Presentation 3.2: Demand side energy managementPresentation 3.2: Demand side energy management Frank...

Presentation 3.2: Demand side energy management Frank Taelman Energy & Maintenance Manager Siemens E-mail: [email protected] Abstract With Demand Side Energy Management Siemens Industrial Services has created a package of services to provide sustained improvement in the energy efficiency of a production facility while reducing energy consumption. The profitability of a production facility also relies on an inexpensive and reliable supply of power, heating, cooling, and compressed air. The provision of energy, is no more than just a secondary process outside the core competence. Most of all, however, it's a cost factor. Aim is to use energy much smarter, thus increasing productivity. Demand Side Energy Management from Siemens Industrial Services takes a detailed look at the technical and economic aspects of the entire process. This enables us to develop a step-by-step concept to improve energy efficiency in line with the business needs – and then to implement it.

265

Demand Side Energy

Management

Frank Taelman 1|23October 2006

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Agenda

� Benefit and Added Value

� Focus

� The Demand Side Energy Management Concept

� The Attractiveness

� Some References

Frank Taelman 2|23

267

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Benefit and Added Value

Frank Taelman 3|23

0 5 10

Time - years

EnergyCosts

Costs are too high!Costs are too high!Costs are too high!

Let’s do theseenergy projectsLet’s do theseenergy projects

O.K., done, Management asks us to execute other tasksO.K., done, Management asks us to execute other tasksO.K., done, Management asks us to execute other tasks

Management says costs are again too high: where did we put this Audit?Management says costs are again

too high: where did we put this Audit?

We’ve seen itbefore...We’ve seen itbefore...We’ve seen itbefore...

A one shot energy

reduction program

“Yoyo”-effect

Non sustainable

A continuous energy

reduction program

Sustainable

solution5 10

Years

Top Management wants sustainable energy reduction!Top Management wants

sustainable energy reduction!

Energy projects are justa beginning…

Energy projects are justa beginning…

Production, Planning, Logistic, Maintenance: allfind additional costs savings, implemented on a

sustainable basis.

Production, Planning, Logistic, Maintenance: allfind additional costs savings, implemented on a

sustainable basis.

Expansion

Our new plant isreally energy efficient

Expansion

Our new plant isreally energy efficientOur new plant is

really energy efficient

0

EnergyCosts

TechnicalDevelopment

Process modeling and monitoringsaves energy and increases

productivity

TechnicalDevelopment

Process modeling and monitoringsaves energy and increases

productivity

DSEMDSEM

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Benefit and Added Value

Frank Taelman 4|23

Labor against cost price

x % of the detected yearly

energy savings from projects

that are technically and

economically feasible

y % of the realized yearly

energy savings from projects that are technically and

economically feasible

Labor against fixed price

or

daily rate

No cure, no benefit No performance part

268

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Focus

Focus on the complete energy consumption:

• electricity• gas• steam• compressed air• water

Frank Taelman 5|23

ProductionProduction and and EnergyEnergy usageusageProductionProduction and and EnergyEnergy usageusage OUTPUTOUTPUT

• Waste heat

• CO 2

• Emissions

INPUTINPUT

• Purchase

• Distribution

• Generation

EnergyEnergy MonitoringMonitoring and Analysisand AnalysisEnergyEnergy MonitoringMonitoring and Analysisand Analysis

UtilitiesUtilitiesUtilitiesUtilities

Business Business PracticesPractices Operation, Resources, Maintenance, Logistic SubsiOperation, Resources, Maintenance, Logistic SubsidiesdiesBusiness Business PracticesPractices Operation, Resources, Maintenance, Logistic SubsiOperation, Resources, Maintenance, Logistic Subsidiesdies

!

!!

! !

!!!

!

!!

! !

!!!

October 2006

Energy Management: Macro Level

Frank Taelman 6|23

Client : Energy consumer

EnergyQuality

Metering & Monitoring

Energy reporting

Energy Consumptio

n Forecasting

Energy Awareness

Energy Audit

Own Energy Production

Energy Distribution

Equipment Standard

Energy Purchasing

Energy Benchmarki

ng

Energy Legislation

Exploitation of fossil fuels

Research and Development of alternative fuels

Production of

Renewable energy

Energy Production

Energy Transportation &

Distribution

Government

Other energy

consumers

Installation &

Service suppliers

SisterCompany

client

SisterCompany

client

269

October 2006

Reject Power For SIPAPERCIS

Frank Taelman 7|23

Rejects

Fuel Value ~Lower Heating Value

12.000 kJ/kg (TS ~ 55%)

De-inking Sludge

Fuel Value ~ Lower Heating Value

3.800 kJ/kg (TS ~ 65%)

Bio Sludge


385 kJ/kg (TS ~ 18%)

Fiber Sludge


6.300 kJ/kg (TS ~ 56%)

October 2006

Reject Power For SIPAPERCIS

Frank Taelman 8|23

20MW

40MW

100MW

Rejectsto

Fuel Turbine+

Generator

Fuel

G

50k

tpa

200k tpa

Specialpaper rejectsincinerator

Generalwaste &biomass

unit

Steam ElectricityRejects

Steam Electricity

Preparation Incineration Steam & Electricity production

RejectsUpcyclin

g

Rejects

Rejects

270

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

The DSEM Concept

Frank Taelman 9|23

• Strengths and weaknesses

• Key action points• Benchmarking

• Potential

• Energy map, potential scan

• Project(s) execution

• Performance and performance improvement

monitoring

One2FiveOne2Five

EPS-Energy

potential scanEPS-Energy

potential scan

Project(s)Project(s)

MonitoringMonitoring

(1) Orientation

(2)Analysis

(4)Implementation

(5)

Sustainability

ROIROI(3)

Planning

One2FiveOne2Five

EPS-Energy

potential scanEPS-Energy

potential scan

Project(s)Project(s)

MonitoringMonitoring

(1) Orientation

(1) Orientation

(2)Analysis

(2)Analysis

(4)Implementation

(4)Implementation

(5)

Sustainability

(5)

Sustainability

ROIROI(3)

Planning(3)

Planning

• Projects planning

• Calculation of ROI

Demand Side Energy Management is a concept, not a tool nor a product, in order to:

• control & minimize the energy costs• create energy consumption transparency• increase energy awareness & maturity level

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 1: Orientation

Frank Taelman 10|23

Quick scan One-2-Five measures the energy management level:• holistic method by means of yes/no answers• the energy management & capability level is checked and benchmarked

• result: energy saving potential & critical improvement action setting

271

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 1: Real Case

Frank Taelman 11|23

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 2: Energy Potential Scan

Frank Taelman 12|23

� Analysis of total energy consumption

� List of projects with invest & saving

� Supported by calculations & external suppliers

� According the 6-sigma DMAIC standard

� All projects are technically feasible

� Supported by studies, if needed, from external

companies

272

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 2: Real Case (1/2)

Frank Taelman 13|23

Description Minimum Maximum Minimum Maximum

Optimization of the heat exchanging process 875.000,00 € 1.250.000,00 € 680.000,00 € 850.000,00 €

Install drive for the mixer tank A 15.000,00 € 25.000,00 € 5.000,00 € 10.000,00 €

Optimization of the drive parameters for the mixer tank B 1.000,00 € 5.000,00 € 10.000,00 € 15.000,00 €

Optimization of the lighting 5.000,00 € 10.000,00 € 3.500,00 € 5.000,00 €

Optimization of the operation mode of the mixers in tanks 1 to 6 100,00 € 1.000,00 € 27.000,00 € 33.000,00 €

Correct dimensioning of pump A1Z 10.000,00 € 15.000,00 € 10.000,00 € 15.000,00 €

Install new pump 4EZX 10.000,00 € 15.000,00 € 5.000,00 € 10.000,00 €

Optimization of the compressed air generation 40.000,00 € 55.000,00 € 50.000,00 € 60.000,00 €

Optimization of the energy sent back in the net (power generation) 1.000,00 € 5.000,00 € 5.000,00 € 10.000,00 €

Optimization of the water circuit (4 pumps out) 35.000,00 € 55.000,00 € 50.000,00 € 65.000,00 €

Install drive for the mixer in pulper 1A 3.000,00 € 5.000,00 € 12.000,00 € 15.000,00 €

Install drive pump pulper 7V 1.000,00 € 5.000,00 € 5.000,00 € 10.000,00 €

Optimization of the heat exchanging in the power generation 80.000,00 € 120.000,00 € 165.000,00 € 205.000,00 €

Install drive for the mixer in pulper 3E 1.000,00 € 5.000,00 € 20.000,00 € 30.000,00 €

Automatic shutdown of the pump 4ERT5 5.000,00 € 10.000,00 € 5.000,00 € 10.000,00 €

Automatic washing of the turbine 10.000,00 € 15.000,00 € 40.000,00 € 55.000,00 €

Optimization of the operation mode of the mixers 8 and 9 1.000,00 € 5.000,00 € 25.000,00 € 30.000,00 €

Correct dimension of the degasser 10.000,00 € 15.000,00 € 10.000,00 € 15.000,00 €

Replace mechanical breaks by generators 50.000,00 € 75.000,00 € 40.000,00 € 60.000,00 €

Shutting down fan - € 1.000,00 € 5.000,00 € 10.000,00 €

Estimated invest Estimated yearly saving

































Automatic washing of the turbine 10.000,00 € 15.000,00 € 40.000,00 € 55.000,00 €

Optimization of the operation mode of the mixers 8 and 9 1.000,00 € 5.000,00 € 25.000,00 € 30.000,00 €

Correct dimension of the degasser 10.000,00 € 15.000,00 € 10.000,00 € 15.000,00 €

Replace mechanical breaks by generators 50.000,00 € 75.000,00 € 40.000,00 € 60.000,00 €

Shutting down fan - € 1.000,00 € 5.000,00 € 10.000,00 €

Estimated invest Estimated yearly saving

Concrete project list from a real DSEM project

All projects are technically feasible

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 2: Real Case (2/2)

Frank Taelman 14|23

The DMAIC methodologyTitel:

Define 4444

Measure 4444

Analyze 4444

Improve 4444

Control 4444

Define Improve ControlMeasure Analyze

Define Phase

OK

What?What is the problem? Make a detailed description based on facts and figures.

Identify the (local) client?Who suffers from this problem?

What are the losses?

Identify the expectations?What are the specifications?

What does the client expect?

Make a visualization (process mapping)What are the interactions?

SIPOC: Supplier - Input - Process - Output - Customer

Borderlines of the project?When started?

Expected milestones

Who is working on the project (project team)?

Define Improve ControlMeasure AnalyzeMeasure Phase

OK

What is the measuring strategy?What data do we need?

How did we defined the measuring strategy? (Brainstorming - Fish bone)

When are the measurements scheduled / executed?

What measurement devices are used? (tolerance)

Measuring system?Is the measurement repeated and confirmed?

Is measurement on different points in time needed?

How is the data collected?Historical data - Manual data collection - ….

Data evaluation?Is the data visualized? (pareto - line diagram - histogram - others - …

What are the temporary conclusions?


Analyze Phase

OK

Analyze the data?Are the data in line with the expectations?

Are the figures explainable? (are they in a theoretical possible range)

Is there a relation between the figures?

Are we using uniform measuring units?

Do we use convert factors?

What is the physical phenomenon behind this process?

Influences from: Man - Machine - Method - Material - Environment - Measurement

Is there a constant in the figures?

Do we need techniques to evaluate the figures and to take conclusions? (Statistical analysis - Fish boon -

brain storming - …)

What is the main cause /conclusion?Will this solve the problem?

Why - Why - Why - Why - Why - …


Improve Phase

OK

How will we solve the main cause?

What are the alternatives?

What are pro / con's for every alternative?

Do we have specifications for the (technical) solution?

What is the effect on: Quality

Cost

Delivery

Safety

Man

Environment

Is a project description made (lastenboek)?

Do we have sent quotations to possible suppliers?

What are the offers?

Is the proposed solution accepted by the client?

What is the planning?Short term - Long term solution

Installation period

Test period

Documentation received

Education


Control Phase

Implement and Communicate

Is the solution standardized?

Are visualizations in place?

Is the documentation updated?

Are the procedures / instructions updated?

Is the preventive maintenance plan updated?

Is the BOM (Bill Of Material) updated? - Install base list

Are the users trained?

Are the audits updated?

Evaluation

Can we close the project?

Can we prove the results with data?

Is the a possibility for horizontal expansion?

How can we speed up this analysis in future?

Sustainability

How can we follow up this issue over time?

What has to be checked - reported?


Define Phase

OK

What?

Identify the (local) client?Heat losses: has to be compensated (extra cost)

Heat has to be evacuated via ventilation.

Identify the expectations?Lower energy (gas - gasoil) consumption due to reduced losses.

Lower energy consumption and cost.

Make a visualization (process mapping)

Borderlines of the project?Pipes > 2"; Temp > 50°C

Isolation can be installed during production

Project team: André Poirier - Frank Taelman - Supplier (e.g. Kadant - Johnson)

A lot of pipes from the distribution of steam, thermo oil and condensate are not or bad (damaged)

isolated. This results in energy losses and heat up of space that doesn't need to be heated.


273

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 3: Planning Phase

Frank Taelman 15|23

� Priority setting in the project detected by the EPS

� Fine-tuning of the ROI’s of the high priority projects

� Price request towards external suppliers

� Aligned planning with the production & maintenance

� Forecast of energy saving

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 3: Real Case

Frank Taelman 16|23

274

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 4: Implementation

Frank Taelman 17|23

Target DSEM = cutting energy, NOT selling projects

� Projects are executed by the party chosen by the customer

� Siemens can support

� Project management

� Coordination of external partners

� Support of projects executed by the customer itself

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 5: Sustainability Phase

Frank Taelman 18|23

� After the projects have been realized:

� An after calculation is executed

� The real ROI is defined

� If this result is not in line with the expectations,

corrective action will be taken

� This phase grants transparency of savings

� Metering, monitoring & reporting

� On-line metering & monitoring systems

� Frequent energy meeting & reporting

275

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 5: Real Case

� Transparency in the energy consumption

� On-line energy consumption & energy balance monitoring

system + remote energy reporting quarterly

� Regular energy meetings (variances are explained)

� From 0,5 stars up to 4,2 stars on a scale of 5 of the Quick

scan One-2-Five

� Awareness about the importance of energy

� Over 150.000 EUR yearly energy savings per year with less

than 10.000 EUR investments in one year

� Clear definition of over 1.000.000 EUR concrete

economically achievable energy savings projectsFrank Taelman 19|23

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Step 5: Real Case - Transparency

Frank Taelman 20|23

Total electricity consumption [kWh/ ton]

330,00

350,00

370,00

390,00

410,00

430,00

450,00

470,00

jan/04 jan/05 jan/06

Total gas consumption [kWh/ton brutto]

1500,00

1600,00

1700,00

1800,00

1900,00

2000,00

2100,00

2200,00

2300,00

2400,00

jan/04 jan/05 jan/06

kWh/h

Nm³/h

Euro/h

kWh/to

kWh/h

Nm³/h

Euro/h

kWh/to

kWh/h

Nm³/h

Euro/h

kWh/to

GAS

Nm³/h

Euro/h

kWh/h

kWh/to

Streichanlage Kartonmaschine

GTelek. WT1

kW/h

kW/h

K B K

Euro/h

kW/h

K B P

Euro/h

00

0

0.00

0

0

elek. WT2

kW/h

165

0

#NV

#NV

#NV

#NV

NETZ2934 kWh

293 Euro/h

kW/h

elek. RUECK

Euro/h

600

4,59

kW/h

elek. BEZUG

Euro/h

00,00

Euro/h12,59

1320310,58

14728

1317

14692

310

OEL

m³/h

Euro/h

#NV

#NV

kWh/h

Bad Euro/to

Bad kWh/to

kWh/to

kWh/to

kWh/to

kWh/to

kWh/tokWh/to

0 kWh/h

3369 kWh/h

to³/h

to / to

Frischdampf

Bad7,05

GAS

DTKessel

3/4

ηelek

ηelek

22.91

0

276

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

The Attractiveness of DSEM

� Focus especially on reducing the energy consumption,

not only on reducing costs through negotiating energy prices,

nor on selling projects or products

� Wide focus: not only on the board machine, but as well on

power generation, monitoring, subsidies, maintenance,

management, awareness, …

� The process: logical, and every step adds value

� Performance based agreement: the risk is shared by the

customer and Siemens. An optimal working relationship is

needed to achieve the best results.

� Sustainability: through the use of Quick scan One-2-Five,

the critical actions remain active until they are fulfilled.

Frank Taelman 21|23

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Some References

Frank Taelman 22|23

20.000 EUR

750.000 EUR

1.050.000 EUR

125.000 EUR

745.000 EUR

120.000 EUR

545.000 EUR

600.000 EUR

1.000.000 EUR

350.000 EUR

225.000 EUR

Savings

Germany20 daysDSEMFoodSauces

Germany45 daysDSEMMetalAluminum

UK45 daysDSEMPulp & PaperPackaging paper

Automotive

Pulp & Paper

Pulp & Paper

Beverage

Pulp & Paper

Automotive

Pulp & Paper

Pulp & Paper

Pulp & Paper

Beverage

Branch

Netherlands5 daysOne-2-FiveBoard & test liner

Belgium5 daysOne-2-FiveCar

Belgium35 daysEnergy planCoat & paint

Germany200 daysDSEMDecor

Belgium220 daysDSEMSoya milk

Belgium10 daysPump & fan studytest liner

Germany330 daysDSEMWLC

Germany60 daysDSEMDecor

Canada100 daysDSEMImage & decor

Belgium15 daysEnergy planFruit juices

CountryDurationTypeType of product

Cross-industry experience as added value

277

Agenda

Benefit and added

value

Focus

The concept

The attractiveness

of DSEM

Some references

Contact

October 2006

Contact

Frank Taelman 23|23

Frank Taelman

Energy Manager

Siemens NV/SA

Demeurslaan 132

B-1654 Brussels

Belgium

E-mail: [email protected]

278

Presentation 3.2: Demand side energy managementPresentation 3.2: Demand side energy management Frank...

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