The Brand Felt Ltd. - Excelling in Manufacturing through Energy Efficiency
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1 The Brand Felt Ltd. - Excelling in Manufacturing through Energy Efficiency Chris Russell P.Eng., CEM Chris.Russell@enbridge.com
2 The Brand Felt Company Background Canadian manufacturer of Industrial Wool Felt located in Mississauga Ontario Industries serviced, include automotive, chemical, steel, equine, metal fabricating, architecture, interior design Pharmaceutical, aerospace, military, furniture, display and exhibit industries Only Pressed Felt manufacturer in Canada Main objective is to develop and provide environmentally friendly felt products.
3 The Brand Felt Competitive Advantage & Strategic Priorities Find more sales contracts to remain profitable, instead of finding ways to reduce energy Production is more important than worrying about energy consumption in the product As long as the plant is running - Brand Felt is happy
4 The Brand Felt Competitive Advantage & Strategic Priorities No idea the cost of energy into product, or cost variation day to day More concerned with just paying the energy bills it s a cost of doing business Main objective is to continue producing felt products.
5 Monthly Consumption [ m3 ] Manufacturing Excellence and Energy Efficiency Understanding Where and How Energy is Used Average 3-year annual gas consumption 60,000 Boiler seasonal 50,000 40,000 SEASONAL PROCESS Boiler process heating load in blue 30,000 steam Steam sent to heat 20,000 load in red exchangers 10,000 Steam sent to 0 equipment
6 Monthly Consumption [ m3 ] Manufacturing Excellence and Energy Efficiency Understanding Where and How Energy is Used Seasonal Space Steam Heating Requirements Exchangers Equipment 60,000 50,000 SEASONAL PROCESS 40,000 30,000 20,000 10,000 Process Loads Felting, Fulling, Dying & Drying 0 Steam Energy Boiler & Air Converters Compressor
7 Industrial Programs CEM Program for Industry and Institutions Aspires to take energy consumption onto the daily production meeting report to make energy visible. Energy management is a transformational rather than transactional process. Transforms energy from a fixed cost to an operational input so it can be measured, understood and managed.
8 Brand Felt Working with Enbridge Signing up with CEM (Comprehensive Energy Management) Worked with Enbridge to enroll into the CEM Program Secured upper management buy-in to the ideals of the program and support this new initiative Developed an Energy Policy with attainable energy intensity reduction goals Main objective is to make energy visible.
9 Industrial Programs Industrial Custom Program Knowledge Development Brand Felt understands that they are paying for utilities. They reached out to Enbridge to take advantage of incentive programs and now work together to better understand the impact of the resources to their bottom line
10 Manufacturing Excellence and Energy Efficiency Understanding Where and How Energy is Used 60,000 Historical Consumption + Outdoor temperature 30.0 Monthly Consumption [ m 3 ] Monthly Consumption [ m 3 ] Monthly Consumption as Function of Outdoor Temperature 60,000 50,000 40,000 30,000 20,000 10, Outdoor Temperature [ C ] 50,000 40,000 30,000 20,000 10, Outdoor Temperature [ C ]
11 Industrial Programs Industrial Custom Program Knowledge Development Brand Felt understands that they are paying for utilities. They reached out to Enbridge to take advantage of incentive programs and now work together to better understand the impact of the resources to their bottom line Opportunity Identification Enbridge and Brand Felt worked together to identify where to begin metering the process, how to collect and store the data and how to identify possible energy improvement initiatives
12 Brand Felt Working with Enbridge Signing up with CEM (Comprehensive Energy Management) Developed a road map of the equipment and where the steam energy and hot water is going in the facility
13 Industrial Programs Industrial Custom Program Knowledge Development Brand Felt is beginning to understand what the information is telling them about variances in the daily operation of the facility Opportunity Identification Enbridge and Brand Felt worked together to identify where to begin metering the process, how to collect and store the data and how to identify possible energy improvement initiatives Potential Quantification Enbridge helped Brand Felt, by incentivizing the purchase and installation of the meters and data acquisition equipment. This data is used to quantify energy project potential
14 Manufacturing Excellence and Energy Efficiency How to Meter and Monitor Energy Data Water Flow Water Flow Steam Flow Boiler Meter Meter Meter Controller Omega ftb Rosemount Vortex Rosemount Vortex Webmaster boiler 8007b-pr Flow Meter Flow Meter PLC
15 Industrial Programs Industrial Custom Program Knowledge Development Brand Felt is beginning to understand what the information is telling them about variances in the daily operation of the facility Opportunity Identification Enbridge and Brand Felt worked together to identify where to begin metering the process, how to collect and store the data and how to identify possible energy improvement initiatives Engineering Analysis Brand Felt has started to send their collected data to Enbridge to help analyze steam and natural gas usage. The long term goal is to develop and quantify projects using this monitored and collected data Potential Quantification Enbridge helped Brand Felt, by incentivizing the purchase and installation of the meters and data acquisition equipment. This data is used to quantify energy project potential
16 Manufacturing Excellence and Energy Efficiency Understanding Where and How Energy is Used
17 Manufacturing Excellence and Energy Efficiency Understanding Where the Steam is Going Steam meter pictogram based on individual meter flowrates
18 Manufacturing Excellence and Energy Efficiency Boiler Water and Blowdown Information Boiler PLC software was unlocked to give real-time information. Important to trouble
19 Manufacturing Excellence and Energy Efficiency Comparing Collected Data Daily natural gas consumption on boiler month over month comparison
20 Industrial Programs Industrial Custom Program Knowledge Development Brand Felt is beginning to understand what the information is telling them about variances in the daily operation of the facility Action and Implementation Brand Felt has implemented steam controls to eliminate manual settings. They have also partially eliminated steam in favour of hot water removing the over processing of the felt Engineering Analysis Brand Felt has started to send their collected data to Enbridge to help analyze steam and natural gas usage. The long term goal is to develop and quantify projects using this monitored and collected data Opportunity Identification Enbridge and Brand Felt worked together to identify where to begin metering the process, how to collect and store the data and how to identify possible energy improvement initiatives Potential Quantification Enbridge helped Brand Felt, by incentivizing the purchase and installation of the meters and data acquisition equipment. This data is used to quantify energy project potential
21 Manufacturing Excellence and Energy Efficiency Daily Cost Variance of Operating the Boiler Colour coded calendar shows every day energy cost relative to lowest consumption green days Additional TV screens are mounted in each office to inform managers and supervisors
22 Manufacturing Excellence and Energy Efficiency Notifications Electronic real time notification system in place texts to plant operations and maintenance staff smart phones s to upper management when energy consumptions exceed daily expected targets Objective has been reached: energy is now visible.
23 Manufacturing Excellence and Energy Efficiency Compressor Oil to Water Heat Exchanger Heating Water for free
24 Manufacturing Excellence and Energy Efficiency Heating the Building based on Outside Temperature instead of ALWAYS Operating Boiler at Maximum Future option will be to heat the building with wastewater through a heat exchanger
25 Manufacturing Excellence and Energy Efficiency Smart Felt Drying Process HUMIDITY ACCEPTABLE % OF DROPPING DRYNESS REACHED WET FELTS INTO DRYING ROOM DRYING PROCESS STARTS STILL ADDING HEAT DRYING PROCESS STOPPED Temperature and humidity required in felt drying rooms Based on outdoor air temperature and humidity being brought into felt drying process Heating stops when felts
26 Manufacturing Excellence and Energy Efficiency Understanding Where and How Energy is Used When process is running Brand Felt has detected recurring spikes in temperature Green temp in Red temp out
27 Manufacturing Excellence and Energy Efficiency Beneficial Collaboration Non-energy benefits Investment decision drivers Energy benefits Value Cost Risk mitigation Reduce carbon footprint Enhance working conditions (lower equipment temperatures) Improve boiler operations & reduce maintenance Improve public image Improve Plant Safety Reduced Maintenance Lower Lower administrative energy costs costs Improve labour productivity Lower Operating and Maintenance costs Lower exposure to future pricing movements Better employer reputation Reliable supplier Reduce energy consumption
28 THANK YOU! Thank you to Holger Roth and The Brand Felt Ltd. Contact info : Chris Russell, P.Eng. Chris.Russell@enbridge.com enbridgesmartsavings.com/business
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