Ing. Jeroen Wynants - - Media met oog voor de...
30
Ing. Jeroen Wynants Endress+Hauser Belux “Meten is weten: betrouwbare meetinstrumenten voor een effectief persluchtbeheer"
Transcript of Ing. Jeroen Wynants - - Media met oog voor de...
Ing. Jeroen WynantsEndress+Hauser Belux
“Meten is weten: betrouwbare meetinstrumenten voor een effectief persluchtbeheer"
09/19/2016
The Industrial Production Process – W.A.G.E.S
Inside Industry - Perslucht
Raw Materials
Labor
Wat
er
Air
Gas
Ele
ctri
city
Ste
am
Products
Emissions/
Effluents
Slide 2 Jeroen Wynants
09/19/2016
Focus on Energy Usage
Inside Industry - Perslucht
Capital
20%
Raw Materials
35%
Energy
35%
Labour
10%
Cost Drivers in the Chemical Industry
(Source: Bayer Industry Services)
Slide 3 Jeroen Wynants
09/19/2016
International Energy Management Standards e.g. EN16001/ISO50001 – Plan Do Check Act Circle
Inside Industry - Perslucht
Slide 4 Jeroen Wynants
09/19/2016
Environmental Management According EMAS+ISO 14001
Inside Industry - Perslucht
A.5. Checking
A.5.1. Monitoring and measurement
The organisation shall establish, implement and maintain a procedure(s) to
monitor and measure, on a regular basis, the key characteristics of its
operations that can have a significant environmental impact. The
procedure(s) shall include the documenting of information to monitor
performance, applicable operational controls and conformity with the
organisation’s environmental objectives and targets.
The organisation shall ensure that calibrated or verified monitoring and
measurement equipment is used and maintained and shall retain associated
records.
Slide 5 Jeroen Wynants
09/19/2016
Energy Savings Process
Inside Industry - Perslucht
Data
Collection
Energy Analyses
Energy Reporting
Optimize
Controlling of
Energy Data
Transparency of
Consumption
Customer
Slide 6 Jeroen Wynants
09/19/2016
Energy Monitoring, Analysis and Reporting
Inside Industry - Perslucht
Energy Measurement
Visualization and
Recording
Analysis and Reporting
Calculation and
Transmission
Utilities
Steam
Air
Electricity
Gas
Oil
Water
Heating
Cooling
Process Fluids
Energy Monitoring Software
(EMS)
Slide 7 Jeroen Wynants
09/19/2016
Metering Levels - Energy Accountable Centers (EACs)
Inside Industry - Perslucht
WaterGas
Electricity
EAC 1
EAC 2
EAC 3
EAC 4
EAC 5EAC 6
Slide 8 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Metering Levels of Utilities ( Example )
Slide 9 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Distribution and Consumption – Monitoring
• For energy monitoring purposes the mass is used to get the energy
consumption of an area, or the performance of a certain process or line.
monthly weekly daily
Area steam energy consumption ton Quantity Demand/ Target x x
Area steam quality dryness fract ion Quality Monitoring/ Alarm x x x
Utilit ies to Area steam energy losses kWh Quantity Trend/ Alarm x x
Area heating energy consumption kWh Quantity Demand/ Target x x
Area cooling energy consumption kWh Quantity Demand/ Target x x
Area CA consumption Nm³ Quantity Demand/ Target x x
Utilit ies to Area CA losses Nm³ Quantity Trend/ Alarm x x x
Area water consumption m³ Quantity Demand/ Target x x
Area electricity consumption m³ Quantity Demand/ Target x x
Area total energy consumption kWh Quantity Demand/ Target x x
Line steam energy consumption ton Quantity Demand/ Target x x
Line steam quality dryness fract ion Quality Monitoring/ Alarm x x x
Area to Line steam energy losses kWh Quantity Trend/ Alarm x x x
Line heating energy consumption kWh Quantity Demand/ Target x x
Line cooling energy consumption kWh Quantity Demand/ Target x x
Line CA consumption Nm³ Quantity Demand/ Target x x
Area to Line CA losses Nm³ Quantity Trend/ Alarm x x x
Line water consumption m³ Quantity Demand/ Target x x
Line electricity consumption kWh Quantity Demand/ Target x x
Line product processed liter Quantity Trend/ Target x x
Line total energy consumption kWh Quantity Target/ Benchmark x x
Energy consumption per liter kWh/ liter Performance Target/ Benchmark x x
KPI unit KPI type Analysis
LINE/ PROCESS - Metering Leve l 3 - Consumption
AREA - Metering Leve l 2 - Dis tribution
Review periodMetering point KPI name
Slide 10 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Case Study 4 – Energy Management @ PC-Flowtec
Slide 11 Jeroen Wynants
09/19/2016
eSight@Flowtec: Compressed Air
Inside Industry - Perslucht
Slide 12 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Compressed Air 1
• Supervision of Filters
The choked filter cost us 200 CHF / month!
Slide 13 Jeroen Wynants
09/19/2016
Supervision of Filters
Inside Industry - Perslucht
Slide 14 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Compressed Air 2
• Compressed Air Production vs. Electricity
3Pr NmoductionAir
kWhonyConsumptiElectricitSEC
Slide 15 Jeroen Wynants
09/19/2016
1st week: compressor 1
Inside Industry - Perslucht
Slide 16 Jeroen Wynants
09/19/2016
1st week: compressor 4
Inside Industry - Perslucht
Slide 17 Jeroen Wynants
09/19/2016
Which was the main compressor?
Inside Industry - Perslucht
Slide 18 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Compressor No. 4…
• Worst performance but highest capacity…
• Loses oil -> high temperature at outlet during survey!
• Filters were not suitable for this machine (too fine)
• Heat recovery was not working at the beginning…
Slide 19 Jeroen Wynants
09/19/2016
1st week: Compressed Air Pressure
Inside Industry - Perslucht
Slide 20 Jeroen Wynants
09/19/2016
SEC vs. Air Production
Inside Industry - Perslucht
Slide 21 Jeroen Wynants
09/19/2016
CUSUM: Losses on the Weekend and at Night!
Inside Industry - Perslucht
Losses during week-ends
Night time losses
£€€€
Slide 22 Jeroen Wynants
09/19/2016
Maximum Demand Compressors
Inside Industry - Perslucht
Slide 23 Jeroen Wynants
09/19/2016
Cost of Compressed Air
Inside Industry - Perslucht
Equivalent to 10% of total electricity consumption
Savings Potential > 30 000 CHF/a
Slide 24 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Submetering Concept
F2, F5 (nord): #1
F3, F7, F8, F5 (south): #2
Glassblasting: #3
Slide 25 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Physical Properties: Mechanical Design
• Laser-etched scale for simple and accurate
depth adjustment
• ¾” and ½” BSP or NPT compression fitting
with PEEK seal for flexible installation
adjustment and sealing longevity
• Robust sensor design with guard for added
protection against dropping
Slide 26 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Measurements of heating system
• Measurements using eSight have shown
that the performance of the heating system
was very bad (delta T 2…5°C!)
• A detailed check of the installation
showed some hydraulic short-circuits in
the system (now delta T >20°C!)
• Fixing these problems lead to oil savings
of 1000 kWh/day (100 litres of oil / almost
250 kg CO2 PER DAY )
Slide 27 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Industrial Gases
• Flowtec has an industrial gas bill of >250 kCHF/a
• Mainly nitrogen is used (re-flow ovens)
• Distribution to cost centres was wrong by 25%!
• Leakage in N2 distribution could be found
• Still unsolved: strong variations of N2 flow
• Great field trial for t-mass 150
Slide 28 Jeroen Wynants
09/19/2016
Inside Industry - Perslucht
Next Steps
• First simple measures resulting from measurements using eSight have led to energy savings of more
than 50’000 CHF/a
• New part of the factory tour including eSight presentation is very successful: we put ourselves into
our customers’ shoes!
• Customers impressed by eSight: “better than solutions of the competition”
• Optimization Team called
into life in production,
e.g. compressed air system
will be upgraded
• System used for training
internal and external
Slide 29 Jeroen Wynants
