Energy Saving of Utility Plant by IT

Transcription

1 Thailand Green IT Seminar 2013 Energy Saving of Utility Plant by IT Azbil Corporation Advanced Automation Company Advance Solution Division Mike Suzuki Copyright 2011 Yamatake Corporation All Rights Reserved.

2 Table of Contents 1. Introduction to Azbil Corporation 2. Air Compressor Energy Savings 3. Boiler, Turbine and Chiller Energy Savings 4. Energy Management (Monitoring) 5. Reference 2

3 3 Introduction to Azbil Corporation

4 Group Symbol azbil (Automation Zone Builder) represents our philosophy of realizing safety, comfort and fulfillment in people s lives, and contributing to global environmental preservation through humancentered automation.

5 Our Business Area Measurement and Control Solutions through IT and control technology Building Automation Advanced Automation Life Automation Offices Hospitals Computer centers Schools Hotels District Cooling Process industries Assembly industries Life line infrastructure Water meters City gas and LP gas Residential air-conditioning 5

6 (As of October 2010) Overseas Network Azbil Information Technology Center (Dalian) Co., Ltd. Azbil Control Instruments (Dalian)Co., Ltd. Yamatake Environmental Control Technology (Beijing) Co., Ltd. Azbil North America, Inc. Azbil BioVigilant, Inc. Azbil Control Solutions (Shanghai) Co., Ltd Shanghai Azbil Automation Co., Ltd. Yamatake Automation Products Shanghai Co., Ltd. Azbil Hong Kong Limited Azbil Vietnam Co., Ltd. Abu Dhabi Branch Azbil Korea Co., Ltd. Azbil Taiwan Co., Ltd. Azbil Philippines Corporation Azbil Brazil Limited. Azbil Europe NV Middle East Branch Azbil India Pvt. Ltd. Global Network PT. Azbil Berca Indonesia Azbil Singapore Pte. Ltd. Azbil Malaysia Sdn. Bhd. Azbil (Thailand) Co., Ltd. Companies incorporated abroad Overseas branches and representative offices

7 7 Azbil Solution

8 Today s Topic - Energy Saving By IT - Utility Plant Issue Stable Supply & Energy Saving 8

9 Air Compressors Energy Saving Unit quantity control system pressure measurement control Compressors Receiver tank Monitoring in each building Monitoring for each piece of equipment Leak monitoring Cost allocation to each division 9 Factory pipeline network

10 Point of Energy Saving Reduce the air cost (Supply Side) Reduce unloaded operation time Stop the stand-by compressor Reduce the header pressure Reduce the warming-up time 1 Reduce air consumption (Demand Side) Reduce the air leakage Air control by demand Schedule control Air Compressor

11 Energy Saving Solution Reduce Air Cost (Supply Side) Suppression of header pressure fluctuation Reduce header pressure Selection for compressors Scheduled (production) Control Reduce Air Consumption (Demand Side) Find Air leakage Supply suitable pressured air to each line 1 Header pressure 3 4 Flow meter Control Valve pressure Line Flow meter 5 Air Compressor Air leakage detector

12 Reduce Air Cost Header Pressure Control Stabilize the pressure with continuous control and then Decrease header pressure Decrease Header Pressure by Air Load Quantity Control of the Compressor Reduce the unloaded operation time Stop the stand-by compressor Compressor Integration Schedule Control Set the target value of the header pressure and quantity of compressor according to the factory s operation status. Deal with the rapid load change when launching the factory operation

13 Header Pressure Control Header Pressure On-Off Control PID Control 0.65MPa 0.60MPa 0.55MPa Original Set point for Header Pressure Set point for Header Pressure after better control 0.57MPa Minimum Pressure to meet user demand Energy Saving Δ0.03MPa t 13

14 Energy Saving from Header Pressure Control Example Compressor Capacity:100kW*2+50kW 2=300kW Screw (Oil) type Load : 80% Operation hour:24h/d 280d/y Electric Tariff :4THB/KWh In case of 0.1Mpa Reduction Annual Cost Saving = = 520KTHB/Year Energy Saving by 0.1Mpa reduction for Header Pressure Recipro 10% Screw (Oil) 8% 14 Screw(Oilfree) 5% Turbo 1%

15 Header Pressure Control - Decrease Header Pressure by Air Load - Reduce Leakage by demand side control. And decrease more Header Pressure Air/energy saving control system INV 1 Header pressure VPC SP PC Pressure:790kpa Factory A Terminal pressure 3 Pressure:790kpa 4 Header Terminal pressure Factory B 15

16 Reduce Air Cost Header Pressure Control Stabilize the pressure with continuous control and then Decrease header pressure Decrease Header Pressure by Air Load Quantity Control of the Compressor Reduce the unloaded operation time Stop the stand-by compressor Compressor Integration Schedule Control Set the target value of the header pressure and quantity of compressor according to the factory s operation status. Deal with the rapid load change when launching the factory operation

17 Load demand Quantity Control of the Compressor To operate the minimum quantity of the compressors by predicting the compressor load from the PID control output based on header pressure as a master signal. Base unit Stop, Start ( load 0%,/100%) Set the priorities of each compressor s operation. Control the quantity regardless of the maker or capacity of compressor. Example : Compressor No.1 : 15kW with inverter No.2 : 11kW No.3 : 22kW No.4 : 22kW No.5 : 37kW In case of load-up 1. (No.1 100% <Air consumption)- Start up No.2. Compensate for deficiency with No.1 2. ((No. 2 + No.1 100%)<Air consumption)- Start up No.3, and stop No.2. Compensate for deficiency with No.1 In case of load-down 3. ((No.2 +No.1 100%)> Air consumption )- Stop No.3, No1 100% 4. ( No.1 100% >Air consumption)- Stop No.2 Our Bench Mark is around 10% 17 cost reduction No. 1 (with inverter) No. 3 ( or No. 4) No.2 No Start up compressor kW 22kW 15kW 11kW 15kW Individual performance

18 Reduce Air Cost Header Pressure Control Stabilize the pressure with continuous control and then Decrease header pressure Decrease Header Pressure by Air Load Quantity Control of the Compressor Reduce the unloaded operation time Stop the stand-by compressor Compressor Integration Schedule Control Set the target value of the header pressure and quantity of compressor according to the factory s operation status. Deal with the rapid load change when launching the factory operation

19 Schedule Control Set the target value of header pressure and numbers of compressors running according to factory s operation status. => Corresponding to the rapid load change when launching the factory operation 19

20 Reduce Air Consumption (Leakage Detector) By portable ultrasonic wave acoustic sensor with parabolic hood, It is very effective to find leakage points in your facilities. Operation panel indicates bar graph, numerical value, signal level and also you have a head phone to find leakage points. Data storage 500 point and can transfer to PC though serial communication

21 Leakage Example Case1: Automobile factory in S.E.A. Factory Area No. of Leak Points Ave. Diameter Equiv. kw/diam Hrs of Operation per Day Daily Loss (kwh) Annual Loss (kwh) Annual Loss (MYR) 1. Compressor ,592 65, Shop A , , , Shop B , , , Assembly Shop ,360 29, Assembly Shop ,488 23, Quality Inspection ,864 21,859 Total Point : 110 5,358 1,478, ,662

22 Job Reference (Energy Saving for Air Compressors) Total site 113 sites ( ) 109 sites in Japan 2 sites in Thailand 2 sites in Indonesia Typical examples of actual results Company Industry Number of Compressor Compressor Total Air Production Efficiency[kWh/m3] Improvem Total Recp Turb Scrw Scrw(I) Rated Power km3/h Before After ent A Machine ,880 42, rate 6.7% B Machine , % C Machine , % D Steel , , % E Glass , , % F Machine , % G Machine ,165 77, % H Machine , % I Food , % J Chemical , % K Chemical , % L Power , % 22

23 Improvement Ratio Number of Site Total Job Reference (Energy Saving for Air Compressors) 10 Number of Actual Results 100% 8 80% % 40% 20% Compressors Total Rated Power[kW] 0% Improvement Ratio 40.0% 35.0% 30.0% 25.0% 20.0% 15.0% 10.0% 5.0% 0.0% ,000 1,200 1,400 1,600 1,800 2,000 Compressors Total Rated power[kw] 23

24 Energy saving for boilers / turbines and Chillers 24

25 Utility Equipments Turbo Absorption Several Types 25 Cogeneration Heat Pump

26 How do you find CO2 / Cost minimum operation? Turbo Absorption CO2/Cost Minimum Operation 26 Cogeneration Heat Pump

27 Example Chilled Water Demand 27 For minimum cost operation, what I should operate this chiller plant? 1)Usage of Chillers (different capacity and different efficiency.) 2)Usage of Cooling Tower 3)Usage for Thermal Storage Tank (different electric tariff) Many kinds of operation to supply demand.. What is the cost minimum operation??

28 2. Introduction of the best practice DCS Plant Control U-OPT Guidance for well-trained operators 28

29 What is U-OPT?

30 Saving by U-OPT Company Annual Energy Cost Annual CO 2 Emissions Utility Equipment Annual Reduction of Energy Cost Annual Reduction of CO 2 Emissions (US K$) (Tons) (US K$) (Tons) A 40, ,000 Boiler, generator, chiller, heat storage B 5,000 60,000 Boiler, generator, chiller, heat storage C 10,000 30,000 Boiler, generator, chiller, heat storage D 2,000 5,000 Boiler, generator, chiller, heat storage 1,600 (4.0 %) 350 (7 %) 600 (6.0 %) 200 (9.6%) 14,000 (7.0 %) 4,800 (8.0 %) 2,400 (8.0 %) 400 (8.0 %) U-OPT

31 31 Energy Management (Monitoring)

32 Scale change Energy Management (Monitoring) To maximize the benefits from energy savings by IT, monitoring is very important. EneSCOPE is Azbil s energy management (monitoring) Comparison Button solution. Function of EneSCOPE Graph Items Daily, Monthly, Yearly Data Comparison Target value Graph Type Line graph Bar graph Pie Chart Gant Chart Scatter Plot Other function Data Down Load Scale change Easy to define calculation Date selection Daily, Monthly, Yearly Drill down Menu Data Down load to Excel

33 33 Reference

34 RENKEI Control Guide Book "RENKEI" control is a Japanese generic concept of optimisation control technology that maximizes the total energy efficiency by controlling independent equipments to work in concert with each other for harmonizing the demand and supply of energy. See More! 34

35 Introduction to the Demonstration Corner Controller Air Leak Detector Harmonas-FLEX Pressure Sensor PID Control Wide Rangeability Valve Air Flow Sensor Out door type In door type Small Flow type High Flow type

36 Thank you! Contact Us Azbil (Thailand) Co.,Ltd. TEL : 66(0) info@th.azbil.com URL :