Energy-Saving Activities by Green IT Initiative in...

___________________________________________________________________________

2010/TEL42/DSG/WKSP2/007

Energy-Saving Activities by Green IT Initiative in 2009

Submitted by: Yokogawa Electric Co.

Green ICT SeminarBandar Seri Begawan, Brunei Darussalam

3 August 2010

Energy-Saving ActivitiesBy Green IT Initiative in 2009

August ３. 2010

Yokogawa Electric Corporation

Kazuro Ito

Copyright 2009, Green IT Promotion Council 2

Contents

1. DATA Center by NTT DATA Intellilink Corp.

2. Public Facilities by Panasonic Corp.

3. Plant-1 by Yokogawa Electric Corp.

4. Plant-2 by Toshiba Mitsubishi-Electric

Industrial Systems Corp.


Data Center-Singapore-

NTT DATA Intellilink Corporation


Suｒvey Items

1. Power Usage Effectiveness (PUE) Survey

ＰＵＥ＝Ｔｏｔａｌ Energy Consumption/Energy Consumption of ICT

◆ PUE means energy efficiency level in Data Centers based on DC power.

◆ PUE suggests the existence of power loss.

◆ PUE is useful to find out when the air conditioners and power facilities

should be renovated.

2. Assessment of thermal environment

(Ambient temperature by thermo cameras, temperature loggers, flow

meters and Computational Fluid Dynamics (CFD) Analysis etc.)

3. Analysis of PAC operation

*PAC: Package Air Conditioner


Target

・ Target: A dａｔａｃｅｎｔｅｒｉｎＳｉｎｇａｐｏｒｅ

・ Surveyed Items

◆PUE Survey ： Sector2 , Sector1◆Thermal Environment Survey : Sector2 , Sector1◆CFD Analysis ： Sector2

Sector2

Sector1

Data Center Area (Top View)


Temperature distribution of the room was obtained. Center and upper part of the machine room was higher in temperature than other places.

1 2 3 4 5 6 7

1 2 3 4 5 6 7

Image of measurement

Racks

Shield

Support bar

Cable racks

30℃

15℃

16

18

20

22

24

26

28

Thermal Environment Survey


FL+1.8m

Horizontal

A

B

C

A

B

C

Vertical

A-A

B-B

C-C

①

②

A

B

C

A

B

C

①Improvement hot air recirculation

②Improvement of over suction

【Capping】

Installation of cold isle cappings


0

0.5

1

1.5

2

2.5

3

0 20 40 60 80 100Capacity rate of PAC[%]

Syst

em

CO

P o

f P

AC

[-]

*Electrical power consumption was

calculated by the current of A/C-1

～7,10,11

and measured by the kWh meters of

A/C-9～6.

COP is lower than that of the latest systems. Renovation is recommended.

A/C No.

Survey area of thermal environment

A/C-1

A/C-2

A/C-3

A/C-4

A/C-5

A/C- 6

A/C-7

A/C- 8

A/C- 9

A/C-10

A/C-11

A/C

0

10

20

30

40

50

60

70

80

A/C-1 A/C-2 A/C-3 A/C-4 A/C-5 A/C-6 A/C-7 A/C-8 A/C-9 A/C-10 A/C-11

0

0.5

1

1.5

2

2.5

3

3.5

4

Syst

em

CO

P o

f P

AC

[-]

Electrical power consumption

Cooling capacity

System COP

Ele

ctri

cal p

ow

er

and

co

olin

g ca

pac

ity[

kW]

Capacity rate of A/C[%]

Sys

tem

CO

P o

f A/C[-]

Thermal Environment Survey

Performance rate of A/C : 40 to 80％, System COP : 1.5 to 2.7


Expected effect

Electric Power Reduction = 841,000KWh / 1Year

・CO2 Reduction460 t-CO2 / 1Year

・3.5% improvement on PUE

Sector1 Sector2


Public Facilities-Chulalongkorn University in Thailand-

Panasonic Corporation


Our target is a building of the faculty of engineering at Chulalongkorn University.

Introduction of candidate

His and Her Majesty receiving wreath from students when arriving at Chulalongkorn University.(from Imperial Household Agency HP)

http://ja.wikipedia.org/wiki/%E3%83%95%E3%82%A1%E3%82%A4%E3%83%AB:Main_auditorium_of_Chulalongkorn_University_IMG_0338.jpghttp://www.chula.ac.th/index_eng.htm


Both equipments and operations were found to be improved in air-conditioners (A/Cs) and lightings.

Summary

The temperature setting of

air conditioners

Targets

Increase the standard temperature setting by 2 degrees to 77℉（25℃）, and encourage people to abide by the rule.

Effective countermeasures

Air Conditioners Reduce cost and CO2 emission by installing multi-air conditioning system

FL stabilizers Replace the current copper steel type stabilizers

with inverter type models.


In some areas, A/Cs had been operated at lower temperatures.

Case1 -Increase temperature setting of A/Cs

75°F⇒ 77°F

If set at too low, like 70°F, then an error message comes out.

Although pre-defined temperature was 75°F, it had not been well managed to be so.The target value has been newly set at higher temperature of 77°F and well monitored.

10% of energy reduction is expected by changing temperature set shown above.

That will be equivalent to around 95.6 CO2-ton/year.

Increase the temperature setting of air conditioners.


Multi-air conditioning systems have yet to be used.

Case2 -Use High Efficiency A/Cs

BEFORE AFTER Building multi-air conditioning system

The air conditioners were not recent models and their COPs were not high.

Due to lack of the functional flexibility of the systems, the places where

temperature control was not required have wastefully been air-conditioned.

We estimate the annual energy consumption of air conditioner will be 595,886kWh/year.

By implementing multi-air conditioning system, annual energy reduction

is expected to be 305,210 kWh/year.

That will be equivalent to around 167.9 CO2-ton/year.

Use building multi-air conditioning systems


Current copper steel stabilizer consumes more electricity than inverter stabilizer.

Case3 -Use Inverter type stabilizers in FL-

Currently, copper steel stabilizer, 4,630 units in use, consumes 13% more electricity than inverter stabilizer.

Current annual electricity consumption is 327,243kWh/year

Electricity consumption by current equipment：40WElectricity consumption by improved equipment：35W2908 lamps can be replaced to reduce CO2 emission of 22.5 ton/year.

Replace FL stabilizers with inverter models


Expected effect

CO2 Reduction424 t-CO2 / 1Year

Increase temperature setting

of air conditioners

Use high efficiency air conditioners

Use inverter stabilizers

By other miscellaneous improvements


Plant -1 -Rayong Olefins Co., Ltd. (ROC)&

Thai Acrylic Fibre Co., Ltd. (TAF)-

Yokogawa Electric Corporation


• Step 1

-Target selection (Oct.)“Heat exchanger” &“Ethylene cracking furnace”

-Related operation and maintenance analysis (Oct.)

• Step 2

Frame work study for energy saving (Dec.)

• Step 3

Energy saving proposal to ROC management (Jan.)

Survey Process - ROC

Quoted from Web sites.

Fig-1: Heat exchanger Fig-2 Fouling

Fig-3: Ethylene cracking furnace Fig-4: Tubes

Sample images,not at ROC


Current status and issuesHeat exchangers (HEXs) - ROC

• No heat performance monitoring tools had been available for hundreds of HEXs, thus maintenance targets were listed up based on human experiences. (Time Based Maintenance; TBM)

• Suppose current one HEX performance is as blue line on the right, it will trace red dotted line if it is not cleaned or trace green dotted line if it is cleaned at next turn around. And the difference between the two lines is energy loss.

Heat transferefficiency

Time

Turn around Turn around

Cleaned

Not Cleaned

Operationcycle

Current HEXperformance

• Cleaning needs to be judged keeping balance between the loss and maintenance cost. But without performance monitoring the judgement is difficult to made.

Differenceof energyconsumption

Fig-1: Heat transfer efficiency


Current status and issuesEthylene cracking furnaces - ROC

• No tool had been available for uneven coking tube detection.

• Thus constant volume steam was supplied for de-coking. Even tubes were relatively clean.

• It is likely that this leaves some coking areas after de-coking and it lowers heat transfer efficiency and shorten the next cycle length.

Constant steam feedfor de-coking

Steam

Condition of Heat exchanging tubes

Relatively clean tubeDirty tube

Moderately dirty tube

24 tubes

Fig-1: Constant de-coking steam feed


Survey process （Detail）Ethylene cracking furnaces - ROC

Red bar shows worst 5 severely coking tubes.• Coking status survey of 24 tubes

was done at a cracking furnace by newly developed MVSA (Multi variable statistical analysis) based InsightSuiteAE’s

“Smart fault diagnostician”

---Fig-1

• Optimum de-coking steam supply methods were studied based on the severity

Fig-1: Smart fault diagnostician

Tube & related process

Coking rate


Expected effect - ROC

Electric Power Reduction = 807,000KWh / 1YearSteam Reduction = 290 t-CO2 / 1YearFuel = 300 t-CO2 / 1Year

CO2 Reduction1400 t-CO2/ 1Year

Heat Exchanger Ethylene Cracking Furnace


• Step 1

-Target selection (Oct.)

“Dryer temperature control loops” & “Control valves of entire plant”

-Related operation analysis(Oct.)

• Step 2

Frame work study for energy saving (Dec.)

• Step 3

Energy saving proposal to TAF management (Jan.)

Survey Process

Survey Process - TAF

Fig-1: Dryer and control equipment

Fig-2: Control valve

Temperature sensors Control valves

Air

Air

Air chamber

SteamPlug


Energy-saving proposals and the Effect Control loops @ dryers details - TAF

Proposals• Execution of tuning of control valves

and loops at surveyed dryer by tuning simulator “TuneVP” Fig-1,2

• Introduction of InsightSuiteAE’s“Control loop diagnostician”, “Control valve diagnostician” & “TuneVP” to all other dryers for more savings through plant life-time

Effect• Drying steam saving by lowering zone

temperature pattern• Air compressor power saving

(Indirect effect: Less product quality variance)

Target temperature

Actual temperature

(1) Minimize fluctuation

(2) Lowering set point

(3) Expand to all zones

Fig-1: TuneVP (Tuning simulator)

Fig-2: Expected tuning result

Time

Temp


Energy-saving proposal and the Effect Control loops @ dryers details - TAF

Fig-1: Control loops tuning trial (Before)

Fig-2: Control loop tuning trial (After)

Disturbance: Line speed change(+ interference from up stream zones to down stream zones.)

Dryer temperaturesZone 1, Zone 2Zone 3, Zone 4Zone 5, Zone 6

Time

Temperature/Line speed

Time

Temperature/Line speed


Electric Power Reduction = 6,400KWh / 1YearSteam Reduction = 490 t-CO2 / 1Year

CO2 Reduction494 t-CO2/ 1Year

Control loops Stable valve controls

Expected effect - TAF


Plant -2 -Rayong Olefins Co., Ltd. (ROC)&

Thai Acrylic Fibre Co., Ltd. (TAF)-


Summary

ROC

Cooling water pump etc

Targets

Inverter type speed control for motors in

pumps especially with medium voltage

motors

Effective countermeasures

TAF

Water pump for chiller etc


Survey Process （Detail）PUMP Q-H CurveP

um

p H

ead

; H

Pump Flow ; QQ1

H1

Flow loss Curve

R = Q2

H = A-(A-1)Q2

REQUIRED MOTOR

POWER


Survey Process （Detail）Valve Control vs Speed control

Pu

mp

H

ea

d ;

H

Pump Flow ; QQ1

H1

Flow loss Curve

R = Q2

H = A-(A-1)Q2

REQUIRED MOTOR

POWER

A

0.7x Q1

Pu

mp

H

ea

d ;

H

Pump Flow ; QQ1

H1

Flow loss Curve

R = Q2

H = A-(A-1)Q2

REQUIRED MOTORPOWER

A

0.7x Q1

Valve Control Speed Control


Target item at ROC

Item No. : PM-2400C

Equipment : Cooling water pump

Motor rating : 10P-1850kW-6600V-50Hz-F eG3

6.6kV-2600kVA TMdrive-MVG is applicable.

(*The existing eG3 motor shall be replaced

with a new explosion-proof motor

in order to get variable speed motor

explosion-proof certificate.)


Inverter -TMdrive-MVG 6.6kV-2600kVA-

6.6kV-2600kVA


Expected effect

Electric Power Reduction = 7,266,000KWh / 1Year

CO2 Reduction4,032 t-CO2 / 1Year

ROC

Electric Power Reduction = 1,204,000KWh / 1Year

TAF

CO2 Reduction668 t-CO2 / 1Year


Conclusion

The Japanese companies engaged in this survey assured

themselves of its business models through these activities.

Japan’s Energy Saving Products and Solutions by IT will contribute

to energy-saving in ASEAN countries and world wide.

Thank you very much for the cooperation of the partner companies

and the great help from the Japanese Government (METI).

Copyright 2009, Green IT Promotion Council 35 35

Green IT The best practices collection 2009

＝Contents＝•Member Introduction

•Product Introduction

etc

Http://greenit-bestpractice.jp/en/

•Search by keyword

•Search by information category

•Search company list

etc
http://greenit-bestpractice.jp/en/http://greenit-bestpractice.jp/en/http://greenit-bestpractice.jp/en/

Energy-Saving Activities by Green IT Initiative in...

Documents

Transcript of Energy-Saving Activities by Green IT Initiative in...