Pepsi Co. College Point, NY

Transcription

1 Pepsi Co. College Point, NY Data Integrator Initial Data Summary Data Description Beginning on March 1, 7, Consolidated Edison Solutions began sending CDH Energy data for the Pepsi Co. plant located in College Point, NY. The data is uploaded to CDH every 15 minutes and contains information for generator power output, facility power import, gas use, feedwater flow and steam heating load. This documents summarizes the data being collected and the remaining questions. DG/CHP Integrated Data System Channels Two distinct engine generator systems can be identified from the data; the first set has engines 1 and while the second set has engines 3 and 4. Each system consists of two engine generators and heat recovery to steam. The electrical generation and gas consumption of the generators are in separate data channels. The steam heat recovery is available in a single generator per generator set. Table 1 shows the processed data channels from rawdata used in the DG/CHP Integrated Data System for engines 1 and. Table shows the processed data channels from rawdata used in the DG/CHP Integrated Data System for engines 3 and 4. The facility purchased energy/demand will be assigned to engines 1 and and zeroes will be used for engines 3 and 4; these channels are only valuable on a full facility basis by summing the two databases. CDH Energy Corp. 1 February 8

2 Table 1. Data Integrator Database Mapping for Generators 1 and Integrated Data System Channel Units of Measure Raw Data Row Description [Label] 1 Raw Data Units Raw Data Mult. 4 Calculation Formula Eng1Net-kWh [WG1], kwh/int Output EngNet-kWh [WG] kwh 1. = (WG1 + WG) Eng1Net-kWh [WG1], = (WG1 + WG)* kw kwh 1. Output Demand EngNet-kWh [WG] (6 min/hour 15 min/int) Engine1Gas [FG1], cuft/int Gas Input EngineGas [FG] ccf 1 = FG1 + FG Total Facility Purchased Energy kwh/int ElMtr-Totalizer [WT] kwh. = WT Total Facility = WT * Purchased Demand kw ElMtr-Totalizer [WT] kwh. (6 min/hour 15 min/int) Other Facility Gas Use cuft/int FirmGas [FTF] ccf 1 = FTF Total Facility Energy kwh/int Calculated Total Facility Demand kw Calculated Useful Heat Recovery MBtu/int HWB1Steam [QH1] Btu 1, = QH1 /1 Unused Heat 5 Recovery MBtu/int N/A Status/Runtime of Hours Calculated Ambient Temperature 3 F N/A F Total CHP Efficiency % LHV Calculated N/A Electrical Efficiency % LHV Calculated N/A 1 The Raw Data Row Description listed is from the Coned Solutions AST files, the label, in square brackets, is assigned by CDH Energy and used for reference in the calculation formula. All Facility Purchased Energy and Demand is assigned to the first database. This data is only examined on a full facility basis. 3 Hourly Temperature from wunderground.com for the JFK airport in Brooklyn, NY has been used for the ambient temperature 4 Raw Data Multipliers are specified by Coned Solutions and are applied to the rawdata before using the calculation formula. 5 There is no data available for this channel from the Coned Solution data CDH Energy Corp. February 8

3 Table. Data Integrator Database Mapping for Generators 3 and 4 Integrated Data System Channel Units of Measure Raw Data Row Description [Label] 1 Raw Data Units Raw Data Mult. 4 Calculation Formula Eng3Net-kWh [WG3], kwh/int Output Eng4Net-kWh [WG4] kwh 1. = (WG3+ WG4) Eng3Net-kWh [WG3], = (WG3 + WG4) * kw kwh 1. Output Demand Eng4Net-kWh [WG4] (6 min/hour 15 min/int) Engine3Gas [FG3], cuft/int Gas Input Engine4Gas [FG4] ccf 1 = FG3 + FG4 Total Facility Purchased Energy kwh/int N/A kwh. = Total Facility Purchased Demand kw N/A kwh. = Other Facility Gas Use cuft/int N/A ccf 1 = Total Facility Energy kwh/int Calculated Total Facility Demand kw Calculated Useful Heat Recovery MBtu/int HWB Steam [QH34] Btu 1, = QH34 / 1 Unused Heat 5 Recovery MBtu/int N/A Status/Runtime of Hours Calculated Ambient 3 F N/A F Temperature Total CHP Efficiency % LHV Calculated N/A Electrical Efficiency % LHV Calculated N/A 1 The Raw Data Row Description listed is from the Coned Solutions AST files, the label, in square brackets, is assigned by CDH Energy and used for reference in the calculation formula. All Facility Purchased Energy and Demand is assigned to the first database. This data is only examined on a full facility basis. 3 Hourly Temperature from wunderground.com for the JFK airport in Brooklyn, NY has been used for the ambient temperature 4 Raw Data Multipliers are specified by Coned Solutions and are applied to the rawdata before using the calculation formula. 5 There is no data available for this channel from the Coned Solution data CDH Energy Corp. 3 February 8

4 Data Verification Figure 1 shows a time series and shade plot of generator 1 output. A shade plot has the date along the x-axis and the time of the day along the y-axis. The relative power for each period is shown with shades of gray. Darker shades indicate greater power output while light gray corresponds to minimum power. White indicates periods of no data. Generator 1 had higher peak outputs in the initial data collection and in the past month than from mid-april through early September. Normal operating patterns seem to be five or six days a week with occasional periods of being shutdown during the week for a few hours. The peak output was 39 kw in March. 4 Pepsi Co. - College Point, NY: Generator 1 Output Demand (kw) Hour of Day Pepsi Co. - College Point, NY: Generator 1 Output March April May June July August Sep October NovemberDecemberJanuary Day (MAX/MIN = 39./. kw) Figure 1. Generator 1 Output Time Series and Shade Plot CDH Energy Corp. 4 February 8

5 Figure shows the shade plot and times series for generator Output. The peak output for this generator was 39 kw. The data shows increased output after October 6 th. 4 Pepsi Co. - College Point, NY: Generator Output Demand (kw) Hour of Day Pepsi Co. - College Point, NY: Generator Output March April May June July August Sep October NovemberDecemberJanuary Day (MAX/MIN = 39./. kw) Figure. Generator Output Time Series and Shade Plot CDH Energy Corp. 5 February 8

6 Figure 3 shows the shade and time series plots for generator 3 Output. The peak output for this generator was 39 kw. Similar to the other engines, output was higher in March and September than from April through August. There was a period in August where data was not collected from 9am through 1am for a period of several weeks. The output was higher in December and January than from September through November. 4 Pepsi Co. - College Point, NY: Generator 3 Output Demand (kw) Hour of Day Pepsi Co. - College Point, NY: Generator 3 Output March April May June July August Sep October NovemberDecemberJanuary Day (MAX/MIN = 39./. kw) Figure 3. Generator 3 Output Time Series and Shade Plot CDH Energy Corp. 6 February 8

7 Figure 4 show the shade and time series plots for generator 4 Output. The peak output for this generator was 33 kw. Similar to generator 3, there was a period in August where data was not collected from 9am through 1am for a period of several weeks. 4 Pepsi Co. - College Point, NY: Generator 4 Output Demand (kw) Hour of Day Pepsi Co. - College Point, NY: Generator 4 Output March April May June July August Sep October NovemberDecemberJanuary Day (MAX/MIN = 388./. kw) Figure 4. Generator 4 Output Time Series and Shade Plot CDH Energy Corp. 7 February 8

8 Generator Fuel Use Patterns Gas use data is being reported for each of the generators individually. Gas Use for generator 1 is much lower in the period before April 6 than after because of an apparent scaling change. According to the gas use, both generators did not operate significantly from a period in mid- August through early September, which is also confirmed by the power data. There was period in December where the data for Generator Fuel Input was zero (the generator power indicated operation) probably due to a data collection error. 5 Pepsi Co. - College Point, NY: Generator 1 Fuel Input Fuel Use (cf/hr) Fuel Use (cf/hr) Pepsi Co. - College Point, NY: Generator Fuel Input Figure 5. Gas Use Data for Generators 1 and CDH Energy Corp. 8 February 8

9 Figure 6 shows the gas use for Generator 3 and 4. Gas Use for Generator 3 is much lower in the period before April 6 than after because of an apparent scaling change. There is one period of high gas consumption for both generators in March, this is probably due to a data collection error and will be masked by data quality checks with the generator power. Fuel Use (cf/hr) Pepsi Co. - College Point, NY: Generator 3 Fuel Input 1 Fuel Use (cf/hr).5e4.e4 1.5E4 1.E4 Pepsi Co. - College Point, NY: Generator 4 Fuel Input 5.E3 Figure 6. Gas Use Data for Generators 3 and 4 CDH Energy Corp. 9 February 8

10 Steam Loads Steam data is being collected for the two systems. The steam output for generators 1 and is represented by the channel HWB1. The steam output for generators 3 and 4 is represented by HWB. All of the data reported so far for System 1 is zero. There is steam data for system but non-zero steam loads have been observed during periods of no Generator Output for either Generator 3 or 4. There is an apparent change in the steam output in September, representing either a change in the multiplier or decreased steam production. Steam Load (MBtu/h) Pepsi Co. - College Point, NY: HWB1Steam. Steam Load (MBtu/h) Pepsi Co. - College Point, NY: HWBSteam Figure 7. Plot of Steam Data Collected CDH Energy Corp. 1 February 8

11 Table 3 is a table of generator output, gas use and calculated generation efficiency on a monthly basis. From the table, the generator efficiencies for Generators 1 and 3 are impossibly high for March and April. This indicates a scaling change was made and the date was identified as April 6 th. Generators and 4 have a total generation efficiency that seems high before October 6 th. After October 6 th, all of the generation efficiencies are normal, with the exception of Generator for a period when gas data was not reported (see Figure 5). Table 3. Monthly Table of Generator Electrical Efficiencies Energy Produced (kwh) Generator 1 Generator Generator 3 Generator 4 Gas Generation Energy Gas Generation Energy Gas Generation Energy Gas Consumed Efficiency Produced Consumed Efficiency Produced Consumed Efficiency Produced Consumed (CCF) (% LHV) (kwh) (cf) (% LHV) (kwh) (CCF) (% LHV) (kwh) (cf) Generation Efficiency (% LHV) Date Mar 7 133, % 18,54 1,655 41% 1, % 15,5 1,486 38% Apr 7 11,5 14,61 3% 8,693 6,41 49% 94,53 9,653 36% 8,18 5,58 53% May 7 143,9 19,389 7% 11,31 9,73 46% 119,43 18,854 3% 59,79 4,491 48% Jun 7 14,58 19, 4% 15,9 9,7 4% 55,175 8,931 3% 84,4 7,841 39% Jul 7 1,518 18,5 5% 1,85 1, 43% 96,557 16,54 1% 77,36 7,478 38% Aug 7 61,985 8,67 6% 69,387 5,755 44% 93,9 14,93 4% 84,71 7,89 4% Sep 7 14,915 14,56 33% 86,33 5,81 54% 9,845 11,41 3% 76,81 6,39 44% Oct 7 17,331 1,711 31% 15,454 1,55 31% 16,67 14,887 31% 96,56 1,9 9% Nov 7 13,97 14,96 34% 6,137 7,98 3% 13,165 11,57 33% 96,88 1,88 9% Dec 7 91,953 9,683 35% 13,889,36 193% 16,44 11,33 34% 17,54 13,44 9% Jan 8 1,833 1,58 35% 11,4 11,161 37% 98,79 1,538 34% 93,969 11,67 3% Total 1,63,95 141,318 33% 1,6,36 81,537 45% 1,89,38 18,66 31% 871,54 9,589 35% Table 4 shows the CHP Efficiency for the two systems. The CHP efficiency for system 1 is simply the electrical efficiency by the calculation because the steam generation data from this system is always zero. For Generator 3 and 4, the CHP Efficiency is high in March and April due to gas scaling issues. The CHP Efficiency from May-January is 3-49%, a reasonable efficiency for a CHP system of this type. Table 4. Monthly Table of Total CHP Efficiency Energy Produced (kwh) Gas Consumed (CCF) Generator 1 and Generator 3 and 4 Steam Generation Total CHP Energy Gas Steam Generated Efficiency Efficiency Produced Consumed Generated (MMBtu) (% LHV) (% LHV) (kwh) (CCF) (MMBtu) Generation Efficiency (% LHV) Total CHP Efficiency (% LHV) Date Mar 7 151,675,77. 68% 68% 118,4 1, % 398% Apr 7 1,943,1. 37% 37% 174,71 15, % 59% May 7 64,64 9,11. 33% 33% 178,48 3, % 41% Jun 7 3,5 8,47. 3% 3% 139,17 16, % 49% Jul 7 4,63 8,45. 31% 31% 173,793 3, % 43% Aug 7 131,37 14,45. 33% 33% 178,61, % 46% Sep 7 11,148 19, % 39% 169,646 17, % 4% Oct 7 1,785 5,16. 31% 31%,773 6, % 3% Nov 7 194,34 1, % 33% 199,53 3, % 34% Dec 7 15,84 1,43. 66% 66% 13,786 4, % 35% Jan 8 13,53 1, % 36% 19,698, % 34% Total,69,961, % 37% 1,96,74 18,655, % 43% CDH Energy Corp. 11 February 8

12 Assumptions 1. HWB1 Steam is assumed to represent heat recovery for engines 1 and while HWB is assumed to represent heat recovery for engines 3 and 4. Summary Questions Here is a summary of the questions from a review of the data set: 1. There is no steam data collected for HWB1. Is this a problem with the data channel or is the load actually zero?. Why are there periods of HWB Steam data when neither Generator 3 or 4 is operating? Recommendations All data problems, with the exception of the steam generation data, have been solved and the site is now loaded into the CHP database. Coned Solutions is working to solve the problems with the steam load data. Until the problems are resolved, this data will be masked from the online database. CDH Energy Corp. 1 February 8

13 Data Channel Summary Table 5. Summary of Data Channels From Coned Solutions Coned Solutions Data Channel Units File Prefix Mult. Min Max Avg ElMtr-Totalizer kwh PepsiHWB TotalCogenGas cf PepsiHWB-1 1, 19, 1, Engine1Gas cf PepsiHWB-1 1 1, EngineGas cf PepsiHWB-1 1 1, Eng1Net-kWh kwh PepsiHWB EngNet-kWh kwh PepsiHWB HWB1Fd-Wtr gal PepsiHWB HWB1Steam Btu PepsiHWB-1 1,. Engine3Gas cf PepsiHWB- 1 1,4 47. Engine4Gas cf PepsiHWB- 1 6, 88.5 Eng3Net-kWh kwh PepsiHWB Eng4Net-kWh kwh PepsiHWB HWBFd-Wtr Gal PepsiHWB- 1. HWBSteam Btu PepsiHWB- 1, 5, 67,494 IntrptGas cf PepsiHWB- 1, 6, 1.65 FirmGas cf PepsiHWB- 1, 1, CDH Energy Corp. 13 February 8