PEPITe - Energymaestro - Evènement Siemens (novembre 2011)

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PEPITe - Energymaestro - Evènement Siemens (novembre 2011)

  1. 1. EMPOWERING YOU
  2. 2. ENERGYMAESTRO – PRESENTATION OUTLINE1.  Challenges in energy management today2.  ENERGYmaestro methodology3.  ENERGYmaestro examples of implementationUlrika Wising – VP Sales & Marketing Slide | 2
  3. 3. INDUSTRY HAS ALREADY SAVED A LOTBut we can still do more! •  2010 McKinsey report : There is still a potential to reduce energy consumption up to 25% by improved energy management Slide | 3
  4. 4. WE ALL WANT TO SAVE ON ENERGY COSTS Investments Procurement Operations Energy Cost Savings Slide | 4
  5. 5. ENERGY MANAGEMENT CHALLENGES•  Reduce energy costs •  Operations are while maintaining production-oriented, not production levels cost optimization-oriented•  Secure already made •  Few actionable investments for parameters for operators increased energy •  Problem solving is based efficiency on opinions and•  Increase experience rather than on sustainability facts Slide | 5
  6. 6. EFFECTIVE ENERGY MANAGEMENT•  Is integrated in the overall management of production, quality and energy•  Is part of a continuous improvement activity •  Perform Audit •  Install necessary measurements •  Install a Data historian •  Implement the “management” part of an energy management system (targets, responsibilities, models) •  Improve (training, audit, projects) Slide | 6
  7. 7. METHODOLOGY Impact of decision on day-to-day energy cost Level 1: Monitoring of total GJ/day of steam consumed Managers Is there a problem with the mill steam consumption? GAP Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not, NOW Supervisors Is it because of the steam users or the steam recovery? Target Level 3: Monitoring of specific equipment / process Recovery Users Operators Reboiler Tempering Heat exchanger Pickling Gap Analysis KPI definition Water recirculation Water / Air heating Data collection Variability analysis Targeting + modeling Monitoring Implementation Slide | 7
  8. 8. GAP ANALYSIS 1. Assess 3. Analyze where you and closeKPI are the gap Design 2. Target Maintenance where you want to be Variability OEE NOW Waste = Opportunity TARGET time Energy projects are rarely pure energy projects Slide | 8
  9. 9. GAP ANALYSIS NA Europe BAT Slide | 9
  10. 10. METHODOLOGY Impact of decision on day-to-day energy cost Level 1: Monitoring of total GJ/day of steam consumed Managers Is there a problem with the mill steam consumption? GAP Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not, NOW Supervisors Is it because of the steam users or the steam recovery? Target Level 3: Monitoring of specific equipment / process Recovery Users Operators Reboiler Tempering Heat exchanger Pickling Gap Analysis KPI definition Water recirculation Water / Air heating Data collection Variability analysis Targeting + modeling Monitoring Implementation Slide | 10
  11. 11. KPI DEFINITIONImpact of decision on day-to-day energy cost Level 1: Monitoring of total GJ/day of steam consumed Managers Is there a problem with the mill steam consumption? Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not, Supervisors Is it because of the steam users or the steam recovery? Level 3: Monitoring of specific equipment / process Recovery Users Operators Reboiler Tempering Heat exchanger Pickling Water recirculation Water / Air heating Slide | 11
  12. 12. KPI DEFINITION (SMART)•  WHO? WHAT? WHEN? HOW? the right decision-making support to the right people, at the right time Role of KPI •  related to business goals •  linked to relevant targets •  assigned to people that are accountable •  actionable •  visually adapted to user •  easy to interpret •  in limited number (<5) Slide | 12
  13. 13. KPI DEFINITION Slide | 13
  14. 14. METHODOLOGY Impact of decision on day-to-day energy cost Level 1: Monitoring of total GJ/day of steam consumed Managers Is there a problem with the mill steam consumption? GAP Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not, NOW Supervisors Is it because of the steam users or the steam recovery? Target Level 3: Monitoring of specific equipment / process Recovery Users Operators Reboiler Tempering Heat exchanger Pickling Gap Analysis KPI definition Water recirculation Water / Air heating Data collection Variability analysis Targeting + modeling Monitoring Implementation Slide | 14
  15. 15. DATA COLLECTION – EXAMPLEIt all starts with a very simple question:What makes the natural gas consumption at the furnacevary? Slide | 15
  16. 16. What makes the natural gasconsumption at the furnace vary? Slide | 16
  17. 17. METHODOLOGY Impact of decision on day-to-day energy cost Level 1: Monitoring of total GJ/day of steam consumed Managers Is there a problem with the mill steam consumption? GAP Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not, NOW Supervisors Is it because of the steam users or the steam recovery? Target Level 3: Monitoring of specific equipment / process Recovery Users Operators Reboiler Tempering Heat exchanger Pickling Gap Analysis KPI definition Water recirculation Water / Air heating Data collection Variability analysis Targeting + modeling Monitoring Implementation Slide | 17
  18. 18. VARIABILITY ANALYSIS steam per ton of paper The causes for variability in steam use is not clear Slide | 18
  19. 19. VARIABILITY ANALYSIS Step 1: Quantifying variability Peak consumption Medium consumption ≈ + 3 €/t ≈ + 2.5 €/t Low consumption Slide | 19
  20. 20. VARIABILITY ANALYSISPareto Root cause data analysisStep 2: chart % 30 25 20 15 10 5 0 A B C D E F G H I J K L M N O P Parameters Slide | 20
  21. 21. METHODOLOGY Impact of decision on day-to-day energy cost Level 1: Monitoring of total GJ/day of steam consumed Managers Is there a problem with the mill steam consumption? GAP Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not, NOW Supervisors Is it because of the steam users or the steam recovery? Target Level 3: Monitoring of specific equipment / process Recovery Users Operators Reboiler Tempering Heat exchanger Pickling Gap Analysis KPI definition Water recirculation Water / Air heating Data collection Variability analysis Targeting + modeling Monitoring Implementation Slide | 21
  22. 22. TARGETING AND MODELINGKPI: Dirty Steam/MW USER CASE Slide | 22
  23. 23. TARGETING AND MODELING Best performance Most of the bad when steam valve performance1 2 is open <15% and occurs when heating tower KPI steam valve is outlet temp is open more than >85°C 15% Valve Valve 1 opening 2 opening < 15% > 15%USER KPI KPI CASE Heating Heating 1 tower temp. tower temp. >1.1 <1.1 > 85 °C < 85 °C Slide | 23
  24. 24. METHODOLOGY Impact of decision on day-to-day energy cost Level 1: Monitoring of total GJ/day of steam consumed Managers Is there a problem with the mill steam consumption? GAP Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not, NOW Supervisors Is it because of the steam users or the steam recovery? Target Level 3: Monitoring of specific equipment / process Recovery Users Operators Reboiler Tempering Heat exchanger Pickling Gap Analysis KPI definition Water recirculation Water / Air heating Data collection Variability analysis Targeting + modeling Monitoring Implementation Slide | 24
  25. 25. MONITORING Previously unseen situation! Operator alerts energy 0 00! improvement team for more 00, EAR! !$6 ER Y ENT investigations P RR Predicted regimes ECU ! NGS R OF I SAV KPI>1.1 KPI<1.1 A: Performance is C: Performance is > 1.1 good and we know good “but we doActual why not know why”valueof KPI B: Performance is D: Performance is < 1.1 bad “but we do bad and we know not know why” why USER Insight to solve the problem CASE 1.  CO pre-heater < 15% 2.  Temp heating tower > 84,5°C Slide | 25
  26. 26. METHODOLOGY Impact of decision on day-to-day energy cost Level 1: Monitoring of total GJ/day of steam consumed Managers Is there a problem with the mill steam consumption? GAP Level 2: Monitoring of GJ recovered / GJ boilers Is the ratio normal, and if not, NOW Supervisors Is it because of the steam users or the steam recovery? Target Level 3: Monitoring of specific equipment / process Recovery Users Operators Reboiler Tempering Heat exchanger Pickling Gap Analysis KPI definition Water recirculation Water / Air heating Data collection Variability analysis Targeting + modeling Monitoring Implementation Slide | 26
  27. 27. IMPLEMENTATION•  An energy management system should be an integral part of the manufacturing management system – not a stand alone separate system ENERGY, Cos PRODUCTIVITY t AND QUALITY SHOULD BE Ene rgy MANAGED TOGETHER WITH A COST OPTIMIZATION FOCUS Slide | 27
  28. 28. IMPLEMENTATION “Turning everyone into a decision maker.Impact of decision on day-to-day energy cost Push decision-making Managers down to the lowest level. Our experience strongly Supervisors suggests that when you ask employees to make most of the decisions, they become more Operators productive” - Nucor Slide | 28
  29. 29. IMPLEMENTATION USER CASE Slide | 29
  30. 30. A PEPITe Technology Ulrika Wisingu.wising@pepite.be - www.myenergymaestro.com - +32 478 170 193 Slide | 30

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