ENEA – EN 16.001 – February 2011/1_Corra'.pdf · •Identify energy saving and make the...

10 February 2011

ENEA – EN 16.001 – February 2011

Alexander Corrà - HSE Energy Management 210 February 2011

Summary

• Tenaris & TenarisDalmine

• The background of the Energy Management in Tenaris

• An “Energy Efficiency Plan” becomes an “Energy

Management System”


Tenaris: Global Industrial System

• Annual manufacturing capacity of six million tons of steel pipes

- 3.4 million tons of seamless pipes

- 2.7 million tons of welded pipes

• 4 electric steel shops

• 16 seamless rolling mills

• 32 welded tube mills

• 52 heat treatment lines (28 in hot rolling mills )

• 78 premium threading lines

• One Health, Safety and Environment Management System

Serving the world’s energy industry and other industrial applications

Worldwide Operations


Turnover: € 1,6 billion

People: 3071

TenarisDalmine Plants (31-12-2007)

ArcoreProducts: Mechanical tubing, Structural tubing, Hollow bars

PiombinoProducts: Butt welded steel pipe for plumbing

Sabbio BergamascoProducts: Cylinders/Large cylinders, Accumulators

DalmineProducts: Mechanical tubing, OCTG, Line pipe, Tubes for petrochemical plants, Pipe for high-temperature service, Hollow bars, Structural tubing.

Costa VolpinoProducts: Seamless cold drawn tubes for hydraulic circuits and cylinders, Tube for automotive, Heat-exchanger tubes.


Summary


• The background of the Energy Management in Tenaris- Tenaris QHSE Policy

- Energy & ETS in UE, an increasing scope…

- The Plan of Tenaris: a multi level approach

- Tenaris & Energy Efficiency




Tenaris QHSE Policy

We are committed to developing a long term sustainable business:•Minimizing the environmental impact of our operations•Making the most efficient use of natural resources and energy•Integrating environmental management in all business processes•Holding employees committed and responsible for environmental performance•Establishing an open and transparent dialogue with related stakeholders

It all starts from a formal It all starts from a formal commitment on the energy commitment on the energy

efficiencyefficiency


Energy & ETS in UE, an increasing scope…

… an increasing impact!!!… an increasing opportunity!!!

The case of TenarisDalmine:

– In 2005 the steel shop within the scope of the ETS

– In 2007, start up of the new NGCC 120 MW Power plant

– In 2008 inclusion of Rolling mills in the scope of the ETS

The scope of emission under ETS has been increased 10 times in 3 years for our sector.


The Plan of Tenaris: a multi level approach

• Short and Medium term– Energy Efficiency Plan (TENARIS

“CO2 Emission and Energy Saving Plan - EESP”)

• Long term– Standardization for the energy

management procedures– R&D projects

• Energy recovery from fumes• Energy recovery from the process• Oxicombustion

Successful keys:

• Communication & Information

• Metering & Controlling


TENARIS “CO2 Emission and Energy Saving Plan (EESP)”

• First step (1 year):

– Assessment of the initial performance

– Metering, benchmark and reporting

– Waste reduction plan – operative practice review

• Second step (3 years):

– Investments plan

– Efficiency Standardization in new project and purchasing

– Cultural change.

Objective: Reduce Tenaris specific consumption by 10 % on Electricity and 15 %on Natural gas.

EESP has been launched in 2009 and is a four year plan, the following activities should be done :

Correct ineffectiveness

of the past past

Save futuresfuturesineffectiveness and

prevent wasteswastes

Reduce product costcost

Reduce environment environment impact

Reduce energyenergy request

Energy consumptions audit

Cul

tura

l ch

ange

Inve

stm

ents

Engineering

Purchasing

Operations

Maintenance

Management

Industrial energy efficiency

Energy Energy savingsaving

Correct ineffectiveness

of the past past

Save futuresfuturesineffectiveness and

prevent wasteswastes

Reduce product costcost

Reduce environment environment impact

Reduce energyenergy request

Energy consumptions audit

Cul

tura

l ch

ange

Inve

stm

ents

Engineering

Purchasing

Operations

Maintenance

Management

Industrial energy efficiency

Energy Energy savingsaving


• 2006 Tenaris Dalmine: − An Energy Saving Plan was launched. Objectives 7% and 6% in specific consumption reduction in natural gas and electricity.

− Planed activities were: Metering, Controlling, Training & Communication, Standardization, Investment plan and Waste reduction plan.

• 2007 Tenaris Dalmine:− A 120 MWe high efficiency Combined Cycle Power Plant started the operation to self-production of electricity, steam and hot water both inside and outside the plant (district heating).

Tenaris & Energy Efficiency:


•2008 Tenaris Dalmine:− The first high efficiency combustion system has been installed in a reheating furnace (in collaboration with R&D CSM).

• 2008 Tenaris:− A new mill with high efficiency performances (aligned with the TS BAT) was commissioned.

− The CO2 data collection & Sustainability KPIs has been reported to WSA.

http://www.worldsteel.org/?action=programs&id=70



• 2009 Tenaris:− A global Energy Efficiency Plan was launched. Objectives 15% and 10% in specific consumption reduction in natural gas and electricity.

− And R&D department for Energy Efficiency has been created.

• 2009 Tenaris Dalmine:− The Energy Efficiency plan was awarded with the UE recognition “Motor Challenge Programme”



•2010 Tenaris Dalmine:

− Tenaris Dalmine and its power plant were certified with the EN UNI 16.001 “Energy Management System”

−10.000 “Titoli di Efficienza Energetica TEE” (1 TEE= 1 ton of oil saved) have been assigned by the Italian authorities for the main high technology investments. Expectations for next 5 years: more than 40.000 TEE



Summary


• The background of the Energy Management in Tenaris




An “Energy Efficiency Plan” becomes an “Energy Management System”

• Why build a system?

− To maintain the results in the future.

− To make the management independent of the people.

− To standardizes the tools to drive the activities.

• How to build the system?:

− Defining a policy.

− Planning the structure, resources and the scopes.

− Finding the “as is” and defining the targets.

− Implementing a monitoring system.

− Checking the trends and auditing the system.

− Doing periodical management reviews.

− Making continuous improvement.

Alexander Corrà - HSE Energy Management 16

Policy and Structure

10 February 2011


Energy Management Manual

10 February 2011

The main document of the system: “The manual”

• Overview

• Scope

• Boundaries

• Reference and law requirements

• Energy Management System

• Model of the System

• Energy management Policy

• Planning

• Operative and implementation

• Monitoring

• Management review by the direction


Documents management

10 February 2011

• Assure the availability of the availability of the documentsdocuments to each key function

• To maintain up dated up dated all the documentation

• ShareShare easily new versions

• Inform the people about new or new or reviewed documentsreviewed documents


Objectives:

• Picture of energy and emissions usageenergy and emissions usage. Check the measurementmeasurementsystem.

• Define a modelmodel of energy distribution and the “tableau de board”.

• BenchmarkBenchmark the KPIs.

• Identify energy savingenergy saving and make the technical and economic feasibility (investment, wastes, standards and working practices).

• Define the CO2 and energy saving objectivesobjectives for each PU and build next tree years masterplanmasterplan.

An example of energy distribution on a typical mill:

Assessment: the “as is”.

EE distribution

61%

10%

7%

6%

5%

4%2%1% 4%

EAFProcessWater pumpsFanCompressed airOil pumpsilluminationMovementother

Percentuale Energy Consumption [TEP](anno di budget 2008/2009)

61,5%

35,5%2,4%0,6%

Metano EE Azoto Ossigeno


CH4 consumption by mill: All energy cost and consumptions by mill and cdc:

• Tenaris Energy Monitor (TEM) is the on line visualizationon line visualization on the intranet for consumption data collected from the distribution networks of every energy exploited in the plant.

• The purpose of the system is to be the instrument devoted to monitoring and managementmonitoring and managementfactory energy consumption together with testing and quantifying the results of the Tenaris plan for energy efficiency.

Metering - Monitoring:


Auditing the System

• Planning the audits to all the function. At least once a year

• Training the auditors team

• Design a system to manage the “non conformity” and the preventive and corrective actions


Management review

•Inputs:- Check the action on going- Review of the policy- Assessment of the legal requirements- Assessment of the objectives and the trends of KPIs- Report of finding in the audits already done.

• Outputs:- New targets- Policy variations- Resources allocation


Improvements – List of opportunities:

Investment class

13%

29%

51%

7%MeteringElectrical powerNatural gasDistrict heating

1. Matrix of priority:• Savings• Pay back• Environment, production and

quality impact• Renewable energy

2. List of opportunities:• Defined during the assessment• Listed by priority:

- Investments- Operative practices- Maintenance- ecc

3. Budget and targets:• Planning resources and people


Matrix of priority

Coeff. Di priorità 1 3 3 1 2 1 1PROGETTI a b c d e f G TOTIlluminazione capannoni 1 5 1 1 5 1 3 34Revamping forno LR10 5 4 3 2 5 3 1 37Inverter ventilatori ACC 3 3 3 2 5 2 1 36

Example:Example:


Efficiency Standardization - BAT:

Tool:Tool:

The Best Available Techniques (BAT) are a list of engineering, purchasing and maintenance standard that Tenaris wants define to guaranty our high energy

efficiency performance.

Applicability:Applicability:

To all new investment and revamping. The main equipments involved are Furnaces, Motors, Compressors, Fans and Pumps.

Sources:Sources:

• IPPCIPPC – European Commission. • European Commission – EuropumpEuropump Motor MEPS Guide• IECIEC 60034-30 Rotating electrical machines • The European Motor Challenge ProgrammeMotor Challenge Programme• U.S. DOEU.S. DOE – Air Movement and Control, Association International, inc• ISO/DIS 12759ISO/DIS 12759: Fans – Efficiency classification for fans• ISO 9906ISO 9906: Rotodynamic pumps – Hidraulic performance acceptance tests• Europump and Hydraulic Institute U.S. DOEHydraulic Institute U.S. DOE


Cultural change

• Training programme

• Communication programme– Flash– Video– Advertising

• Formal objectives to reduce energy consumption

• Periodical management review


Conclusions

10 February 2011

• The management of the energy consumptions is a successful key in our days

business environment.

• As the safety and quality, the energy management must be deep seated in

the culture of the company.

• The EN 16.001 helps in the previous points and in:- Reduce costs

- Reduce environment impact

- Promote energy efficiency in all employees

- Involves outsourcing, clients and providers in the scope

• The certification assure the durability of the results even in moments when

the energy efficiency is not high stressed

ENEA – EN 16.001 – February 2011/1_Corra'.pdf · •Identify energy saving and make the...

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