ROMA Maggio Leonardo Olivari. Corso di formazione ed aggiornamento per EM

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1 Corso di formazione ed aggiornamento per EM Esperienze di Energy Management e di implementazione di un Sistema di Gestione Energia in un industria. ROMA Maggio 2016 Leonardo Olivari

2 Summary Tenaris & TenarisDalmine Production Energy Management in TenarisDalmine Corso formazione per EM TenarisDalmine Presentation 2

3 Agostino Rocca Corso formazione per EM TenarisDalmine Presentation 3

4 Techint Group Corso formazione per EM TenarisDalmine Presentation 4

5 Tenaris Global industrial System (Feb. 2014) Corso formazione per EM TenarisDalmine Presentation 5

6 Market Segments Leading global manufacturer and supplier of tubular products and services used in: Drilling, completion and production of oil and gas OCTG Premium Connections Offshore Line Pipe Transportation of oil and gas Process and power plants Specialized industrial and automotive applications Onshore Line Pipe Hidrocarbon Processing Power Generation Industrial & Automotive Corso formazione per EM TenarisDalmine Presentation 6

7 TenarisDalmine (August 31, 2013) Corso formazione per EM TenarisDalmine Presentation 7

8 Summary Tenaris & TenarisDalmine Production Energy Management in TenarisDalmine Corso formazione per EM TenarisDalmine Presentation 8

9 Tenaris production cycle Corso formazione per EM TenarisDalmine Presentation 9

10 TenarisDalmine - production (seamless and welded pipes) Corso formazione per EM TenarisDalmine Presentation April 29/04/ ,

11 Products/clients differentiation (data refers to 31/12/2013 on turnover) Corso formazione per EM TenarisDalmine Presentation 11

12 Summary Tenaris & TenarisDalmine Production Energy Management in TenarisDalmine Corso formazione per EM TenarisDalmine Presentation 12

13 Energy Efficiency 2006 a strategic choice! Why? Energy is a third component of TenarisDalmine product cost, after Raw material and Labour. Reduce energy costs was essential to ensure the competitiveness and business sustainability at TenarisDalmine. Corso formazione per EM TenarisDalmine Presentation 13

14 Energy Efficiency 2006 a strategic choice! How? New organization New activities Before PRODUCTION MSTE OPERATION After MSTE ENMA yousave Gruppo innowatio PRODUCTION OPERATION Focus on energy aspects Metering Energy Assessment Priority list of Energy projects Investments Training and communications Continuous Improving Groups Operative Practice and Procedure Cultural change! Corso formazione per EM TenarisDalmine Presentation 14

15 Energy Efficiency Tenaris Dalmine steps for energy efficiency. 2006: An Energy Saving Plan was launched. Objectives 7% and 6% in specific consumption reduction in natural gas and electricity. Planned activities were: Metering, Controlling, Training & Communication, Standardization, Investment plan and Waste reduction plan. Corso formazione per EM TenarisDalmine Presentation 15

16 Energy Efficiency Tenaris Dalmine steps for energy efficiency. 2007: A 120 MWe high efficiency Combined Cycle Power Plant started the operation to self-production of electricity, steam and hot water both inside and outside the plant (district heating). Corso formazione per EM TenarisDalmine Presentation 16

17 Energy Efficiency Tenaris Dalmine steps for energy efficiency. 2008: The first high efficiency combustion system has been installed in a reheating furnace. (45% methane saving) Corso formazione per EM TenarisDalmine Presentation 17

18 Energy Efficiency Tenaris Dalmine steps for energy efficiency. 2009: A global Energy Efficiency Plan was launched in Tenaris, also creating an R&D department for Energy Efficiency. The crisis Help ENMA to implement a new program oriented to reduce Energy losses, thanks to: New Courses internal inspection program A first standardization of operating procedure for reduce energy consumption, mainly during a non production period. A first step of Compressed air reduction plan has been conclused Tenaris Dalmine receives external recognitions: Titoli di Efficienza Energetica TEE (1 TEE= 1 ton of oil saved) have been assigned by the Italian authorities for the main high technology investments. Corso formazione per EM TenarisDalmine Presentation 18

19 Energy Efficiency Tenaris Dalmine steps for energy efficiency. 2010: Joint activity between Dalmine and Lloyd s for obtaining: EN Energy Management System certification for Dalmine Accreditation as EN certifier for Lloyd s Register - It was reinforced activities of audit, inspection, and opportunity identification. - In three areas was installed new Lighting system - Nitrogen/air conversion program has been completed Corso formazione per EM TenarisDalmine Presentation 19

20 Energy Efficiency Tenaris Dalmine steps for energy efficiency. 2011: New regenerative burners has been installed in a major Rotative fournace. Decrease of Natural Gas specific consumption (20% methane saving) Decrease of consumption during non operative period Corso formazione per EM TenarisDalmine Presentation 20

21 Energy Efficiency Tenaris Dalmine steps for energy efficiency. 2012: April 2012 Tenaris Dalmine & CTE got the ISO certification. As conseguence of EnPI analisys, a new program of pump systems efficiency improuvement has started. At Tenaris level was written BAT - Best Available Tecnologies in order to define Optimal way» for every specific application Continuous Improvement Groups (GMC) methodology was structurally applied to energy management. Corso formazione per EM TenarisDalmine Presentation 21

22 Energy Efficiency Tenaris Dalmine steps for energy efficiency. 2013: A big project of Heat recovery, based on 2 Steps, was launched. - Installation a new HRSG in major hot rolling mill. - Heat recovery in EAF (Electrical Arc Furnace). Continuous penetration of energy policy in every business functions: -Design of new lines according to Best Available Technologies - Inclusion of energy efficiency as a criterion of purchasing components (Pumps, electric motors) - Installing VSD to better regulate the water flows. Corso formazione per EM TenarisDalmine Presentation 22

23 Energy Efficiency Tenaris Dalmine steps for energy efficiency. SGE Sabbio Costa Volpino Dalmine Piombino Arcore 2014: May 2014 Dalmine Obtained the ISO certification for all the Italian sites. Closed 12 Continuous Improvement Groups in energy consumption reduction Corso formazione per EM TenarisDalmine Presentation 23

24 Energy Efficiency Tenaris Dalmine steps for energy efficiency. SGE Sabbio Costa Volpino Dalmine Piombino Arcore 2014 And Now?? Looking for some big investment (difficult in terms of return of investment) HRSG in a major hot rolling mill will start up at the and of 2014 Heat recovery project in Steel Shop (EFER) is on going Optimization of energy use thanks to implementation of strong EnPI, audit, inspection, new Continuous improvement Groups Corso formazione per EM TenarisDalmine Presentation 24

25 Thank you!!! Leonardo Olivari Energy Management TENARIS DALMINE Piazza Caduti 6 luglio 1944, Dalmine (BG) 035 / * lolivari@tenaris.com Corso formazione per EM TenarisDalmine Presentation 34