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RECON
PURPOSE ,[object Object],[object Object],[object Object]
OBJECTIVES  WHY DO THIS?  ,[object Object],[object Object]
PRINCIPLES HOW DO WE WANT TO DO THIS? ,[object Object],[object Object],[object Object],[object Object],[object Object]
PROCESSES  WHAT WILL CHANGE? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
TOOLS SOFTWARE, HARDWARE, MANUALS  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
PLANT ENERGY PROFILER
RECON DIAGNOSTIC
STANDARD SCORECARD
IMPLEMENTATION WHO IS INVOLVED? ,[object Object],[object Object],[object Object],[object Object],[object Object]
SUCCESS  WHAT DOES SUCCESS LOOK LIKE? ,[object Object],[object Object],[object Object],[object Object],[object Object]
FOUR STAGES IN RECON ,[object Object],[object Object],[object Object],[object Object]
  PREREQUISITES ,[object Object],[object Object],[object Object]
  ACHIEVE SPONSORSHIP & AWARENESS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
  ESTABLISH COMMON METRICS ,[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object],[object Object],PI ReCon Train the Trainer v0.2
[object Object],[object Object],[object Object],[object Object],[object Object],PI ReCon Train the Trainer v0.2
PI ReCon Train the Trainer v0.2
  SET PRIORITIES ,[object Object],[object Object],[object Object],[object Object],[object Object]
HOTLIST
Diagnostic Identifies Opportunity Hotlist! Profiler Quantifies Opportunity ReCon Team Assesses Difficulty & Visibility Select 20 Balanced Objectives Priority A High Opportunity Low Difficulty Short Result Cycle Priority C Low Opportunity Low Difficulty High Visibility Priority D High Opportunity Higher Difficulty Longer Results Cycle Priority B High Opportunity Higher Difficulty Longer Result Cycle
PROCESSES ,[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object]
PRACTICES ,[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],PI ReCon Train the Trainer v0.2
PROJECTS ,[object Object],[object Object],[object Object],[object Object]
WHAT NEW OCEAN CAN HELP ? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
WITH NEW OCEAN ,[object Object],[object Object],[object Object],[object Object],PI ReCon Train the Trainer v0.2
OPPORTUNITIES ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Electric Motors ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
ENERGY EFFICIENT MOTORS ,[object Object],[object Object],[object Object],[object Object]
CASE STUDY  ,[object Object],[object Object],PI ReCon Train the Trainer v0.2 Cutting  3,000 MWh/year  Saving  $560,000/year  CO2 Reduced 1,288 tons/year Efficiency Motor
VARIABLE SPEED DRIVES ,[object Object],[object Object],[object Object]
VSDS - VFDS PI ReCon Train the Trainer v0.2 A 250kW fan Three 132 kW fans saving  $210,000/year  Energy saving  3,300 MWh/year CO2 reduction  1,500 tons/year
CORRECTLY SIZE MOTORS  VS  REGULAR MAINTENANCE  ,[object Object],[object Object],[object Object],[object Object]
COMPRESSED AIR SYSTEMS ,[object Object],[object Object],[object Object]
PI ReCon Train the Trainer v0.2
ONLY ONE KW OF WORK FOR 7.5 KWS INPUT Compressed Air Basics v1.4 7.5 Kw Electric power input is required for 1 Kw output of Compressed Air work
COMPRESSOR UNIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
MAINTENANCE
THE DISTRIBUTION SYSTEM ,[object Object],[object Object]
Air In Compressed Air and Oil Air/Oil Separator Compressed Air Out
BOILERS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],PI ReCon Train the Trainer v0.2
PI ReCon Train the Trainer v0.2 -40 -20 0 20 40 60 80 16.0 14.0 12.0 10.0 8.0 6.0 4.0 2.0 0.0 % Excess Air % Gas Concentration by Volume 85% 75% 80% 70% Combustion Efficiency (Eff) %CO 2 %O 2 %CO Eff Excess Air Incomplete Combustion Efficiency
PI ReCon Train the Trainer v0.2 C O O + HEAT (Methane) O O C H H C H H N N N N N N N N O O N N N N N N N N O O O O C O H H O H H + Usable HEAT Hot   Nitrogen N N N N N N N N N N N N N N N N Waste Heat
PI ReCon Train the Trainer v0.2 Burner Air In Gas In Process  Heat User Control  Processor Combustion Gas O 2  Sensor Signal from Temperature or Pressure control Motorized Valves O 2
[object Object],[object Object],PI ReCon Train the Trainer v0.2
MONITORING EQUIPMENT PI ReCon Train the Trainer v0.2 3 Meters are Critical to Monitor Boiler KPIs Fuel Input Steam Output Totalizing Fuel Meter Totalizing Steam Meter Boiler Water  Softener Deaerator Totalizing Water Meter
[object Object],[object Object],[object Object],PI ReCon Train the Trainer v0.2
LOAD MANAGEMENT Example: Measured 100,000   KJ/Hour Fuel input Measured  80,000   KJ/Hour Steam output Totalizing Fuel Meter Totalizing Steam Meter Totalizing Water Meter
[object Object],[object Object],[object Object],[object Object],PI ReCon Train the Trainer v0.2
PI ReCon Train the Trainer v0.2 Feedwater Flash Steam Boiler Deaerator (DA) End Users Steam to Users Condensate Return Blowdown Preheated Make up Water Liquid blowdown Make up Water To Drain Heat Recovery Hx Flash Tank Heat Recovery Hx
PI ReCon Train the Trainer v0.2
SAVING FROM FURNACE PI ReCon Train the Trainer v0.2 Gross Energy  Input Available Energy Chimney Gas Losses Dry Wet Wall Losses Energy  to Process Fuel Fired Heater
EXCESS AIR PI ReCon Train the Trainer v0.2 Mount of Heat used Air to Fuel (A/F) Ratio Insulation  Chimney
PI ReCon Train the Trainer v0.2 C O O + HEAT (Methane) O O C H H C H H N N N N N N N N O O N N N N N N N N O O O O C O H H O H H + Usable HEAT Hot   Nitrogen N N N N N N N N N N N N N N N N Waste Heat
AIR TO FUEL (A/F) RATIO PI ReCon Train the Trainer v0.2 Burner Air In Gas In Process  Heat User Control  Processor Combustion Gas O 2  Sensor Signal from Temperature or Pressure control Motorized Valves O 2
PI ReCon Train the Trainer v0.2 Exhaust Gas Chimney Exhaust Fan Multiple Burners and Zones ,[object Object],[object Object],Oven Damper Chimney save
CONCLUSION WITH NEW OCEAN ,[object Object],[object Object],[object Object],[object Object],PI ReCon Train the Trainer v0.2

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Re con

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  • 18. PI ReCon Train the Trainer v0.2
  • 19.
  • 21. Diagnostic Identifies Opportunity Hotlist! Profiler Quantifies Opportunity ReCon Team Assesses Difficulty & Visibility Select 20 Balanced Objectives Priority A High Opportunity Low Difficulty Short Result Cycle Priority C Low Opportunity Low Difficulty High Visibility Priority D High Opportunity Higher Difficulty Longer Results Cycle Priority B High Opportunity Higher Difficulty Longer Result Cycle
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  • 34. VSDS - VFDS PI ReCon Train the Trainer v0.2 A 250kW fan Three 132 kW fans saving $210,000/year Energy saving 3,300 MWh/year CO2 reduction 1,500 tons/year
  • 35.
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  • 37. PI ReCon Train the Trainer v0.2
  • 38. ONLY ONE KW OF WORK FOR 7.5 KWS INPUT Compressed Air Basics v1.4 7.5 Kw Electric power input is required for 1 Kw output of Compressed Air work
  • 39.
  • 41.
  • 42. Air In Compressed Air and Oil Air/Oil Separator Compressed Air Out
  • 43.
  • 44. PI ReCon Train the Trainer v0.2 -40 -20 0 20 40 60 80 16.0 14.0 12.0 10.0 8.0 6.0 4.0 2.0 0.0 % Excess Air % Gas Concentration by Volume 85% 75% 80% 70% Combustion Efficiency (Eff) %CO 2 %O 2 %CO Eff Excess Air Incomplete Combustion Efficiency
  • 45. PI ReCon Train the Trainer v0.2 C O O + HEAT (Methane) O O C H H C H H N N N N N N N N O O N N N N N N N N O O O O C O H H O H H + Usable HEAT Hot Nitrogen N N N N N N N N N N N N N N N N Waste Heat
  • 46. PI ReCon Train the Trainer v0.2 Burner Air In Gas In Process Heat User Control Processor Combustion Gas O 2 Sensor Signal from Temperature or Pressure control Motorized Valves O 2
  • 47.
  • 48. MONITORING EQUIPMENT PI ReCon Train the Trainer v0.2 3 Meters are Critical to Monitor Boiler KPIs Fuel Input Steam Output Totalizing Fuel Meter Totalizing Steam Meter Boiler Water Softener Deaerator Totalizing Water Meter
  • 49.
  • 50. LOAD MANAGEMENT Example: Measured 100,000 KJ/Hour Fuel input Measured 80,000 KJ/Hour Steam output Totalizing Fuel Meter Totalizing Steam Meter Totalizing Water Meter
  • 51.
  • 52. PI ReCon Train the Trainer v0.2 Feedwater Flash Steam Boiler Deaerator (DA) End Users Steam to Users Condensate Return Blowdown Preheated Make up Water Liquid blowdown Make up Water To Drain Heat Recovery Hx Flash Tank Heat Recovery Hx
  • 53. PI ReCon Train the Trainer v0.2
  • 54. SAVING FROM FURNACE PI ReCon Train the Trainer v0.2 Gross Energy Input Available Energy Chimney Gas Losses Dry Wet Wall Losses Energy to Process Fuel Fired Heater
  • 55. EXCESS AIR PI ReCon Train the Trainer v0.2 Mount of Heat used Air to Fuel (A/F) Ratio Insulation Chimney
  • 56. PI ReCon Train the Trainer v0.2 C O O + HEAT (Methane) O O C H H C H H N N N N N N N N O O N N N N N N N N O O O O C O H H O H H + Usable HEAT Hot Nitrogen N N N N N N N N N N N N N N N N Waste Heat
  • 57. AIR TO FUEL (A/F) RATIO PI ReCon Train the Trainer v0.2 Burner Air In Gas In Process Heat User Control Processor Combustion Gas O 2 Sensor Signal from Temperature or Pressure control Motorized Valves O 2
  • 58.
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Editor's Notes

  1. PI ReCon Train the Trainer v0.2
  2. ReCon Stage 2 Compressed Air Basics v1.4 Compressed air is a very expensive utility. Power is put into the system in the form of electricity to the compressor motor. The first bar of this chart shows the KW input to the motor. The motor has an efficiency loss, so the second bar shows the power actually input into the motor. The last bar shows how much power is actually usable in the compressed air. The rest of the power is lost in compressor friction and heat. 7.5 Kw electrical input are required for one Kw compressed air work. This is due to the inefficiencies in compressing air.