Steam Trap Savings Discovery B Sperling Sealed Air Final · 2019. 9. 18. · Diversey Care honored...

2015 Sealed Air Corporation. All rights reserved.

Steam Trap Savings Discovery: A Novice Auditor's Journey

Barry Sperling


Why A Novice Auditor’s Journey ?

1. We were looking for a way to add value to our offering in cleaning and sanitation

2. Customer kept asking about energy savings

3. This is the presentation I wish I could of attended in 2013!

VISIONTo create a better way for life

MISSIONWe Re-imagine™ the industries we serve to create a world that feels, tastes and works better.


WHO WE ARESealed Air creates a world that works better by re-imagining the industries we serve. By uniting ingenious ideas and diverse expertise, we discover new possibilities and create new approaches that enhance business and the world we live in. Where we thrive is transforming sustainable, end-to-end solutions into business-changing results.


A Global Network Backed by Local Expertise


• Engineered Solutions & Packaging Systems• Packaging Design & Testing• Lean Six Sigma Expertise• Service & Support

• Packaging/Hygiene Solutions

• Engineering Plant Designs

• Full Range of Equipment/Systems

• Manage Water, Energy

• Building & Kitchen Care Services

• Infection Prevention

• Fabric Care

• Consulting Services & Consumer Brands

How We Deliver Value

2014 Sales: $1.7B

26% of 2014 Adj. EBITDA

2014 Sales: $2.2B


2014 Sales: $3.8B


Who We ServeDIVERSEY CARE PRODUCT CAREFOOD CARE

31%

Fresh Red MeatDairy SolidsOther FoodSmoked & ProcessedPoultryBeverages

11%18%

15%

11% 13%

Source: Sealed Air Estimates

End Market Mix Food Care


Our Aspirations

A Better Way for Life

Helping people around the world live better lives

Food Security Healthy Environments

ResourceConservation

Enhancing Lives

Reducing the impact of our global operations

Greenhouse Gas

Emissions

Water Consumption

Waste to Landfills

Energy Consumption

Delivering solutions that meet customers’ sustainability needs

Ethical Supply Chain

Sustainable Innovations

Quantified Benefits

Responsible Materials

Recent Awards and Recognition

Recognized as a top 10 global innovator and socially responsible leader for 3 consecutive years

Diversey Care honored for fulfilling a 10 year commitment to reduce CO2 emissions:

48% reduction from 2003 levels by the end of 2013

Named to the 2014 Climate Disclosure Leadership Index for being in the top 10% of S&P 500

companies for data completeness and quality


We address real challenges that our food and beverage customers face everyday:

We deliver purposeful innovation that generates measureable business results

throughout the value chain.

And sustainability is core to everything we do.

Food Care Focus


Diversey Hygiene Solutions and Services can

• Reduce spread of disease in livestock• Reduce microbial activity on foods being

processed• Minimize water usage in food and beverage

processing• Minimize energy consumption• Reduce cleaning downtime and quantity of

plant hygiene chemicals while retaining full efficacy

• Improve quality of effluent leaving processing facilities

All of which can decrease food waste or enhance availability and quality of drinking water


Diversey Hygiene Platform Sustainability

Hygiene Platform Extended Shelf Life

EfficientMaterial Use

Efficient Energy Use

EfficientWater Use

ReducedFood Waste

Open Plant Cleaning

Clean In Place

Sanitizers

Track Treatment

Bottle Care

Membrane Cleaning

Process Improvement Audits


We combine Hygiene and Packaging Solutions throughout the Value Chain to Maximize Sustainability and Reduce Food Waste

ConsumersRetail/Food ServiceFood Production Packaging/Distribution

PREVENT CONTAMINATION

PROTECT & ENHANCE

MAXIMIZE EFFICIENCY & VALUE

• Processing in healthier environments

• Health benefits for workers and consumers

• Preventing contamination & yield loss

• Ensuring food is distributed efficiently and without damage

• Providing choice and improving the shopping experience

• Reducing product shrinkage through extended shelf life

• Higher quality meals through superior packaging technology

• Reduced prep time• Portioning and

dispensing solutions

• Reducing waste from spoilage and leftovers

• Making it easier to prepare healthy meals


Sustainable Materials

Water Use

Energy

Design /Operation

Logistics

Waste to

Landfill

Effluent

GHG Emissions

Land/Animal Stewardship

Health & Wellbeing

Inclusion

Social Responsibiity

Stakeholder Satisfaction

Certification

Sustainability Goals Approach Examples

Supply ChainCompliance

Diversey® Enduro Power™Hybrid technology foam that increases contact time, reduces water usage and labor while increasing productivity; Eliminates need for bleach cleaning event

Diversey® EnergyCheck™Customized analysis of specific energy users;Identification of opportunities to reduce cost, improve process performance, generate savings; Implementation plan with timelines

Cryovac® VPPVertical pouch packaging has virtually no headspace which offers longer shelf life; Also available with Freshness Plus® film that offer odor scavenging which minimize off odors and help to reduce food waste; Reduced pack weight vs. cans offers improved logistics and reduced carbon footprint

TempTrip® Temperature MonitoringMonitors cold chain integrity


Cryovac® OptiDure™Thinner film formulated for high abuse resistance enables safe delivery of foods for export:;Helps to reduce food waste from damaged packaging

Cryovac® Darfresh®Family of vacuum skin films that extend shelf life which helps to reduce food waste;Low package volume and reduced pack weight offers improved logistics and reduced carbon footprint; Hermetic leak-proof seal reduces cross-contamination

Cryovac® Grip and Tear® Barrier Vacuum shrink packaging is leak-proof so reduces cross-contamination;Patented knifeless, easy-opening featurereduces risk of injury both in plant for further processing or in consumer homes

Deosan® Teat DipReduces losses from poor udder health by using proven biocides for optimum bacteria kill; Reduces contamination from cow to cow

Diversey® AquaCheck™Customized footprint of water use in plant;Identification of opportunities to reduce cost, improve process performance, and generate water and effluent savings

Diversey® AquaCheck™Customized footprint of water use in plant;Identification of opportunities to reduce cost, improve process performance, and generate water and effluent savings

Diversey® EnergyCheck™Customized analysis of specific energy users;Identification of opportunities to reduce cost, improve process performance, generate savings; Implementation plan with timelines

Copyright © 2015 Sealed Air

aquaCheckA Systematic Approach:• aquaCheck is a consulting service that utilizes a systematic

approach to measure and analyze water and energy consumption in facilities and implement practical recommendations to maximize performance, decrease environmental impact and save money for a cleaner, healthier future.

The aquaCheck Objective:• To provide a baseline of water use efficiency that defines a

water flow map, and provides opportunities and specific recommendations for continuous improvement.


A Systematic ApproachWhat has happened

so far?

aquaSCANTrend and analyze historic water and energy. Benchmark within company and

industry.

Holistic overview and environmental

footprint

Where are we now?How far can we go?

aquaPROBEAudit processes to determine the mass balance and cost impact for each resource user.

Detailed Water balance and target setting

How do we get there?

aquaSOLVEImplement

recommendations to maximize

performance.

Water Efficiency implementation


The aquaCheck ProcessTwo stage audit system

❶ aquaScan

High level overview− Develop historical water use, effluent loading and cost trend

analysis

− Define potential opportunity from industry modeling

− Provide the elements for environmental performance reporting

− Define season trend and variability in water to occupancy volumes


aquaScan Benchmarking

Annu

al W

ater

Con

sum

ptio

n

Annual Facility Activity


The aquaCheck Process❷ aquaProbe

Detailed mass balance of all users of water

− Develop detailed water balance and cost analysis by station

− Define primary effluent contamination (surcharge) sources

− Present baseline data for future decisions


*sum of incoming and effluent cost not including surcharges

Incoming Water $2.24

Waste Water *$6.73

Hot 140ᵒFWater $6.82

Waste Water $11.31

Waste Water $6.93

Filtered Water $2.44

Softened Water $2.74

Steam Production

$73.88

Waste Water $7.23

Boiler Feed Water $3.85

Condensate to Drain $12.72

Water Value Stream

Sewer Charge $4.49

Costs are $ per 1,000 gallons (K-Gal)

Identifying the Value StreamsWater picks up cost as it travels through a facility. Value (cost)

streams, identified in aquaCheck, are an important measure for impact analysis


Beverage CustomerGoal: Customer looked to the aquaCheck team:

• To identify and map all water users at the selected site;

• To identify both water savings projects at the site and projects that could be replicated at other sites;

• To partner as needed to implement the savings projects

Result:Over 8 million gallons in savings wererecommended. Leaks, boiler wateroptimization, water reuse projects,and CIP optimization wererecommended to achieve their goal.

The customer used the results fromthis audit to multiply the savingsacross several sites, implementingprojects, and improving their wateruse ratio.

Action: The aquaCheck team measured continuous flows and events of water usage to identify 90% of the water users.


Water Mass Balance Annual Use

Water in Product 82,139 $ 83,754 Syrup Room 7,168 $ 64,223 Packaging Hall 9,775 $ 87,584 Utilities & Water Treatment 80,918 $725,025

All Water180,000 kgal

Volumekgal

Value$

SCAN 210,000 kgal/yearPROBE 180,000 kgal/ yearPercent 86%


Water Mass Balance Volume

Tank 4 Treated Water Rinse 25 $ 222 Tank 2 3 Step Cold 21 $ 186 Rapid Mixer 1 3 Step Hot Detergent Wash 19 $ 169 Rapid Mixer 1 3 Step Warm Det. Wash 19 $ 169 Tank 8 Treated Water Rinse 19 $ 166 Tank 14 Treated Water Rinse 15 $ 139 Tank 2 3 Step Warm Det. Wash 13 $ 115 Tank 19 Treated Water Rinse 12 $ 111 Tank 14 Treated Water Rinse 12 $ 111 Tank 15 5 Step Hot Det. Wash & Sanitize 12 $ 109 Tank 10 3 Step Cold 10 $ 93 Tank 11 3 Step Cold 10 $ 93 Tank 13 3 Step Cold 10 $ 93 Tank 14 3 Step Cold PAA 10 $ 93 Tank 8 3 Step Cold 10 $ 93 Tank 17 3 Step Cold PAA 10 $ 93 Tank 1 Treated Water Rinse 10 $ 87 Tank 11 Treated Water Rinse 9 $ 83 Rapid Mixer 3 3 Step Hot Detergent Wash 8 $ 75

Volumekgal

Value$SCAN 210,000 kgal/year

PROBE 180,000 kgal/ yearPercent 86%

aquaCheck for Thermal Energy1. Develop a value stream for steam cost2. Mass balance steam flow by tracking condensate3. Sort highest users of steam by volume of condensate4. Find efficiency projects


Steam Mass Balance1. Measure the condensate2. Allow for flash Steam percentage evaporation3. Build mass balance table and compare to total steam

use


Significant Steam Users (High Intensity)1. Brew House (Estimated to be >50% of all Use)2. Bottle Pasteurizer 3. Can Pasteurizer4. CIP Systems


Tools1. Flexim 601 Ultrasonic Flow

Meter2. Fluxdata Software3. Excel4. Steam Cost agreed on with the

site



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Fermentation CIPCondensate Flow

Condensate Flow hl/hrTotal Volume hl

1.41 hl =135 kg Steam



Start0120

Stop0220


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Why is steam flowing here?

Customer SCADA(Supervisory Control and Data Acquisition)


Steam Leak1. Leak was only active after the line

beyond the pressure control valve was pressurized. (Intermittent)

2. The flow (savings) could be estimated from meter logged data.

Mass Balance Progress1. Brew House – Very complex project

A. Jacketed TanksB. 6-8 F&T trapped Heat Exchangers

2. Bottle Pasteurizer- Successful3. Can Pasteurizer- No Success4. CIP Systems- Mixed


Steam

In

Out


Bottle Pasteurizer 1. Good Data2. Quantifiable3. Shows savings opportunity4. 8 Heat Exchangers feeding into

on 6” line

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Flow hl/hrTotal Volume, hl

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Bottle PasteurizerCondensate Flow

Flow hl/hrTotal Volume, hl


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Brew HouseAbove and Below Failed Trap

Condensate Flow above the Steam Trap, hl/hr

Condensate Flow BH CIP Only hl/hr

Total Brew house CIP Volume, hl

Drip Line Trap


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Brew House CIPAll Events

Condensate Flow

Condensate Flow, hl/hrTotal Volume, hl

8.1 hl776 kg Steam

Mash tun 2

Meura

Mash in Tank

Prerun Tank

Wort heater

Wort Kettle

Whirpool

Trub Tank

Wort WayLong

6.8 hl651 kg Steam

1.2 hl115 kg Steam

1.7 hl163 kg Steam

1.1 hl105 kg Steam

3.3 hl316 kg Steam

0.7 hl67 kg Steam

0.4 hl38 kg Steam

1.8 hl172 kg Steam

Can Pasteurizer 1. Overwhelming flash steam2. No useful quantification3. 2 traps suspected failed


Mass Balance


Mass Balance Progress1. Program relies on savings that come from measuring

use volume2. Some applications could not be measured3. Leaks and steam traps failures keep coming up.


Steam Trap Auditing 1. Timing of training preventing certification

prior to business objectives coming due.2. UE system online resources were significant

very good.3. We had the internet!4. Good experience with the Ultraprobe 3000


Steam Trap Auditing 1.Great resources available for free2.Great support from the customer3.Steam Trap Training had been

completed


Steam Trap Supplier PDFs


Steam Trap Auditing


1. Sound Recording Library

2. Examples of traps commonly found

Steam Trap Auditing


Steam Trap Auditing Additional Tools


1.Temperature Gun2.Tags3.Camera4.Gloves (optional)


Survey Detail


Failed Trap Summary

Summary1. Steam Trap auditing is a great program

for thermal energy savings discovery

2. Training is preferred but if not available start on your own

3. Great Ultrasonic tools are available and with a little experience ROIs are quickly met.


Questions?

Steam Trap Savings Discovery B Sperling Sealed Air Final · 2019. 9. 18. · Diversey Care honored...

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Transcript of Steam Trap Savings Discovery B Sperling Sealed Air Final · 2019. 9. 18. · Diversey Care honored...