Copyright 2011 Yamatake Corporation All Rights Reserved.

Energy Saving of Utility Plant by IT

Azbil Corporation

Advanced Automation Company

Advance Solution Division

Mike Suzuki

Thailand Green IT Seminar 2013

2

1. Introduction to Azbil Corporation

2. Air Compressor Energy Savings

3. Boiler, Turbine and Chiller Energy Savings

4. Energy Management (Monitoring)

5. Reference

Table of Contents

3

Introduction to Azbil Corporation

azbil （Automation・Zone・Builder） represents

our philosophy of realizing safety, comfort and

fulfillment in people’s lives, and contributing to

global environmental preservation through human-

centered automation.

Group Symbol

Building

Automation Advanced

Automation Life

Automation

•Process industries

•Assembly industries

•Offices

•Hospitals

•Computer centers

•Schools

•Hotels

•District Cooling

•Life line infrastructure

•Water meters

•City gas and LP gas

•Residential air-conditioning

Measurement and Control

Solutions through IT and

control technology

5

Our Business Area

Companies incorporated abroad

Overseas branches and representative offices

（As of October 2010）

Azbil Taiwan Co., Ltd.

Azbil Philippines Corporation

PT. Azbil Berca Indonesia

Azbil Europe NV

Azbil (Thailand) Co., Ltd.

Azbil Malaysia Sdn. Bhd.

Azbil Korea Co., Ltd.

Azbil Singapore Pte. Ltd.

Yamatake Environmental Control Technology (Beijing) Co., Ltd.

Azbil Hong Kong Limited

Azbil Vietnam Co., Ltd.

Azbil Control Instruments (Dalian)Co., Ltd.

Azbil Information Technology Center (Dalian) Co., Ltd.

Middle East Branch

Azbil India Pvt. Ltd.

Azbil North America, Inc.

Shanghai Azbil Automation Co., Ltd.

Yamatake Automation Products Shanghai Co., Ltd.

Azbil Control Solutions (Shanghai) Co., Ltd

Azbil BioVigilant, Inc.

Abu Dhabi Branch

Azbil Brazil

Limited.

Global Network

Overseas Network

7

Azbil Solution

8

Utility Plant Issue

“Stable Supply & Energy Saving”

Today’s Topic

- Energy Saving By IT -

9

Air Compressors Energy Saving

Compressors

Unit quantity control system

Receiver tank

pressure measurement

control

Monitoring in each building

Cost allocation to each division

Monitoring for each piece of equipment Leak monitoring

Factory pipeline network

Point of Energy Saving

１

３

４

５

◆ Reduce air consumption

(Demand Side)

•Reduce the air leakage

•Air control by demand

•Schedule control

◆ Reduce the air cost (Supply Side)

•Reduce unloaded operation time

•Stop the stand-by compressor

•Reduce the header pressure

•Reduce the warming-up time

Air Compressor

Energy Saving Solution

Header pressure

pressure

Line Flow meter

１

３

４

５

◆ Reduce Air Consumption

(Demand Side)

•Find Air leakage

•Supply suitable pressured air to each line

◆ Reduce Air Cost (Supply Side)

•Suppression of header pressure fluctuation

•Reduce header pressure

•Selection for compressors

•Scheduled (production) Control

Air leakage detector

Air Compressor

Flow meter Control Valve

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

Header Pressure Control

13

On-Off

Control

PID

Control

Energy Saving

t

Header

Pressure

Minimum Pressure to

meet user demand

0.65MPa

Δ0.03MPa

0.60MPa

0.55MPa 0.57MPa

Original Set point for

Header Pressure Set point for Header

Pressure after better

control

Energy Saving from Header Pressure

Control

14

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 ＝300×0.8×0.08×24×280×4

＝ 520KTHB/Year Energy Saving by 0.1Mpa reduction for

Header Pressure

•Recipro 10%

•Screw (Oil） 8%

•Screw（Oilfree） 5%

•Turbo 1%

15

Header Pressure Control

- Decrease Header Pressure by Air Load -

Air/energy saving control system

Header pressure

Terminal pressure

Factory B Header

１

３

４

INV

Terminal pressure

Factory A

Pressure：790kpa

Pressure：790kpa

PC

VPC

SP

Reduce Leakage by demand side control.

And decrease more Header Pressure

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

Quantity Control of the Compressor

Example ： Compressor No.1 : 15kW with inverter No.2 : 11kW No.3 : 22kW No.4 : 22kW No.5 : 37kW

Load d

em

and

Start up compressor Individual performance 1 2 3 4

No. 3 ( or No. 4) No.2 No. 2

No. 1 （with inverter）

22kW

15kW 11kW

15kW

15kW

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

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.

Our Bench Mark

is around 10%

cost reduction

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

Schedule Control

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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

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

Leakage Example

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 33 2 1.5 16 792 218,592 65,578

2. Shop A 15 5 9.85 16 2,364 652,464 195,739

3. Shop B 24 3 3.36 16 1,290 356,106 106,832

4. Assembly Shop 15 2 1.5 16 360 99,360 29,808

5. Assembly Shop 12 2 1.5 16 288 79,488 23,846

6. Quality Inspection 11 2 1.5 16 264 72,864 21,859

Total Point : 110 5,358 1,478,874 443,662

Case1: Automobile factory in S.E.A.

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Job Reference

(Energy Saving for Air Compressors)

Total site 113 sites ( - 2012)

109 sites in Japan

2 sites in Thailand

2 sites in Indonesia

Typical examples of actual results

Compressor Total

Total Recp Turb Scrw Scrw(I) Rated Power Before After

A Machine 7 0 1 5 1 1,880 42,638 0.110 0.103 6.7%B Machine 10 0 0 6 4 460 6,809 0.111 0.098 11.7%C Machine 7 0 0 6 1 349 4,923 0.116 0.098 15.3%D Steel 10 6 4 0 0 4,790 270,395 0.091 0.087 4.7%E Glass 7 4 2 1 0 2,250 142,924 0.093 0.086 7.7%F Machine 5 0 0 5 0 309 8,584 0.130 0.111 15.0%G Machine 7 0 2 5 0 2,165 77,802 0.134 0.127 5.7%H Machine 5 4 1 0 0 970 27,940 0.139 0.119 14.3%I Food 4 0 0 3 1 660 38,035 0.116 0.113 1.9%J Chemical 5 0 0 5 0 870 55,440 0.125 0.115 8.1%K Chemical 4 0 0 4 0 870 25,992 0.141 0.127 10.0%L Power 4 0 0 4 0 560 10,836 0.140 0.135 3.2%

Improvementrate

Number of CompressorCompany Industry

Air Productionkm3/h

Efficiency[kWh/m3]

23

Job Reference

(Energy Saving for Air Compressors)

0%

20%

40%

60%

80%

100%

0

2

4

6

8

10

250 1000 1750 2500 3250 4000 4750

Tota

l

Num

ber

of

Site

Compressors Total Rated Power[kW]

Number of Actual Results

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

35.0%

40.0%

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800 2,000

Impr

ove

men

t R

atio

Compressors Total Rated power[kW]

Improvement Ratio

24

Energy saving for boilers / turbines and

Chillers

Several

Types

Turbo Absorption

Cogeneration Heat Pump 25

Utility Equipments

CO2/Cost

Minimum

Operation

Turbo Absorption

Cogeneration Heat Pump 26

How do you find CO2 / Cost

minimum operation ?

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Example

Chilled Water

Demand

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 ??

2. Introduction of the best practice DCS Plant Control

Guidance for

well-trained operators

U-OPT U-OPT

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What is U-OPT ?

Saving by U-OPT

Company Annual Energy

Cost

Annual CO2

Emissions

Utility

Equipment

Annual

Reduction of

Energy Cost

Annual

Reduction of

CO2

Emissions

(US K$) (Tons) (US K$) (Tons)

“A” 40,000 200,000 Boiler, generator, chiller, heat

storage

1,600

(4.0 %)

14,000

(7.0 %)

“B” 5,000 60,000 Boiler, generator, chiller, heat

storage

350

(7 %)

4,800

(8.0 %)

“C” 10,000 30,000 Boiler, generator, chiller, heat

storage

600

(6.0 %)

2,400

(8.0 %)

“D” 2,000 5,000 Boiler, generator, chiller, heat

storage

200

(9.6%)

400

(8.0 %)

U-OPT U-OPT

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Energy Management (Monitoring)

Energy Management (Monitoring)

To maximize the benefits from energy savings by IT,

monitoring is very important.

EneSCOPE is Azbil’s energy management (monitoring)

solution.

Drill down Menu

Data Down load to Excel

Scale change

Comparison Button

Date selection Daily, Monthly, Yearly

■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

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Reference

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RENKEI Control Guide Book

See More!

http://www.jeita.or.jp/english/public_standard/index.htm

"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.

Pressure Sensor Air Flow Sensor

Out door type In door type High Flow type Small Flow type

PID Control

Controller

Air Leak Detector

Wide Rangeability Valve

Introduction to the

Demonstration Corner

Harmonas-FLEX

Thank you!

Azbil (Thailand) Co.,Ltd.

TEL : 66(0)2664-1900-10

E-Mail : info@th.azbil.com

URL : http://th.azbil.com/

Contact Us