Slide | 1
Slide | 2“WALK THE TALK”…… LET’S HAVE A LOOK AT MY EMIS AT HOMENo needs for newinsulationGood practice:reduce setpoint in ...
Slide | 3SUCCESS FACTORS①  You’re richer than you thinkMeters, historian, display, analysis software…②  Top-down approach,...
Slide | 4WHY DON’T YOU HAVEAN ENERGY MANAGEMENTSYSTEM YET?and should you?Sebastien Lafourcade, Pepite Technologies
Slide | 5WHY AN ENERGY MANAGEMENT SYSTEM?“We have built anew biomassboiler”“We know what todo, we have aproject list”“We a...
Slide | 6THE 5 KEY DRIVERS FOR ENERGY PERFORMANCEDriver Best practice we have seenHow do you ensure thatrecommendations ar...
Slide | 7EXPERIENCE WITH EMIS IN PULP AND PAPER(OR MT&R, M&V, ISO50001…)+ Several ongoing projects in N-A and EuropeEnergy...
Slide | 8WHY SO LITTLE IMPLEMENTATION IN P&P?Strengths Challenges?	  
Slide | 9LET’S LOOK AT TYPICAL ENERGY MANAGEMENTSYSTEM GAP ANALYSIS
Slide | 10GAP ANALYSIS REVEALS LOW LEVERAGE OFABUNDANT DATA AND IT INFRASTRUCTURE
Slide | 11LOW CAPEX REQUIRED BECAUSE OFEXISTING INFRASTRUCTUREgood level ofmetering$SEGDhistorianDCScontrol roomengineerin...
Slide | 12ENERGY IS ALREADY IN PEOPLE MINDSmanagersengineerssupervisorsoperatorsBig costmonitored(ex TMP)EnergyauditsEnerg...
Slide | 13MILLS HAVE GOOD ORGANIZATIONAL ASSETSCorporatetask forceEnergy team/managerGreen beltprogramsProcessknowledgeCon...
Slide | 14P&P: GOOD ASSETS FOR EMIS IMPLEMENTATIONStrengths ChallengesOrganizationEyes onenergyHardware/software
Slide | 15COMPLEX PROCESS INTERACTIONS CREATE A GAPBETWEEN DATA AND ACTIONS•  Energy account centers•  EAC definition is e...
Slide | 16WHOS ACCOUNTABLE FOR WARM WATER SYSTEM?PM1 showerwater tankPM1 showersTSteam makeupVariability reduction can rep...
Slide | 17TYPICAL TARGETING IS NOT PRACTICALPredicting performanceduring start-ups orshutdowns is irrelevantPredicting“bas...
Slide | 18HUMAN CHALLENGES FOR EMIS IMPLEMENTATION•  Focus on production•  Operations are production-oriented, not cost-fo...
Slide | 19ELECTRICITY VS. STEAMThermalElectrical – withoutTMP / GWDElectricalTMP / GWDKPI structure Complex Groups of EAC ...
Slide | 20WHAT CAN WE DO NOW?Strengths ChallengesGap between dataand actionsOperation cultureProblem solvingcultureResourc...
Slide | 21SUCCESS IS A MIX OF PROCESS EXPERTISE,TECHNOLOGY AND PEOPLE ENGAGEMENTThe right tool to the right person at the ...
Slide | 22“TURNING EVERYONE INTO A DECISION MAKER.PUSH DECISION-MAKING DOWN TO THE LOWEST LEVEL”-NUCOROperatorsSupervisors...
Slide | 23EAC IS THE WAY YOU COUNT ENERGY BUT KPISTRUCTURE IS THE WAY YOU MANAGE ITStrategic goalsreduce cost by X M$, be ...
Slide | 24LEVERAGE HISTORICAL DATA TO BRING FACTSIN OPERATOR HANDSActualvalueof KPIPredicted regimes based on 3+ process v...
Slide | 25CLASSICAL EMIS IMPLEMENTATION SCHEME…Upfront investment for mill widemeasurement, IT system,software + serviceca...
Slide | 26IMPLEMENTATION BY PROJECTS PROVIDES BETTERCHANCE OF SUCCESScashflowimplementationUpfront investment forservice a...
Slide | 27APPROACH TO SOLUTION – TYPICAL PROJECTKick	  off	  session	  • KPI	  structure	  • Workshops	  with	  operators	 ...
Slide | 28SUCCESS FACTORS①  You’re richer than you thinkMeters, historian, display, analysis software…②  Top-down approach...
Slide | 29SUCCESSFUL IMPLEMENTATION!DECISIONSUPPORTTOOLSPERFOR-MANCEMONITORING
Slide | 30THANK YOU!Visit: www.myenergymaestro.comSebastien Lafourcade – slafourcade@pepite.ca +1-5124-571-9118
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Why don't you have an energy management system yet

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Energy management systems and ISO 50 001 are making the buzz these days. They promise huge benefits and significant savings. So why is there so few real implementation in industry, particularly in heavy industry. Experiences in pulp and paper industry give some answers and suggest some solutions...

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Why don't you have an energy management system yet

  1. 1. Slide | 1
  2. 2. Slide | 2“WALK THE TALK”…… LET’S HAVE A LOOK AT MY EMIS AT HOMENo needs for newinsulationGood practice:reduce setpoint in FallTOOLS TOTRACK MYENERGYBILL
  3. 3. Slide | 3SUCCESS FACTORS①  You’re richer than you thinkMeters, historian, display, analysis software…②  Top-down approach, bottom-upimplementationNo accountability without actionable parameters③  Start implementation with an energyoptimization projectPilot: people readiness, potential, data available
  4. 4. Slide | 4WHY DON’T YOU HAVEAN ENERGY MANAGEMENTSYSTEM YET?and should you?Sebastien Lafourcade, Pepite Technologies
  5. 5. Slide | 5WHY AN ENERGY MANAGEMENT SYSTEM?“We have built anew biomassboiler”“We know what todo, we have aproject list”“We are looking atenergy everyday”What do you do tosecure return oninvestment?What is your gameplan to implementand sustain?Do you quicklytake actions?
  6. 6. Slide | 6THE 5 KEY DRIVERS FOR ENERGY PERFORMANCEDriver Best practice we have seenHow do you ensure thatrecommendations are followed?Going to the rootcauses (identify all thedrivers and their combinations) andaddressing impacts on production andqualityWhat tools do you use toanalyze process data?Multivariate data analysis softwareHow do you ensure that gainsare sustained?Max of 3 KPI per level with dynamictarget for smart monitoringHow do you empower operatorsto sustain gains?Involvement of operators at every step ofthe problem solving and the data analysisHow do you build peoplecapability in the mills?Self assessment tool and automatedtroubleshooting tool
  7. 7. Slide | 7EXPERIENCE WITH EMIS IN PULP AND PAPER(OR MT&R, M&V, ISO50001…)+ Several ongoing projects in N-A and EuropeEnergy  audit  in  20+  mills  with  focus  on  data  availability  &  quality,  monitoring  capability  and  performance  gap    Par?cipa?on  in  Energy  Blitz  at  15+  mills  with  significant  and  sustainable  cost  reduc?ons  2 EMISimplementation inmills with differentsituation, motivation,and cultureHigh levelmonitoring modelsimplemented in5+ mills  
  8. 8. Slide | 8WHY SO LITTLE IMPLEMENTATION IN P&P?Strengths Challenges?  
  9. 9. Slide | 9LET’S LOOK AT TYPICAL ENERGY MANAGEMENTSYSTEM GAP ANALYSIS
  10. 10. Slide | 10GAP ANALYSIS REVEALS LOW LEVERAGE OFABUNDANT DATA AND IT INFRASTRUCTURE
  11. 11. Slide | 11LOW CAPEX REQUIRED BECAUSE OFEXISTING INFRASTRUCTUREgood level ofmetering$SEGDhistorianDCScontrol roomengineeringmanagementcorporatePLC /serverserverlink to real timeexternal datahigh level ofautomationmost of themills have adata historianaccess to data andinformationdataanalysissoftwarereportingsystem✔ ✔✔✔✔✔✔
  12. 12. Slide | 12ENERGY IS ALREADY IN PEOPLE MINDSmanagersengineerssupervisorsoperatorsBig costmonitored(ex TMP)EnergyauditsEnergyprojectsAwarenesscampaignEyes onbenchmarksHigh levelreportingEnergymanager
  13. 13. Slide | 13MILLS HAVE GOOD ORGANIZATIONAL ASSETSCorporatetask forceEnergy team/managerGreen beltprogramsProcessknowledgeContinuousimprovementOperationchallengesCapabilitybuildingPerformancemanagement
  14. 14. Slide | 14P&P: GOOD ASSETS FOR EMIS IMPLEMENTATIONStrengths ChallengesOrganizationEyes onenergyHardware/software
  15. 15. Slide | 15COMPLEX PROCESS INTERACTIONS CREATE A GAPBETWEEN DATA AND ACTIONS•  Energy account centers•  EAC definition is easy… Effective EAC are challenging todefine!•  Targeting•  Rootcauses of variability are difficult to identify•  Targeting can become very complex•  Simple regression with production is ineffective•  Baseload definition does not really make sense•  Actions – “So what?”•  Lack of targets and actionable parameters•  Risk of displacing energy use
  16. 16. Slide | 16WHOS ACCOUNTABLE FOR WARM WATER SYSTEM?PM1 showerwater tankPM1 showersTSteam makeupVariability reduction can represent up to a $500,000/year savingsLFresh waterPM1 condenserPM1 economizers Hot watertankKraft mill hot waterTMP water heaterTMP cooling dutiesmill excess warm waterPM2 economizersPM cooling dutiesPM effluentheat exchangerT
  17. 17. Slide | 17TYPICAL TARGETING IS NOT PRACTICALPredicting performanceduring start-ups orshutdowns is irrelevantPredicting“baseload” isirrelevant forcontinuousprocessThis is the only areawhere we needperformance equation
  18. 18. Slide | 18HUMAN CHALLENGES FOR EMIS IMPLEMENTATION•  Focus on production•  Operations are production-oriented, not cost-focused•  Accountability for energy costs•  Problem solving culture•  Problem solving is based on opinions and experiencerather than on facts•  Lack of targets and actionable parameters•  Resources•  Competition with other energy project for $ and people•  Lean - “Not another hat”
  19. 19. Slide | 19ELECTRICITY VS. STEAMThermalElectrical – withoutTMP / GWDElectricalTMP / GWDKPI structure Complex Groups of EAC Often in placeMetering vs.EAC and KPIGoodNot completeNot consistentGoodTargeting Complex More typicalAPC with focus onqualityEMISimplementationComplex(interactions)Complex(actionable param.)Complex(culture)VariabilityreductionopportunityHigh Low Medium to highLoadmanagementopportunityDepends onmarginal fuelDepends on themarketPart of it alreadycaptured
  20. 20. Slide | 20WHAT CAN WE DO NOW?Strengths ChallengesGap between dataand actionsOperation cultureProblem solvingcultureResourcesOrganizationFocus on energyHardware/software
  21. 21. Slide | 21SUCCESS IS A MIX OF PROCESS EXPERTISE,TECHNOLOGY AND PEOPLE ENGAGEMENTThe right tool to the right person at the right time
  22. 22. Slide | 22“TURNING EVERYONE INTO A DECISION MAKER.PUSH DECISION-MAKING DOWN TO THE LOWEST LEVEL”-NUCOROperatorsSupervisorsManagersImpactofdecisiononday-to-dayenergycostTopmanagementcommitmentwith global viewon cost controlFocus onactionableparameters inthe controlroom
  23. 23. Slide | 23EAC IS THE WAY YOU COUNT ENERGY BUT KPISTRUCTURE IS THE WAY YOU MANAGE ITStrategic goalsreduce cost by X M$, be energy self sufficient in 5 years, …EAC#2 EAC#3 EAC#4EAC#1M M M MKPI KPIKPI KPI KPIKPIKPI KPITactical levelOperatorsSupervisorsManagersImpactofdecisiononday-to-dayenergycostmill manager: $ vs.budget for the last 3days on his blackberryoperator: % valveopening vs. targetevery hour on DCS
  24. 24. Slide | 24LEVERAGE HISTORICAL DATA TO BRING FACTSIN OPERATOR HANDSActualvalueof KPIPredicted regimes based on 3+ process variables> 1.1< 1.1KPI>1.1 KPI<1.1A: Performance isgood and we knowwhyC: Performance isgood “but we donot know why”B: Performance isbad “but we donot know why”D: Performance isbad and we knowwhyInsight to solve the problem1.  CO pre-heater > 15%2.  Temp heating tower < 84,5°CPreviously unseen situation!Operator alerts energy teamfor more investigations
  25. 25. Slide | 25CLASSICAL EMIS IMPLEMENTATION SCHEME…Upfront investment for mill widemeasurement, IT system,software + servicecashflowimplementationHEAVY ONRESOURCESANDCASHFLOW
  26. 26. Slide | 26IMPLEMENTATION BY PROJECTS PROVIDES BETTERCHANCE OF SUCCESScashflowimplementationUpfront investment forservice and minor ITdevelopmentFIRSTPROJECTFOCUS ONAREA WITHTHE BIGGESTPOTENTIALInvestment for serviceand some IT, requiredmeasurement, softwareKickoff project sub-project #2 sub-project #3
  27. 27. Slide | 27APPROACH TO SOLUTION – TYPICAL PROJECTKick  off  session  • KPI  structure  • Workshops  with  operators  and  stakeholders  • Process  understanding  • Data  collec?on  Data  analysis  • Explora?on  • Rootcause  analysis  (mul?variate  data  analysis)  • Modeling  Implementa3on  prepara3on  • Test  and  valida?on  of  the  model  off  line  • Programming  of  equa?ons  and  dashboard  • Repor?ng  structure  Implementa3on  • Operators  training  • Stakeholder  training  • Closing  session  Immediate actionstaken based onperformance gapanalysis• Awareness• Capability buildingof plant people• First decisions,first savings•  Better knowledgeof operation•  Optimization rulesof the process$$$  $$$  $$$  
  28. 28. Slide | 28SUCCESS FACTORS①  You’re richer than you thinkMeters, historian, display, analysis software…②  Top-down approach, bottom-upimplementationNo accountability without actionable parameters③  Start implementation with an energyoptimization projectPilot: people readiness, potential, data available
  29. 29. Slide | 29SUCCESSFUL IMPLEMENTATION!DECISIONSUPPORTTOOLSPERFOR-MANCEMONITORING
  30. 30. Slide | 30THANK YOU!Visit: www.myenergymaestro.comSebastien Lafourcade – slafourcade@pepite.ca +1-5124-571-9118

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