Energy Management Program. Durez Canada Company Ltd By Anyssa Mohammed & Mandy Wychreschuk

Transcription

1 Energy Management Prgram Durez Canada Cmpany Ltd By Anyssa Mhammed & Mandy Wychreschuk

2 Agenda 1. Intrductin 2. Energy Management Relatinship t Safety 3. Site Utility Csts 4. Energy Prgram Initiative 5. Energy Initiatives 6. Incentives 7. EMIS (Energy Management Infrmatin System) 2

3 Our Cmpany Durez Canada is lcated in Frt Erie. The cmpany belngs t a glbal rganizatin, Sumitm Bakelite Cmpany Ltd. Specialize in the prductin f thermsetting phenlic resins and mlding cmpunds. Prducts are used in a wide variety f applicatins in the il and gas and autmtive industries. Phenlic Resin Mlding Cmpund 3

4 Energy Management Relatinship t Safety Energy management impacts Health & Safety by minimizing hazards, such as: Cmpressed air & steam leaks Expsed piping at elevated temperatures Operatin f mving parts Nise Levels Energy management impacts the Envirnment by: Reducing air & water emissins Creating sustainable peratins by reducing excessive utility cnsumptin Managing energy will becme even mre imprtant due t climate change 4

5 Site Utility Csts 5

6 2015 Utility Bill Breakdwn f the cst fr the utilities: N. Utility % f the 2015 Utility Bill 1 Water 5% 2 Electricity 72% 3 Natural Gas 23% TOTAL ~$ 1.60M Glbal Adjustment accunted fr ~60% f the Energy Bill fr 2015: Ability t ptimize ~40% f the Plant Energy Bill. 6

7 Histrical Electricity Csts Time 2016 Cst ($cents/kwh) % Increase frm 2010 t 2016 Off-Peak % Mid-Peak % On-Peak 18 45% With significant increases in electrical prices/upward trend and the usage being the main part f the plant energy bill, this was the main mtivatin fr develping the Energy Management Infrmatin System (EMIS) 7

8 Energy Prgram Initiative 8

9 Setting up f Energy Prgram Created Multi-discipline Energy Team Energy training and nging awareness fr the team Frm the training, the team established: An understanding that energy csts are cntrllable Energy Plicy Site Perfrmance Screcard Energy Baseline Energy Assessment Site Audits Established a list f annual actins t be taken by different team members t cntrl and reduce energy csts. 9

10 Energy Team Cnsists f a crss-functinal grup frm areas f: Management Maintenance Engineering Accunting Operatins 360 Energy, Energy Cnsultant The cach, creating nging fcus and supprt t team T keep ur prgram sustainable, we depend n 3 main items: Internal energy reprting Management f prcesses and techniques Prperly applying technlgy/equipment t create savings 10

11 Energy Initiatives 11

12 Insulatin Survey What is an insulatin survey? An insulatin survey identifies areas f heat lss within a prcess using an infrared camera. The reasns fr heat lss are als assigned varius categries which include: Mechanical Damage Crrsin Under Insulatin Energy Cnservatin The amunt f heat lss due t the expsed piping cmpared t insulated piping is then determined which translates t a dllar amunt. 12

13 Insulatin Survey Insulated Reactr Insulated Reactr-Infrared Camera The insulatin audit identified numerus areas in arund the plant related t the steam and cndensate systems in additin t valves and flanges that required insulatin. Cst savings were determined using fuel savings by insulating: 2014 Dllar Savings = $37,429 /Year 2016 Dllar Savings = $8,568 /Year 13

14 Steam Trap Survey What is a Steam Trap? A steam Trap is an autmatic valve that allws cndensate, air and nncndensable gases t be discharged while trapping steam in the system. The remval f cndensate prevents the system frm becming built up with water. What is a Steam Trap Survey? Identificatin f all steam traps at site Inspectin f each steam trap t ensure that it is suitable fr its applicatin Ultrasnic leak testing f all steam traps was dne t determine whether it is failing pen r clsed. 14

15 2015 Steam Trap Results An amunt f ~$66,000 in savings was estimated based n the steam lsses due t faulty traps (Mstly failed pen, failed clsed r discnnected). Savings were determined using the cst f fuel/water and chemicals used in steam generatin. 15

16 Air Leak Audit Leaks were identified by an utside cntractr using an ultrasnic leak detectr. Savings were determined by the cst t run the air cmpressr t prduce the amunt f air lst thrugh varius leaks. Ttal savings as a result f repairing leaks: 2014 amunted t ~$40,767/year 2015 amunted t ~ $24,597/year 16

17 Summary f Energy Initiatives YEAR Prject Savings ($) Annual $ Ttal Insulatin Audit $37,429/year 2014 Steam Trap Survey $66,141/year $144,337 Air Leak Audit $40,767/year 2015 Air Leak Audit $24,597/year $24, Insulatin Audit $8,568/year $8,568 Ultrasnic detectr purchased in-huse t perfrm annual Air Leak & Steam Trap audits 17

18 Our cst avidance t date Site energy cnsumptin Cst f electricity Cst avidance Frm 2012 t 2015, ur usage decreased frm ~300kWh t 150kWh per lb. prduced which shws that we have reduced ur cnsumptin. If ur energy cnsumptin in 2015, had been what it was in 2012, ur cst per lb. wuld have increased by 40% (given the increase in electrical prices) Because f ur imprvements, ur csts actually fell by 10% paying nearly 60% less than we wuld have therwise.

19 Energy Incentives 19

20 Incentives Surce Reasn Amunt ($) Enbridge Gas Steam Strap, Insulatin Survey $18, Canadian Niagara Pwer Enbridge Gas Retrfit Incentives/Audit Reimbursement Meter Prject Insulatin $9, (~$40,000+) Expected (~$8,000) Expected TOTAL Received t date $28, Future Amunt Expected $48,000 Our energy prgram is nt driven by utility energy incentives. 20

21 Energy Management Infrmatin System (EMIS) 21

22 EMIS System develped t cach desired behavirs/habits relating t energy cnsumptin in the plant during prductin > Immediate respnse Meters installed n all individual utility lines t prvide data fr analysis n a cntinuus basis (vs Mnthly) Implemented prject in ne prcess building as pilt area. EMIS cntains 3 majr cmpnents: 1. Energy Cnservatin Scenaris 2. Operatr Reprts 3. Management Reprts 22

23 EMIS Prductin prcesses are highly autmated and are perated by Prgrammable Lgic Cntrllers (PLC) with Human Machine Interfaces (HMIs). 23

24 1. Energy Cnservatin Scenaris are based n Requirements f Prductin sequences Adjustable at the HMI with Access Level 24

25 1. Energy Cnservatin Scenaris cntain 4 Actin Levels set by Management: Level 1: Event Tracking nly, n Operatr interactin Level 2: Operatr Ntificatin Pp-up Level 3: Event Tracking with Ntificatin f Ptential Actin Level 4: Event Tracking with Ntificatin f Immediate Actin 25

26 2. Operatr Reprts n HMI Ttal Electrical Cnsumptin per Wrk Area Based n live current cnsumptin & Current Survey Data Target Cnsumptin displayed visually 26

27 3. Management Reprts 6 Reprt Dashbards 27

28 Ad-hc Utility Mnthly Trends 28

29 Thank yu! Questins/Cmments? 29

30 Energy Cnsultants Address: 1480 Sandhill Drive, Unit 8B Ancaster, Ontari, L9G 4V5 Phne: Tll Free: