Energy Monitoring Solutions (EMS)

We help You to save Energy

14/06/2009
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Slide 1

Energy Monitoring Solutions from Endress+Hauser

Agenda
Potential Savings
Energy Monitoring Solutions
Case studies: You can monitor only what you measure !
Case study 1
: Controlling the Boiler efficiency
Case study 2
Case Study 3

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Slide 2

: A monastic brewery subject to the energy agreement

: Steam measurement and Green certificates

Energy Monitoring Solutions from Endress+Hauser

Emissions/
Effluents

Typical Production Process

Labor

Emissions/
Effluents

Products

Steam
Vapeur

Gaz
Gaz

Electricity
Electricit

Slide 3

Air
Air

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Water
Eau

Raw Material

Energy Monitoring Solutions from Endress+Hauser

Why ? The 4 main Reasons

Monsieur Energie
Energy costs

Company image

Rising cost of fuel/gas

year to year

ISO14001 and EMAS

certifications

Legislation
Increase of profits
Reduction of energy
consumption

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Slide 4

Reduction of CO2
emissions (Kyoto
protocol and related
legislations exa: EU
Directives about
emissions trading, )

Industrial companies are subjected to many different lobbies

as Ecology, Economy and Legislations

Energy Monitoring Solutions from Endress+Hauser

Potential Savings
Over the past 15 years, significant development work has
been undertaken in the UK. Results indicate that, when
properly implemented, an EMIS can save 5 to 15 percent of
annual energy costs. As an initial approximation, 8 percent
appears to be a reasonable estimate.

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Slide 5

Office of Energy Efficiency of Natural

Resources Canada:
Energy management information systems:
achieving improved energy efficiency:
a handbook for managers, engineers and
operational staff

Energy Monitoring Solutions from Endress+Hauser

Energy Savings Process

Customer
Metering
& Data
Collection

Controlling of
Energy Data

Optimize
(Understanding to results)

Transparency of
Consumption

Energy Reporting
(Informations to
understanding)
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You cannot optimize what you do not measure !

Slide 6

Data Analyses
(Data to information)

Energy Monitoring Solutions from Endress+Hauser

Pay-back Example of a Printing Company (SC-UK)

Total Operating Expense 6.41Mio.
Capital Cost (20%)

1.75 Mio

Raw Materials (35%)

2 Mio.

Energy Cost (35%)

2 Mio.

Personnel Cost (10%)

0.66 Mio.

Realistic Savings 8% ~ 160,000/year

Typical Payback < 2 years
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Slide 7

Energy Monitoring Solutions from Endress+Hauser

Fast Pay-Back and Sustainable Savings

Energy Monitoring System incl. Sensors:
Investment:
Savings:
Pay-back:

96,000
13,300 per month
8 months

Price in Mio
2.0
without Energy Monitoring
ROI after
7.2 months

1.5

with Energy Monitoring

1.0

0.5

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Slide 8

0
0

10

11

12

Time in Months

Energy Monitoring Solutions from Endress+Hauser

Five Utilities WAGES

Water

ed
s
s
e
r
p
Com
Air

Gas
(NG,
oil an
d
othe
rs)

ity
c
i
r
t
Elec

Steam
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Slide 9

Energy Monitoring Solutions from Endress+Hauser

Energy Monitoring, Analyses and Reporting

Energy Monitoring Software
(EMS)

Utilities
Steam
Compressed Air
Electricity
Gas
Oil
Water
Heating
Cooling

Analyses and
Reporting

Visualization and
Recording

Calculation and
Transmission

Process Fluids
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Slide 10

Energy Measurement

Energy Monitoring Solutions from Endress+Hauser

Features

From a single Measuring point to global Energy Monitoring

Accurate Calculation
and Notification in
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- Data Recording
- Visualization
- Analyses
- Effiziency Calculation
- SEC
- CO2 Emissions
- Supervision of Comp.
Air Filters
- Find leaks

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Slide 11

Price

- Transparency of Energy
- KPIs
- Deviation Analyses
- ROI Calculation
- Benchmark
- Reporting
- Energy Cost per product
- Energy Planning
- Early Detection of
Deviations

Energy Monitoring Solutions from Endress+Hauser

Features

From a single Measuring point Package T

Accurate Calculation
and Notification in
14/06/2009 case of faults

- Data Recording
- Visualization
- Analyses
- Effiziency Calculation
- SEC
- CO2 Emissions
- Supervision of Comp.
Air Filters
- Find leaks

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Slide 12

Price

- Transparency of Energy
- KPIs
- Deviation Analyses
- ROI Calculation
- Benchmark
- Reporting
- Energy Cost per product
- Energy Planning
- Early Detection of
Deviations

Energy Monitoring Solutions from Endress+Hauser

Which measuring technology for which application ?

There is no perfect meter for gases or steam
applications
Most applications can be handled by several
measuring technologies and every principle has
its own advantages and limitations
Endress+Hauser offers a broad range of gas flow
meters, so that we are able to offer the best-fit
solution for the requirements of the application
To be able to offer the best-fit solution,
Endress+Hauser developed for the last 10 years
a know-how in gas measurement, by
considering all the pros and cons of every
measuring technology

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Slide 13

It is essential to take particular care to the

installation requirements (inlet/outlet runs) and
to the individual gas type and application (gas
composition, pressure, T, moisture, )

Energy Monitoring Solutions from Endress+Hauser

Applications Window of Endress+Hauser

Fluid
Technology
Promag
Electromagnetic

Promass
Coriolis

Prowirl
Vortex

Prosonic Flow
Ultrasonic

T Mass
Thermal Mass
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Deltatop
Differential Pressure

Slide 14

Conductive
Liquids
Low
viscosity

High
viscosity

Non-conductive
Liquids
Low
viscosity

High
viscosity

Gases

Steam

Energy Monitoring Solutions from Endress+Hauser

Steam The Most used Energy

Steam represents more than 34 % of the total energy which is
used in industrial applications for the manufacturing of products
more than 83 % of the total energy used in the Pulp & Paper
industry
more than 57 % of the total energy used in the Chemical industry
more than 42 % of the total energy used in the Petrochemical
industry

Steam is mainly measured in

mass units (kg/hr or t/h),
more seldom in kWh
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Slide 15

Energy Monitoring Solutions from Endress+Hauser

Steam The most used technologies

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Slide 17

Vortex

Thermal

Coriolis

Differential Pressure

In very specific applications

Energy Monitoring Solutions from Endress+Hauser

Features

to a Basic Monitoring Memograph M

Accurate Calculation
and Notification in
14/06/2009 case of faults

- Data Recording
- Visualization
- Analyses
- Effiziency Calculation
- SEC
- CO2 Emissions
- Supervision of Comp.
Air Filters
- Find leaks

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Slide 18

Price

- Transparency of Energy
- KPIs
- Deviation Analyses
- ROI Calculation
- Benchmark
- Reporting
- Energy Cost per product
- Energy Planning
- Early Detection of
Deviations

Energy Monitoring Solutions from Endress+Hauser

Case Study 1
Controlling the boiler efficiency
There can be no economy where there is no efficiency
(Benjamin Disraeli, 1 October 1868)

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Slide 19

Energy Monitoring Solutions from Endress+Hauser

Controlling Boiler efficiency gives savings potential

There are several terms used to qualify efficiency when used
in the context of a steam boiler

Steam
Make-up
water

Condensate
return

Feed water
Flue gas

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Slide 20

Nat gas
Blowdown

Energy Monitoring Solutions from Endress+Hauser

Controlling Boiler Efficiency Input-Output Method

Efficiency :

mSteam hSteam mBlowdown hBlowdown mFeedwater hFeedwater

mFuel hFuel
Mass
Enthalpy

Memograph M

Make-up
water

Condensate
return

Steam
[MJ/h]

Flow
Temperature

Feed water
[MJ/h]
Flue gas
Energy

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Slide 21

Nat gas
[MJ/h]
Blowdown

Energy Monitoring Solutions from Endress+Hauser

Actual gas consumption difference compared to expected

Control limits

Target line

Installation of an Economiser
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Slide 22

Energy Monitoring Solutions from Endress+Hauser

Case Study 2
A monastic brewery also subject to the energy agreement
Trappist brewery of Chimay can also improve earnings by
reducing the Energy bill !

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Slide 23

Energy Monitoring Solutions from Endress+Hauser

Return on Investment: Less than 2 months !!

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Slide 24

Energy Monitoring Solutions from Endress+Hauser

Initial situation Split in function of Production

Situation before the installation of the news measuring
equipments:
Distribution of the invoice from the steam boiler and its
consumption on the basis of ratios depending on the produced
quantities
Existing flow meters were not accurate (indication)
Energy balance was not correct

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Slide 25

Energy Monitoring Solutions from Endress+Hauser

Office

Measurements for accurate costs distribution

ReadWin

Electrical cabinet

ETHERNET

3 x Pulse
3 x 4-20 mA

Signal remote Prowirl 72

Field

4-20 mA

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Charcuterie dept
Slide 26

Bottling

Cheese dept

Energy Monitoring Solutions from Endress+Hauser

New situation Reveal savings potentials

After the installation of the new accurate steam measuring
equipments, the measuring results were not according to the
expectations of the end users:
these new meters are not correct !

A good analyses of the measuring results and a walk-around of

the factory showed deficiencies at the existing facilities:

Bad insulation of the 100m steam pipes to the cheese department

Many steam traps were not operating correctly (leaks)
Many classical leaks

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Slide 27

Energy Monitoring Solutions from Endress+Hauser

Result Optimize the energy efficiency sustainably !

Direct impact of these improvement actions resulted in a
reduction of 35 % of steam consumption !
The Return on Investment was less than 2 months !!

Indirect impact of the installation of these flow meters was:

The bill of fuel in 2005 was lower than the one in 2004, even if at
the same time, production was increased and price of fuel went up
with 37%.
All departments were convinced that a continuous measurement
lead to permanent attention

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Slide 28

Permanent measurement is important, not only to reduce

energy costs, but also to discover reduced efficiency earlier
(sustainability)

Energy Monitoring Solutions from Endress+Hauser

Features

up to a Global Energy Monitoring Package S

Accurate Calculation
and Notification in
14/06/2009 case of faults

- Data Recording
- Visualization
- Analyses
- Effiziency Calculation
- SEC
- CO2 Emissions
- Supervision of Comp.
Air Filters
- Find leaks

E+H-BE/JJR
Slide 37

Price

- Transparency of Energy
- KPIs
- Deviation Analyses
- ROI Calculation
- Benchmark
- Reporting
- Energy Cost per product
- Energy Planning
- Early Detection of
Deviations

Energy Monitoring Solutions from Endress+Hauser

Traditional collection of data !!

Data collection
once/month
Old electrical counters

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Slide 38

Paper recording of data

Energy Monitoring Solutions from Endress+Hauser

Fully automatic Data Collection of Energy Data

Software for 15min. to 30min.
Data collection

Energy Monitoring
Software

Data Access Scheduler

Existing SCADA
Client Server

Existing
Production Data

Database
Ethernet

PLC
Field Controller
SFC173

Memograph M

FXZ520
Module

RS485

Fieldgate
FXA520

RS485

4x Pulse

HART-Multiplexer
Energy
Computer
RMx621

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Slide 39

Fieldgate
FXA520

Mobilfunk
GSM/GPRS

Energy Monitoring Solutions from Endress+Hauser

Energy Monitoring Software

Easy Online Data Access
Manual Data Entry
Alarm Configuration
Reporting
Graphic
Analyses

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Slide 40

Energy Monitoring Solutions from Endress+Hauser

Determine relationship by line of best fit

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Slide 41

Energy Monitoring Solutions from Endress+Hauser

Actual gas consumption difference compared to expected

Control limits

Target line

Installation of an Economiser
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Slide 42

Energy Monitoring Solutions from Endress+Hauser

expense

Accumulated energy savings after economiser installation

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Slide 43

If Nat Gas costs 1p/KWh then savings after 15 weeks were

11,050; Equivalent annual savings of 38,000

Energy Monitoring Solutions from Endress+Hauser

Energy Monitoring Customers

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Slide 44

Energy Monitoring Solutions from Endress+Hauser

HARIBO UK
software
Data Access
Scheduler

server
.CSV

Donnes de
production

Database

NETWORK
FXA520
RS485
FXA520
RS485
FXZ520s
FXZ520

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Slide 45

Boiler gas
Compressed
air

Effluent
Steam

Temp
Gas supply
Water supply Pressure
Sub 2 electricity
Comp 1 electricity

Comp. air Water

prod
Towards storage

Electricity
supplier