ENERmanagement 2011ENERmanagement 2011...Tenaris Energy Saving plan Tenaris and Tenaris Dalmine’s...

ENERmanagement 2011ENERmanagement 2011

F d i RiFederico RizzaRegional Energy Consumption Specialist

Tenaris: Global Industrial SystemServing the world’s energy industry and other industrial applications

• Annual manufacturing capacity of six million tons of steel pipes steel pipes

- 3.4 million tons of seamless pipes

- 2.7 million tons of welded pipes

• 4 electric steel shops

• 16 seamless rolling mills

• 32 welded tube mills

• 52 heat treatment lines (28 in hot rolling mills )

• 78 premium threading lines

• One Health Safety and Environment Management • One Health, Safety and Environment Management System Worldwide Operations

MSTE - ENMA Tenaris 217 June 2011

TenarisDalmine Plants

Turnover: € 1,6 billion

People: 2500

Sabbio BergamascoProducts: Cylinders/Large cylinders, AccumulatorsPeople: 2500

DalmineProducts: Mechanical tubing, OCTG, Line

ArcoreProducts: Mechanical tubing, Structural tubing, Hollow bars

pipe, Tubes for petrochemical plants, Pipe for high-temperature service, Hollow bars, Structural tubing.

PiombinoProducts: Butt welded steel pipe for plumbing

Costa VolpinoProducts: Seamless cold drawn tubes for hydraulic circuits and cylinders, Tube for

Products: Butt welded steel pipe for plumbingy y ,

automotive, Heat-exchanger tubes.


TenarisDalmine Plants

Totale energia consumata 180.000 TEP BDG 10/11


Tenaris Energy Saving planTenaris and Tenaris Dalmine’s steps for energy efficiency

• 2006:

A E S i Pl l h d Obj ti f 7% d 6% ifi

Tenaris and Tenaris Dalmine’s steps for energy efficiency.

− An Energy Savings Plan was launched. Objectives of 7% and 6% on specific consumption reduction in natural gas and electricity.

− Planed activities were: Metering, Controlling, Training & Communication, Standardization, Investment plans and Waste reduction plans.Standardization, Investment plans and Waste reduction plans.

• 2007:

− A 120 MWe high efficiency Combined Cycle Power Plant started the operation to self-produce electricity steam and hot water both inside and operation to self-produce electricity, steam and hot water both inside and outside the plant (district heating).

•2008:

The first High Efficiency Combustion System has been installed in a reheating • The first High Efficiency Combustion System has been installed in a reheating furnace (in collaboration with R&D CSM).

•2009:

− A Global Energy Efficiency Plan was launched. Objectives of 15% and 10% in specific consumption reduction in natural gas and electricity.

− And R&D department for Energy Efficiency has been created.


Tenaris Energy Saving planTenaris and Tenaris Dalmine’s steps for energy efficiencyTenaris and Tenaris Dalmine’s steps for energy efficiency.

• 2009:

The Energy Efficiency plan was awarded the UE recognition “Motor − The Energy Efficiency plan was awarded the UE recognition “Motor Challenge Programme”

•2010:

−10.000 “Titoli di Efficienza Energetica TEE” (1 TEE= 1 ton of oil saved) was awarded by the Italian authorities for the most important high technology y p g gyinvestment programs.


Tenaris Energy Saving planTenaris Dalmine: EN 16001 CertificationTenaris Dalmine: EN 16001 Certification

•2010:

− Tenaris Dalmine and its power plant were certified with the EN UNI 16 001 Tenaris Dalmine and its power plant were certified with the EN UNI 16.001 “Energy Management System”

MSTE - ENMA Tenaris 717 June 201117 June

Energy ManagementO i iOrganization

OPER - ITEnMS

OPERATIONMSTEMSTE

ENMA Focus on energy aspectsaspects

People involved:3 T i E M R di M i i• 3 Tenaris: - Energy Manager: Rondi Maurizio

- Eneregy Consumption Regional Specialist: Rizza Federico- Energy Consumption Regional Analyst: Fumagalli Davide

• Yousave (ESCo Company, results focused contract): 5 people.

MSTE - ENMA Tenaris 817 June 201117 June

Yousave (ESCo Company, results focused contract): 5 people.

Energy ManagementGl b lGlobal aspects

Reduce environment environment impactReduce environment environment impact

Reduce product costcost

Reduce environment environment impact

Reduce energyenergy request

Energy Energy

Reduce product costcost

Reduce environment environment impact

Reduce energyenergy request

Energy Energy

Industrial energy efficiency

Energy Energy savingsaving

Industrial energy efficiency

Energy Energy savingsaving

Correct ineffectiveness

of the past past

Save futuresfuturesineffectiveness and

prevent wasteswastes

ura

l nge

ments

Engineering

Management Correct ineffectiveness

of the past past

Save futuresfuturesineffectiveness and

prevent wasteswastes

ura

l nge

ments

Engineering

ManagementCultu

chan

Inve

stmPurchasing

OperationsCultu

chan

Inve

stmPurchasing

Operations

Energy consumptions audit

Maintenance

Energy consumptions audit

Maintenance


Combustion system - Regenerative Burners

Objective: evaluation of the energy saving introduced by the revamping of a standard

combustion system with regenerative burners.

Operating principle: Burners made by a ceramic matrix (Al2O3) work in an

intermittent way to pre-heat combustion air.

Revamping of FTM RHFFTM RHF


New regenerative burners

Combustion system – FTM RHF example

Results:

• Decrease in specific energy consumption [Nm3/ton]: from 49.8 to 40 Nm3/ton (this data are related to the more significant product of the MPM). 2.6 MN3/year

• High thermal efficiency: from 45% to 62% (comparison pre-post revamping)

• Decrease in gas consumption during stanb-by

Classes Production [ton/day]

1 1-500

2 501-1000

3 1001-1500

4 1501-2000

5 2001-2500

6 2501-3000

7 >3000

S ifi ti f t i t t l P d ti l


Specific gas consumption for most important classes (25%-35% of improvement)

Production classes

New air compressor – Nitrogen/air i

0.160.170.180.190.2

OLD compressorNEW compressor Specific consumption comparison:

old-new compressor

conversion

0.080.090.1

0.110.120.130.140.15

[kW

h/N

m3]

[0.12 – 0.104 kWh/Nm3]

Energy saving: 23 kUSD/y

00.010.020.030.040.050.060.070.08

Performance of the new compressor

0

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61

9500100001050011000

5 55

5.65New asset with two

operating compressors:

500055006000650070007500800085009000

Nm

3/h]

5.25

5.35

5.45

5.55

[bar

]

Air flow: ~10,000 Nm3/h

Pressure: 5.5 bar

50010001500

200025003000350040004500[N

4.85

4.95

5.05

5.15

average air flowPower [kW]average pressure

Previous situation:

Air flow < 8000 Nm3/h


0500

4.75Pressure: 4.5 bar

Example of Nitrogen/air conversion

20002100220023002400

Consumption during hot rolling process

Stop of hot rolling process: EXP furnace consumption

12001300140015001600170018001900

3/h]

500600700800900

100011001200

[Nm

3

0100200300400500

10 0

h

10 2

h

10 4

h

10 6

h

10 8

h

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h

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/201

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/201

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1/1/

2011

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/201

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2011

10/2

/201

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/201

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/201

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/201

25/2

/201

27/2

/201

Nitrogen consumption PRE POST

Expander furnace Nitrogen/air conversion: gas consumption during hot rolling stop

Average consumption PRE: ~600 Nm3/hSaving: ~140 kUSD/y


Average consumption POST: ~300 Nm3/h

Saving: 140 kUSD/y

(@ 0.0516 €/Nm3)

Maintenance & Energy SavingLi h i ESCLight system revamping – ESCo contract2009 vs 2010 consumptions:

10 000

12.000

Comparazione consumi illuminazione FAS anno 09‐10

6 000

8.000

10.000

kWh

2 000

4.000

6.000 k

‐

2.000

15‐mar 14‐apr 14‐mag 13‐giu 13‐lug 12‐ago 11‐set 11‐ott 10‐nov 10‐dic

Totale 2009 Totale 2010

• Savings 2010 vs 2009:48%Raw data without normalisation on planned shift 2010


Maintenance & Energy SavingLi h iLight system revamping.Confronto consumi 2010 “vecchio impianto” vs “nuovo impianto”:

200

250

Confronto normalizzato consumi PRE e POST intervento

150

200

MW

h

50

100

0

Aprile Maggio Giugno Luglio Agosto Settembre Ottobre Novembre DicembrePrevisione consumo vecchio impianto con automatismo di spegnimentoPrevisione saving ottenibile con automatismo sul vecchio impiantoConsumo misurato nuovo impiantoConsumo misurato nuovo impianto

• Saving 2010 “new light system” vs “old light system”: 63% (conv.65%)old system” consumption calculated on shifts 2010


Maintenance & Energy SavingAi d d iAir compressed wastes reduction

• Service leakage (5 mm hole= 5 kWh = 3.5 k€/y).

• Pressure Reduction(1 bar less = - 10% energy = 80 k€/y).

• Wrong energy utilisation(nozzle = 40% flow reduction)• Wrong energy utilisation(nozzle = 40% flow reduction).

• Service automatisation (saving during stand-by period and during working cycles).

Potenza impegnata media dal 2007 al 2009 per utenze di servizio(Consumi non legati alle tonnellate prodotte)

• Operative practice to switch off the equipments.

8

10

12

14

16

enza [M

W] rex

natale

0

2

4

6

2005 2006 2007 2008 2009

[anni]

Pot


[anni]

Maintenance & Energy SavingC i I GContinuous Improvement Groups

GMC Leader Reparti Stato Anno Bdg Saving [k€/anno]

Risparmio energiaRisparmio energia centrali oleo-

elettriche serviziRizza Federico FTMF Chiuso 09/10 60

Acque industriali Curti Stefano Sito Dalmine Chiuso 09/10 80

Risparmio energiaconsume Merati Paolo FASI Chiuso 08/09 150

Riduzione consumi illuminazione esterna Gerbelli Cristian CELE Chiuso 08/09 20illuminazione esterna

Risparmio energia consume Rannucchi Andrea FTMC Chiuso 08/09 160

Risparmio aria P l i C i ACC Chi 08/09 230Risparmio aria compressa e azoto Palmeri Costantino ACC Chiuso 08/09 230

TOT. 700


Maintenance & Energy SavingA di & I i lAudit & Inspection example


Maintenance & Energy SavingA di & I i lAudit & Inspection results

aria compressa azoto acqua metano totale per linea

VALORIZZAZIONE RIPARAZIONI PERDITE IN LINEA CON GLI AUDITaria compressa azoto acqua metano

€/gg €/gg €/gg €/gg €/gg K€/anno28/05/2009 AGG 49,5 8,5 1 59 21,529/05/2009 OCTG 79,5 79,5 29,004/06/2009 FIN LP 44 5 44 5 16 2

totale per lineadata linea

04/06/2009 FIN‐LP 44,5 44,5 16,218/06/2009 AGG 54 10 64 23,430/06/2009 OCTG2 13 13 4,7

€/gg 240,5 8,5 1 10 260 totale per

K€/anno 87,8 3,1 0,4 3,7 94,9vettore

AZOTO ARIA COMPRESSA ELETTRICITA' O2 totale per linea

ISPEZIONE AGOSTO 2010 / Week 36 ‐ Azoto e Gas TecniciAZOTO ARIA COMPRESSA ELETTRICITA O2€/gg €/gg €/gg €/gg €/gg €/anno

ACC 35 35 12775FAP 12 4 16 5840

totale per linealinea

FAP 12 4 16 5840FAS 7 17 24 8760Cabina O2 20 20 7300

€/gg 4 17 20 95totale per


€/anno 1460 6205 7300 34,7vettore

Maintenance & Energy SavingO i P i & P dOperative Practice & Procedure

FTMF Example – Layout for procedure application & verificationFTMF Example Layout for procedure application & verification



area ubicazione responsabilità

Id Campataese man altri

Campata C1 2° quarto: prima metà L3‐5Campata C1 2° quarto: seconda metà L3‐6Campata C1 3° quarto: prima metà L3‐11Campata C1 3° quarto: seconda metà L3‐12Campata C1 4° quarto: prima metà L4‐5Campata C1 4° quarto: seconda metà L4 6

areainterruttore

L3 colonna W72stalli tubi, carico e scarico in campata 1

Id Campata

L4 colonna W80Campata C1 4 quarto: seconda metà L4‐6Campata C2 3° quarto: prima metà L3‐9Campata C2 3° quarto: seconda metà L3‐10Campata C3 3° quarto: prima metà L3‐7Campata C3 3° quarto: seconda metà L3‐8

cabina operatori tagliatubi Bronx 1 interno cabina


AGG1

colonna W72L3


cabina operatori CND interno cabina

postazione controllo e riparazione dopo CND localepostazioni controllo estremità tubi localeCampata C2 4° quarto: prima metà L4‐3Campata C2 4° quarto: seconda metà L4‐4Campata C3 4° quarto: prima metà L4 1

colonna W80L4Campata C3 4 quarto: prima metà L4‐1Campata C3 4° quarto: seconda metà L4‐2



cabina operatori CND interno cabina

postazione controllo e riparazione dopo CND locale

AGG2

postazione controllo e riparazione dopo CND localepostazioni controllo estremità tubi locale

cabina operatori provatubi INNSE e verniciatrice interno cabina

zona interna provatubi INNSE

cabina opereatori scarico all'esterno (lato Mariano) interno cabina

scantinato pompe e autoclave provatubi INNSE


uffici locali AGG AGG1‐2 interno uffici


FTMF Example – Procedure applicationFTMF Example Procedure application

vettore energetico

linea ID breve descrizione azione costo

intervento (k€)

risparmio annuo

ottenibile totale

costi (k€)

risparmio 1° anno netto (k€)

GMC FTM FREDDO ‐ RIEPILOGO SCHEDE ANALISI yousaveGruppo innowatio

(k€)(k€)

netto (k€)

AGG 2ID‐FTMF_001 Pulizia rulli raddizzatubi Bronx

Utilizzare ugelli alta efficienza; automatizzare erogazione 0.45 3.80

AGG 1‐2ID‐FTMF_004 Evacquazione contaminanti postazioni CET (1)

Automazione erogazione; utilizzo ugelli ad alta efficienza 0.80 7.10

AGG 1‐2 ID‐FTMF_005 Soffiaggio zona taglio tagliatubi Bronx (1) Utilizzo di ugelli ad alta efficienza 0.30 0.25

AGG 2ID‐FTMF_006

Purga aria per pulizia ugelli marcatrice a fine utilizzo Automatizzare erogazione 1.00 1.35

OCTG ID‐FTMF_007 Asciugatura tubo in uscita DAPCO Automatizzare erogazione 0.60 1.20A i i ili lli d l

OCTGID‐FTMF_008 Barriera antivapore


OCTGID‐FTMF_010 Raffreddamento corpo pompe centrale olio


OCTG ID‐FTMF_012 Soffiaggio tubo dopo ciclo prova idraulica Utilizzo di ugello ad alta efficienza 0.35 0.50

OCTGID‐FTMF_013 Soffiaggio estremità tubo dopo filettatura Utilizzo di pistola erogatrice ad alta efficienza 0.60 0.30

FIN ID‐FTMF_015 Soffiaggio tubo dopo ciclo prova idraulica Utilizzo di ugello ad alta efficienza 0.35 2.80FIN ID‐FTMF_019 Atomizzazione lubrificante calibratrice Modifica automazione erogazione 0.30 0.50

aria compressa

9.09 36.51

FINID‐FTMF_021 Soffiaggio nelle operazioni manuali di molatura (2) Utilizzo di ugello ad alta efficienza 0.14 0.00

FINID‐FTMF_022

Purga aria per pulizia ugelli marcadifetti US Olimpus Modifica automazione erogazione 0.80 0.40

FIN ID‐FTMF_023Soffiaggio nelle operazioni di asciugatura estremità

tubi in uscita da US Olimpus (3)Utilizzo di pistola erogatrice ad alta efficienza 0.50 0.00

FIN ID‐FTMF_024Soffiaggio per pulizia macchina (4)

Utilizzo di pistola erogatrice ad alta efficienza0.15 0.00

FIN ID‐FTMF_025Mescolatore miscela polveri magnetiche Modifica automazione utilizzo mescolatore 0.15 1.20p g 0.15 1.20

AGG 2 ID‐FTMF_003Pompe riempimento autoclave e impianto prova idraulica Adozione di inverter (5) 0.00 0.00

metano OCTG1‐2 ID‐FTMF_14 Riscaldo fusti grasso per filetti (6) Utilizzo di fasce riscaldanti 0.80 0.40 0.80 ‐0.40

(1) applicabile a ciascuna delle 4 postazioni

(2) risparmio non calcolabile, non conoscendo il numero di tubi da molare: con ugello ad alta efficienza si risparmiano 0,60 € per ogni ora di utilizzo totali 9.89 56.17

(3) risparmio non calcolabile, non conoscendo il numero di tubi da riparare: con pistola ad alta efficienza si risparmiano 2,75 € per ogni ora di utilizzo

(4) risparmio non calcolabile, non conoscendo il numero delle operazioni di attrezzaggio: con pistola ad alta efficienza si risparmiano 2,00 € per ogni ora di utilizzo

(5) le misurazioni effettuate indicano in ca 14k€ il risparmio annuo di energia elettrica. Argomento passato in carico a DITE. Vale per le tre provatubi.6

elettricità 0.00 20.06


(6) per ogni postazione

Maintenance & Energy SavingE l d i l l 09/10Example: reduction plan results 09/10

• Operactive Practices

• Procedure & Operactive Practices formalisation on IDM System

Objective: j

• Fix consumptions reduction (plant switched off)

Winter plant stop example:Winter plant stop example:

Confronto 01/01/10 vs storico '08 e '09 Consumi fermata '09/'10 vs. storico '08/'09

9.0

10.0

11.0

12.0

13.0

14.0

MWh

Consumo 01/01/08

Consumo 01/01/09

forecast 01/01/10

883

2,500

3,000

3,500

5.0

6.0

7.0

8.0

31/12

01/01

01/01

01/01

01/01

01/01

02/01

02/01

M

Consumo 01/01/10

Minimo teorico01/01

2,613

0

500

1,000

1,500

2,000

MWhRisparmio totale vs 08‐09

reale 09‐10


TEE & Investements: how to obtain

SAVINGS

MWh

Investments Consumption reduction

% TEE

reduction

ESCo manages TEE request for

yousaveGruppo innowatio

Dalmine

ESCo requires TEE to Gas andElectrical Energy Authority

AEEG GME

TEE


TEE

TenarisDalmine & TEE: a quick overview

MOVTEE 2009 2010 2011 2012 2013 2014 2015

attesi TIPO 1 3656 828 428 328 328attesi TIPO 1 3656 828 428 328 328ottenuti Electrical Energy 2791 1283attesi TIPO 1 9575 9575 9575 1275 1275ottenuti Natural Gas 2916 4176

5707 5459 13230 10402 10002 1602 1602TOT

52485

− TEE obtained till now more than 10.000

− Expectations for next 5 years: more than 40.000

− Working Group: Energy Management team (Tenaris) + Yousave (ESCo) − Working Group: Energy Management team (Tenaris) + Yousave (ESCo) (3 persons)

TEE are entirely obtained by the Energy Service Company Tenaris receives a TEE are entirely obtained by the Energy Service Company. Tenaris receives a percentage according to the contract.


Thank you!!!Thank you!!!Federico Rizza

Regional Energy Consumption Specialist

Piazza Caduti 6 luglio 1944, 124044 – Dalmine (BG) 0039 - 035 / 56026440039- 329 83 16 772


[email protected]

ENERmanagement 2011ENERmanagement 2011...Tenaris Energy Saving plan Tenaris and Tenaris Dalmine’s...

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