Insulation solutions for guaranteed success Insulation Performance Contracting

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1 Bilfinger Efficiency GmbH Insulation solutions for guaranteed success Insulation Performance Contracting Felix Becker ACHEMA 2015, Frankfurt am Main June 15-19, 2015

2 Energy efficiency through optimal insulation FROM INSULATION TO HIGHER ENERGY EFFICIENCY Insulation "Insulation" stands for several simple and effective but also cost-saving measures to both reduce heat and energy losses and to increase energy efficiency. Energy efficiency Energy efficiency forms the second pillar on the path toward lower energy consumption, a reduction in CO 2 and resource conservation. At the same time, energy efficiency contributes substantially to energy security and competitiveness Bilfinger Efficiency GmbH Page 2

3 Energy efficiency potentials COOLING COMPRESSION CONVEYANCE HEATING LIGHTING PUMPING VENTILATION savings potential up to 50% savings potential up to 30% savings potential up to 50% savings potential up to 70% savings potential up to 50% savings potential up to 70% savings potential up to 30% On average, a savings potential of up to 35% by tapping into increased energy efficiency! Bilfinger Efficiency GmbH Page 3

4 Optimal and efficient insulation measures by means of TIPCHECK TIPCHECK stands for Technical Insulation Performance Check is an independent and Europe-wide standardized energy efficiency analysis system for industrial insulation The following areas are inspected and analyzed: savings potentials opportunities to improve processes and increase efficiency energy cost minimization contribution to environmental protection with reduced CO 2 emissions fire hazard detection in walkways and thus an increase in safety Bilfinger Efficiency GmbH Page 4

5 Energy savings potential in industrial facilities Solutions for industrial insulation are of high economic and ecological importance reduce heat and energy losses reduce greenhouse gas emissions increase energy efficiency recoup their investment costs within a few months are simple, effective and cost-saving Sustainable concepts for the insulation of industrial facilities are feasible and effective immediate measures Bilfinger Efficiency GmbH Page 5

6 Potential in industrial facilities Energy-intensive processes at very high temperatures: an investment in technical insulation amortizes for the most part after only one year or less Energy-intensive industrial operations: any type of facility or process can be financially optimized through efficient insulation systems Improvement in production processes: an increase in efficiency = lower energy consumption = reduced costs = less CO 2 High production costs: sustainable insulation for industrial facilities ensures efficient production and heating distribution Bilfinger Efficiency GmbH Page 6

7 Our solution: Insulation Service Contracting STATUS QUO Existing facility with weak points in its insulation boiler walls piping systems (of which many steam pipelines) steam turbines connections to district heating systems containers etc. INSULATION CONTRACTING analysis of insulation & assessment of savings potential via TIPCHECK development of an insulation concept investment- (capex-) neutral implementation of the insulation service immediate realization of savings through a reduction in operating costs (reduction in heating expenditures) TIPCHECK test measurement with the client Bilfinger Efficiency GmbH Page 7

8 Insulation Performance Contracting Choose energy efficiency & save over the long term savings refinance investment needs further savings improve production costs Client decision to optimize the status quo Achieving sustainability and economic success together: optimized and energy-efficient production facilities sustainable and permanent solution presents the insulations s improved quality demonstrates savings engineering optimal insulation realization of insulation performance via contracting potential analysis considers economic efficiency economic optimization and reduction in energy consumption and costs promotes production that is as environmentally friendly as possible Bilfinger Efficiency GmbH Page 8

9 Insulation Performance Contracting Choose energy efficiency & save over the long term savings refinance investment needs further savings improve production costs Client decision to optimize the status quo Achieving sustainability and economic success together: optimized and energy-efficient production facilities sustainable and permanent solution presents the insulations s improved quality demonstrates savings engineering optimal insulation realization of insulation performance via contracting potential analysis considers economic efficiency economic optimization and reduction in energy consumption and costs promotes production that is as environmentally friendly as possible Bilfinger Efficiency GmbH Page 9

10 Examples for heating and energy losses container with hot spot in the lower edge cause: air gap (wool came out of place) operator's loss: /a 16,000 non-insulated pipelines around walkways burn hazard (keyword: occupational safety) operator's loss: /a 2,000 Bilfinger Efficiency GmbH Page 10

11 Examples for heating and energy losses Page 11 non-insulated flange DN 350, T = 200 C at a loss of 0.12/kWh: ( /a 12,000) an energy loss of 100,000 kwh cooling objects can also be investigated photo of bearings with poor insulation due to a pipe length of 2.5 km, example: for 1,600 MWh, a loss of approx. /a 97,500 Bilfinger Efficiency GmbH Page 11

12 Insulation efficiency contracting Operational benefits costs reduced energy costs and increased efficiency payment to contractor renovation without own investment, thus reducing the investment backlog without committing own capital energy (heat) expenses for contracting savings energy (heat) savings energy (heat) cost transparency for individual areas of use increased safety through protection against accidental contact improvement in sustainability Benefits from the implementation current state contract term after the contract term time Bilfinger carries all costs and risks linked to the implementation of these measures remuneration exclusively through savings demonstrated by TIPCHECK Bilfinger Efficiency GmbH Page 12

13 TIPCHECK = a high customer approval "This innovative approach is very useful to us as plant operators. We were able to detect significant energy and cost savings with relatively little effort and within a short period of time." Roland Mayer Civil Engineering & Facility Management OMV Burghausen Savings potentials in figures: 15 TIPCHECKS = - 28 gigawatt-hours = 1,400,000 = 8,500 t CO 2 Further customer references: Bilfinger Efficiency GmbH Page 13

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15 Back-up

16 Practical implementation

17 Insulation Performance Contracting Five steps to success Schematic procedure Phase 1: Phase 2: Phase 3: Phase 4: Phase 5: first meeting with the customer If the indication for potential savings is > 25 thousand ROI < 3a The use of TIPCHECK is recommen-ed to the customer execution of TIPCHECK results of TIPCHECK savings potential ROI < 3a results of TIPCHECK savings potential ROI > 3a agreement on letter of intent for the implementation drafting of detailed business cases including engineering / planning of the most cost-efficient insulation thickness Based on the business cases, the implementation is commissioned with regulations regarding the term, costs, regulations regarding shutdown, conversions, etc. Implementation of the insulation measures TIPCHECK test measurement If the calculated savings are below >5%, the contracting rate will be reduced respectively Bilfinger assumes the costs for TIPCHECK Bilfinger Efficiency GmbH Page 17

18 TIPCHECK Implementation TIPCHECK implementation 1. Meeting with the facility s operator decision regarding the objects that should be investigated information on any relevant data (operating temperature, operating hours, heating costs) Objective: calculation of a cost-efficient insulation thickness 2. TIPCHECK on-site certified TIPCHECK experts from Bilfinger Industrial Services inspect the facility using an infrared camera to determine and document any heat loss 3. TIPCHECK report analysis and detailed report of each thermal image 4. TIPCHECK presentation delivery and presentation of the results and the full TIPCHECK report Bilfinger Efficiency GmbH Page 18

19 Objective Cost-efficient insulation thickness Cost-efficient insulation thickness The thickness of the insulation layer is calculated based on a facility s service life and a minimum for the sum of any costs regarding heat loss, which still accrue despite the insulation, and the one-time investment costs for the insulation. Bilfinger Efficiency GmbH Page 19

20 Presentation and evaluation of hot spots A report is written for each component photographed with an infrared camera. It reveals the following data: - current and potential heat flux density - current and potential heat loss - savings potential in kw through optimized insulation The objective is to determine the respective optimal, i.e. most energy-efficient and economically feasible insulation solution for the facility's operation; in doing so safety factors must not be ignored Bilfinger Efficiency GmbH Page 20

21 Contracting Implementing energy efficiency without the need for own investments FACILITY CONTRACTING Building and facilities analysis Energy concepts and systems design System implementation/optimization Financing Building and/or facility operation Maintenance and repair service Remuneration via fixed basis price Efficiency enhancement Analysis, concept, construction, operation ENERGY SUPPLY CONTRACTING Building and facilities analysis Energy concepts and systems design System implementation/optimization Financing Building and/or facility operation Maintenance and repair service Energy purchasing Remuneration via fixed basic price and variable work price Energy delivery Efficiency enhancement Analysis, concept, construction, operation EFFICIENCY CONTRACTING Building and facilities analysis Energy concepts and systems design System implementation/optimization Financing Building and/or facility operation Maintenance and repair service Energy purchasing Remuneration via fixed basic price and variable work price Energy efficiency guarantee Efficiency guarantee Energy delivery Efficiency enhancement Analysis, concept, construction, operation Bilfinger Efficiency GmbH Page 21

22 Brief introduction to Bilfinger Efficiency As an energy supplier, Bilfinger Efficiency is the interface between group-wide competences and services in the area of energy efficiency The efficiency experts analyse comprehensive savings potentials for commercial and industrial facilities as well as real estate optimize energy needs in order to strengthen your competitive position develop contracting solutions that guarantee savings and reduce energy costs over the long term look after structuring and financing and allow you as our customer to focus on your core business. Bilfinger Efficiency GmbH Page 22

23 Industrial Your industry Our experience Divisions Industrial Maintenance Insulation, Scaffolding and Painting Oil and Gas Industrial Fabrication and Installation Engineering, Automation and Control Support Services Services Design, construction, maintenance and modernization of industrial facilities over their entire lifecycle Bilfinger Efficiency GmbH Areas of Activity Piping systems Machine and fittings service Plant assembly Machinery and apparatus engineering Electrical instrumentation and control technology Laboratory and analysis technology Insulation Scaffolding Corrosion protection Clients Processing and manufacturing industry in the core markets of oil and gas Refineries and petrochemicals Chemicals and agrochemicals Pharmaceutical Food and beverages Energy production Steel and aluminum References Norsk Hydro Norway Siegfried Switzerland E.ON Gas Storage UK Page 23

24 Industrial Facts and figures Key Figures Output volume by region 2014 in million 2014 Output volume 3,705 Employees 33,016 19% America <1% Africa 2% Asia 22% Germany 56% rest of Europe Bilfinger Efficiency GmbH Page 24

25 Industrial Your task Our solution Norsk Hydro aluminum plant Norway Outsourcing solution for maintenance and refractory lining Scope of the order relates to the five locations: Ardal, Holmestrandt, Hayanger, Karmoy (pictured), Sunndal Client Volume Norsk Hydro 53 million p.a. Period Since 1998 Bilfinger Efficiency GmbH Page 25

26 Industrial Your task Our solution Siegfried Switzerland Outsourcing solution for the maintenance of production facilities and site engineering on the basis of pharmaceutical guidelines Continuation of the chemical defense school as part of the outsourcing project Client Siegfried Volume 50 million Period Bilfinger Efficiency GmbH Page 26

27 Industrial Your task Our solution E.ON Gas Storage UK Supply of two gas desiccating plants "Product package" with procedural focus and dimensioning of the system Planning, manufacturing, monitoring of assembly and commissioning Client E.ON Gas Storage Volume 10 million Period Bilfinger Efficiency GmbH Page 27