Energy Monitoring Solutions - Endress+Hauser

8/18/2019 Energy Monitoring Solutions - Endress+Hauser

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Energy Monitoring Solutions from Endress+Hauser

E+H-BE/JJR

Slide 2

14/06/2009

Agenda Potential Savings

Energy Monitoring Solutions

Case studies: You can monitor only what you measure !• Case study 1 : Controlling the Boiler efficiency • Case study 2 : A monastic brewery subject to the energy agreement • Case Study 3 : Steam measurement and ‘Green’ certificates

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Typical Production Process

Raw Material

Labor

E a u

A i r

G a z

E l e c t r i c i

t é

V a p e u r

Products

Emissions/

Effluents

W

a t e r

A i r

G a z

E l e c t r i c i

t y

S t e a m

E m

i s s i o n s /

E f f l u e n t s


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Potential Savings

…Over the past 15 years, significant development work hasbeen undertaken in the UK. Results indicate that, when

properly implemented, an EMIS can save 5 to 15 percent ofannual energy costs . As an initial approximation, 8 percent appears to be a reasonable estimate….

Office of Energy Efficiency of NaturalResources Canada:Energy management information systems:achieving improved energy efficiency:

a handbook for managers, engineers andoperational staff


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Energy Savings Process

Metering& Data

Collection

Data Analyses(Data to information)

Energy Reporting (Informations tounderstanding)

Optimize(Understanding to results)

Controlling of

Energy Data

Transparency ofConsumption

Customer

You cannot optimize w hat you do not measure !


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Pay-back Example of a Printing Company (SC-UK)

Total Operating Expense 6.41Mio. €

Capital Cost (20%) 1.75 Mio

Raw Materials (35%) 2 Mio.

Energy Cost (35%) 2 Mio.

Personnel Cost (10%) 0.66 Mio.

Realistic Savings 8% ~ 160,000€/year

Typical Payback < 2 years


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Fast Pay-Back and Sustainable Savings

Energy Monitoring System incl. Sensors:

Investment: 96,000€Savings: 13,300€ per month

Pay-back: 8 monthsPrice in Mio €

Time in Months3 6

with Energy Monitoring

ROI after7.2 months

2.0

9 120

0.5

1.0

1.5

without Energy Monitoring

1 2 4 5 7 8 10 110


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Five Utilities – WAGES

W a t e r E l e

c t r i c i t y

C o m p r e s s e d

A i r

G a s ( N G ,o i l a n d o t h e r s )

Steam


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Slide 10

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Energy Monitoring, Analyses and Reporting

Energy Measurement

Visualization andRecording

Analyses andReporting

Calculation andTransmission

Utilities

SteamCompressed Air

Electricity GasOil

WaterHeating

Cooling

Process Fluids

Energy Monitoring Software(EMS)


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From a single Measuring point to global Energy Monitoring

F e a t u r e s

Price

Accurate Calculationand Notification incase of faults

- Data Recording - Visualization- Analyses- Effiziency Calculation

- SEC- CO2 Emissions- Supervision of Comp. Air Filters

- Find leaks

- Transparency of Energy - KPIs- Deviation Analyses- ROI Calculation- Benchmark

- Reporting - Energy Cost per product - Energy Planning - Early Detection of

Deviations


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From a single Measuring point – Package T

F e a t u r e s

Price




- Find leaks



Deviations


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Which measuring technology for which application ?

There is no perfect meter for gases or steamapplications

Most applications can be handled by several

measuring technologies and every principle hasits own advantages and limitations

Endress+Hauser offers a broad range of gas flowmeters, so that we are able to offer the best-fit

solution for the requirements of the applicationTo be able to offer the best-fit solution,Endress+Hauser developed for the last 10 yearsa know-how in gas measurement, byconsidering all the pros and cons of everymeasuring technology

It is essential to take particular care to theinstallation requirements (inlet/outlet runs) andto the individual gas type and application (gas

composition, pressure, T°, moisture, …)


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Steam – The Most used Energy

Steam represents more than 34 % of the total energy which isused in industrial applications for the manufacturing of products

more than 83 % of the total energy used in the Pulp & Paperindustry

more than 57 % of the total energy used in the Chemical industry

more than 42 % of the total energy used in the Petrochemicalindustry

Steam is mainly measured in

mass units ( kg/hr or t/h) ,more seldom in kWh


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Steam – The most used technologies

Vortex

Differential PressureCoriolis

Thermal

In very specific applications


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… to a Basic Monitoring – Memograph M

F e a t u r e s

Price




- Find leaks



Deviations


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Case Study 1Controlling the boiler efficiency

There can be no economy where there is no efficiency (Benjamin Disraeli, 1 October 1868)

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Controlling Boiler efficiency gives savings potential

Condensatereturn

Make-up water

Steam

Feed water

Nat gas

Flue gas

Blowdown

There are several terms used to qualify efficiency when usedin the context of a steam boiler


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Controlling Boiler Efficiency – Input-Output Method

Condensatereturn

Make-up water

Steam[MJ/h]

FuelFuel

Feedwater Feedwater Blowdown BlowdownSteamSteam

hmhmhmhm

Efficiency :

Memograph M

Feed water[MJ/h]

Nat gas[MJ/h]

Flue gas

Blowdown

Flow Temperature

Energy

Mass

Enthalpy


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Actual gas consumption difference compared to expected

Installation of an Economiser

Control limits

Target line


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Case Study 2 A monastic brewery also subject to the energy agreement

Trappist brewery of Chimay can also improve earnings byreducing the Energy bill !

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Return on Investment: Less than 2 months !!


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Initial situation – Split in function of Production

Situation before the installation of the news measuringequipments:

Distribution of the invoice from the steam boiler and itsconsumption on the basis of ratios depending on the producedquantities

Existing flow meters were not accurate (indication)

Energy balance was not correct


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Measurements for accurate costs distribution

ReadWin

ETHERNET

F i e l

d

4-20 mA

Signal remote Prowirl 72

3 x 4-20 mA

3 x Pulse

E l e c

t r i c a l c a

b i n e

t

O f f i c e

Bottling Charcuterie dept Cheese dept


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E+H-BE/JJR Slide 27

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New situation – Reveal savings potentials

• After the installation of the new accurate steam measuringequipments, the measuring results were not according to theexpectations of the end users:

“these new meters are not correct !”

• A good analyses of the measuring results and a walk-around ofthe factory showed deficiencies at the existing facilities:

• Bad insulation of the 100m steam pipes to the cheese department

• Many steam traps were not operating correctly (leaks)

• Many ‘classical’ leaks


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E+H-BE/JJR Slide 28

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Result – Optimize the energy efficiency sustainably !

Direct impact of these improvement actions resulted in areduction of 35 % of steam consumption !

The Return on Investment was less than 2 months !!

Indirect impact of the installation of these flow meters was:

The bill of fuel in 2005 was lower than the one in 2004 , even if atthe same time, production was increased and price of fuel went up

with 37%.

All departments were convinced that a continuous measurementlead to permanent attention

Permanent measurement is important, not only to reduceenergy costs, but also to discover reduced efficiency earlier(sustainability)


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E+H-BE/JJR Slide 37

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… up to a Global Energy Monitoring – Package S

F e a t u r e s

Price




- Find leaks



Deviations


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E+H-BE/JJR Slide 38

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Traditional collection of data !!

Data collectiononce/month

Paper recording of data

Old electrical counters


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E+H-BE/JJR Slide 39

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FXZ520Module

4x Pulse

Mobilfunk GSM/GPRS

Existing SCADA

Energy Monitoring Software

ExistingProduction Data

Ethernet

Database

Data Access Scheduler

Client Server

Software for 15min. to 30min.Data collection

FieldgateFXA520RS485

HART-Multiplexer

RS485FieldgateFXA520

PLCField ControllerSFC173

EnergyComputerRMx621

Memograph M

Fully automatic Data Collection of Energy Data


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E+H-BE/JJR Slide 40

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Energy Monitoring Software

Manual Data Entry

Alarm Configuration

Reporting

Easy Online Data Access

Graphic Analyses

f


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E+H-BE/JJR Slide 41

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Determine relationship by line of best fit

E M i i S l i f E d H


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Actual gas consumption difference compared to expected

Installation of an Economiser

Control limits

Target line


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Slide 45

14/06/2009

.CSV

HARIBO – UK

NETWORK

Database

server

softwareDonnées deproduction

Data AccessScheduler

Comp. air Waterprod°Towards storage

RS485FXA520

FXA520RS485

FXZ520’s

Boiler gasCompressedair

FXZ520

Effluent Steam

Gas supply Water supply Sub 2 electricity Comp 1 electricity

TempPressure Electricity

supplier

Energy Monitoring Solutions - Endress+Hauser

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Transcript of Energy Monitoring Solutions - Endress+Hauser