows on each
reverb (except #2) Є Calculations > 100% 3rd party out to calibrate
twice & found no issues w/ xmtrs
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Aluminum Recycler Flow Meter AuditFindings: XMTRs mounted below pipe - moisture
accumulated (2) Orifice plates installed backwards Some O-plates sized for flange tapping,
but installed as D, D/2 Not one air meter had enough straight
pipe Sizing based on nominal pipe size, not
actual pipe ID 1 sized for a 3.5” pipe instead of a 4”
– flow error = 6.5% All natural gas sizings used SG = 0.87
– Correct specific gravity = 0.60– flow error = 20.4%
Correct 20% low
Fixing the issues corrected the plant energy balances.
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Energy Management Best PracticesMinimize Pressure Loss
Save on EnergyOptimize Performance
Correct Flowmeter Installation
Automate Data Collection
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Emerson ConfidentialSlide 31
Flow Meter Pressure Loss Potential Waste of Energy
Copper Smelting Example:• Orifice plate pressure losses (PPL) were bottleneck to proper air delivery to
“converters” (remove impurities from molten Cu)• Replacement with alternate meters maintained control and nearly eliminated PPL• Required Blower discharge pressure dropped from 21 to 16.5 psi
$500k annual reduction in electricity to blowers
.
.
.
Blowers
PL1
PL2
PL3
PL4
FT1
FT3
FT2
PL5
FT4
FT5
FT6
FT7
PL6
PL7
Energy In
Use Point #1
Use Point #2
Use Point #3
Use Point n
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Energy Savings Results Chilled water flows (7) 10” lines, 0-4000 GPM (7) 14” lines, 0-5000 GPM Existing DP/orifice plates
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Energy Savings QBR (pros & cons)14" Line Comparison DP/O-Plate DP/Annubar Magmeter
Performance @ Normal Flow 0.60% 0.90% 0.30%
Turndown with +/- 2% Perf. 6 to 1 5 to 1 33 to 1
Performance @ 10:1 Turndown 8.25% 5.00% 1.00%
PPL @ Normal Flow 5.3 psi 2.1 psi 0 psi
PPL Cost at Normal Flow $8,572 $3,402 $0
PPL Savings @ Normal Flow X $5,170 $8,572
Required Straight Run 56' 16' 8'
Installed Cost $10,450 $7,260 $16,290
ROI X 27.6 mo. 29.4 mo.
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Energy Management Best PracticesMinimize Pressure Loss
Save on EnergyOptimize Performance
Correct Flowmeter Installation
Automate Data Collection
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Energy Management Infrastructure
Strategic Business Decisions Who are the big
users? Who is inefficient? Over time, who is
becoming inefficient?
ROI Driven Actions
Collect Data
Analyze Data (Btu/sq. ft. or Btu/ton, etc.
data)
Report Data (bldg. or
dept. ownership)
Production Unit 1
Production Unit 2
Production Unit n
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Powerhouse
Steam Distribution
Operating Units
Desired Measurement Points
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Process Today
Only about 30% of engineer’s wish list automated…
Points critical for control and safety are wired
Often just 4-20mA– No Diagnostics
High value monitoring points wired
Remaining points manually collected
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Process Pains
In addition to process, automation needs exist for safety, reliability, maintenance, utilities, asset protection and more.
Wired Points– ROI justification is high due to installation costs – Diagnostics are often missing due to legacy
host systems– Automation is limited by the economics of wires
• Corollary: Process efficiency, safety, uptime, are limited by the economics of wires.
Manual Points– Exposes user to process environment– Exposes measurement to human error
• Fatigue, double entrees, repeatability– Time consuming
• Mundane routines, wasted human capability collecting data instead of solving problems
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Achieving real-time data
Emerging customer trend: wireless networks 3X larger than originally intended due to scalability.
Wireless is a truly scalable instrument technology– Start as small as a single gateway
and 5 instruments Gateway
– Capacity for 100 points– 4 second to 60 minute updates– IEC 62591 wirelessHART standard
Ideal for (energy) monitoring applications
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Complete portfolio exists to solve problems in real-time
Smart Wireless THUM Adapter
Hydrocarbon Leak Detection
648 Temperature
CSI 9420 Vibration
6081 pH
702 Discrete
2160 Vibrating Fork Liquid Level Switch
4300 Series Position Monitor
3051S SeriesPressure, Level & Flow
848T Multi Input Temperature6081C Conductivity
Smart Wireless Gateway
Create sustainable, sharable, repeatable solutions
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Pulp & Paper Mill - Wireless Energy Monitoring Implementation
Option 1 Option 2
Total Measurement Points:
15Total Measurement Points:
60$5.5k / point
Wired Flowmeter Cost
Flowmeter $75,000
Wiring/Conduit $225,000
$20k / point!
Wireless Flowmeter Cost
Flowmeters $300,000
Gateways $12,000
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Summary: What is Included in a Good Energy Management Plan? Balance & benchmark: Energy envelopes for energy systems
and process units
Accurate sub metering of all utilities: Electric, steam, water,
compressed air, gas)
Take into account all factors that affect performance
Consider turndown
Install flowmeter correctly, maintain flowmeter
Select flowmeters with minimal PPL: Reduce energy
consumption
Real-time, cost effective information: Wireless
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Energy Management
“If you want to Manage it you have to Measure it”
Questions?