Development of a Cost-Effective Energy Management ... · architecture (cost assessment)architecture...
Transcript of Development of a Cost-Effective Energy Management ... · architecture (cost assessment)architecture...
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Development of a Cost-Effective EnergyEffective Energy Management Information S tSystem
Presented by Alvaro Rozo on behalf of Katherine van Nes – Hatch Ltd.
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ArcelorMittal Hamilton East (AMHE)E M t I f ti S tEnergy Management Information System
Presentation Topics Hamilton EastPresentation Topics• Project Background• Approach
Hamilton East
Approach• Components of an EMIS• Components of the AMHE
Montreal
EMIS
Project Cost Effectiveness Highlights
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Focus on Energygy5%
Sustaining C it l
30%15%CapitalEnergy• Approximated
Operational
20%
Labour
Consummables
Costs (Mining)
30% Other
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ArcelorMittal Hamilton East
• Part of ArcelorMittal Long Carbon North America
• Produces variety of steelProduces variety of steel wire products
• Renown for cold heading products and oil temperedproducts and oil-tempered wire
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Project Driversj• Small facility• Several million on natural
gas and electricity costs• Natural Gas (including
steam) accounting for 85% ) gof energy consumption (GJ)
• Electricity disproportionately accounting for 50% ofaccounting for 50% of overall cost
Expected savings 5 – 8 %
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Energy Management Auditgy g• Benchmarked AMHE energy management
practices via ISO50001 gap analysisp g p y• Identified and ranked preliminary energy
savings opportunities• Preliminary energy models createdPreliminary energy models created• Energy drivers determined• Preliminary implementation plan and
architecture (cost assessment)architecture (cost assessment)• Feasibility of EMIS examined• Paid for via OPA Industrial Accelerator
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program
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EMIS Audit Optionsp
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$ Savings Note
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Project Approach
WP 01 - WP02 - WP03 - WP04 -
j pp
WP 01 Foundational Activities•Foundational activities to set basis for implementation of
Stage Gate Review•BudgetS
WP02 Energy Metering•Energy metering specification, procurement and installation
WP03 EMIS Implementation and Testing•Configuration
WP04 EMIS Commissioning and Handover•System o p e e tat o o
EMIS •Schedule•Implementation Resource Reqts (iTi) and RASCI update
installation•Site data collector•Networking to site data collector
•Configuration and testing of tags in C t li d Hi t i
•Internal Testing•User Acceptance Testing
Commissioning•User Training•System Handover
Centralized Historian
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$ Savings Note
Plan Review Implement
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Components of an EMISEMIS• Energy Account Centers• Meters and Inputs• Data Capture and
IntegrationIntegration• Data Analysis and
ReportingReporting• Management Systems,
People and Procedures
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Source: Natural Resources Canada’s “Energy Management Information Systems Planning Manual and Tool”
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Energy Account CentersMetering and InputsMetering and Inputs
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Energy Account CentersgyEnergy Account Centre (EAC): “The
organization level at which energy performance sho ld be managed”performance should be managed”
EAC Definition Principles:• Combined (i.e. all energy sources)• Process Areas as starting point• General mapping to finance cost centers• General mapping to finance cost centers• Target largest AMHE energy drivers• Maximum information / minimum cost
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$ Savings Note
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Typical Mining EACsyp gPrimary Energy Account Centre
Secondary Energy Account Centre
Primary Energy Account Centre
Secondary Energy Account Centre
1 ‐Mining DrillingBlastingExcavation
3 – Mill Processing GrindingGravity RecoveryScreening & Thickening
/TransportHandling of waste rockDewatering
2 C hi & P i C hi
Leach/Carbon‐in‐LeachCarbon StrippingCyanide DestructionT ili R l i2 – Crushing &
ConveyingPrimary CrushingPebble CrushingConveying
Tailings Reclaim4 – Surface Facilities
Camp Water & HVAC Water Treatment PlantO Pl t
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Oxygen Plant
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A Note on Meteringg
• Meters are expensive
Meter Identifier Location Description
1 Substation 'C'61‐frame East61‐frame West
fMeters are expensive • Strategic planning in
identified derived and needed meters
62‐frame
2 Substation 'C'63,64,65,66 ‐ FramesOil TemperStabilizer Drive / Strander
3 S b i ' ' 23 24 2 26 2 28needed meters 3 Substation 'D' 23,24,25,26,27,28,55‐ Frames
4 Substion 'A'Stabilizer HeatingWire Mill South (30,31,34 ‐ frame)
5 Old Boiler RoomSurface Furnace & Rx GenK C5 Old Boiler Room Kaeser CompressorMain Natural Gas Meter
6 Substation 'B'13‐Frame#1 Cleaning line
7 Substation 'B' 14 F
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$ Savings Note7 Substation 'B' 14‐Frame8 #2 Cleaning Line #2 Cleaning Line & #3 Crane
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Data Capture and Integrationp g
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AMHE Site Characteristics• 10 separate process areas
O 50 ti• Over 50 active energy consumers• Electricity, natural gas, steam• Minimal plant floor data collection• Minimal plant floor data collection • Equipment independently controlled• PI System infrastructure in AMM/Contrecouer• PI System infrastructure in AMM/Contrecouer
(No PI components in AMHE)• Existing Ekho installation in Contrecouer
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Resultant Architecture
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$ Savings Note
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PI Infrastructure• No additional onsite physical
infrastructure• Connection to sub-metering (no PLCs)• Bring back all available variables• Detailed variable analysis• Calculations
– Derived meters (today and future)Derived meters (today and future)– Totalizations in required contexts (kW to
kWh, flow to scf/lbs)Conversion (steam to natural gas)
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– Conversion (steam to natural gas)
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PI Infrastructure –Future OpportunitiesFuture Opportunities• Leverage Asset Framework and Asset Framework
T l tTemplates• Leverage Enhanced Calculation Engine and Templates
Element Attriutes
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Data Analysis and Reportingy p g
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AMHE Key Functionalityy y1. Reduced base load2 R d d i bilit2. Reduced variability
(against energy drivers))
3. Increased efficiency (via
ti loperational opportunities)
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Specific Functionality Geared to AMHE p y
Phas
e 1
Phase 2
Phase 1
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$ Savings Note
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Ekho Functionality
PERFORMANCE MANAGEMENT, KPI’S, OEE
y
DOWNTIMEPRODUCTION QUALITY• Operational
Management
MAINTENANCEHEALTH & SAFETY
ENERGY MANAGEMENT
and Intelligence Software
FOUNDATION MODULES
SAFETY MANAGEMENTSoftware
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Management Dashboard
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Energy Consumption
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Energy Conservation Measure
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Energy Intensity and Baseline Calculation
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CUSUM Analysis
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Wrap UpCost Effective EMIS DevelopmentCost Effective EMIS Development• Audit • Options analysis Funding• Options analysis• Stage gate review following
planningEAC d fi iti
FundingOntario Power Authority Industrial
Accelerator ProgramA dit fi d• EAC definition
• Meter placements• Meter selection
- Audit financed- Horizon Utilities
80% up to $75,000• Architecture• Functional Requirements
definition geared to need
- Union Gas50% up to $100,000
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definition geared to need
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Katherine van Nes, P.Eng, PMP, g,• [email protected]• Information Management Consultant / Project
Managerg• Hatch Engineering
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B ht t b
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