Why don't you have an energy management system yet
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- 2. Slide | 2 “WALK THE TALK”… … LET’S HAVE A LOOK AT MY EMIS AT HOME No needs for new insulation Good practice: reduce setpoint in Fall TOOLS TO TRACK MY ENERGY BILL
- 3. Slide | 3 SUCCESS FACTORS ① You’re richer than you think Meters, historian, display, analysis software… ② Top-down approach, bottom-up implementation No accountability without actionable parameters ③ Start implementation with an energy optimization project Pilot: people readiness, potential, data available
- 4. Slide | 4 WHY DON’T YOU HAVE AN ENERGY MANAGEMENT SYSTEM YET? and should you? Sebastien Lafourcade, Pepite Technologies
- 5. Slide | 5 WHY AN ENERGY MANAGEMENT SYSTEM? “We have built a new biomass boiler” “We know what to do, we have a project list” “We are looking at energy everyday” What do you do to secure return on investment? What is your game plan to implement and sustain? Do you quickly take actions?
- 6. Slide | 6 THE 5 KEY DRIVERS FOR ENERGY PERFORMANCE Driver Best practice we have seen How do you ensure that recommendations are followed? Going to the rootcauses (identify all the drivers and their combinations) and addressing impacts on production and quality What tools do you use to analyze process data? Multivariate data analysis software How do you ensure that gains are sustained? Max of 3 KPI per level with dynamic target for smart monitoring How do you empower operators to sustain gains? Involvement of operators at every step of the problem solving and the data analysis How do you build people capability in the mills? Self assessment tool and automated troubleshooting tool
- 7. Slide | 7 EXPERIENCE WITH EMIS IN PULP AND PAPER (OR MT&R, M&V, ISO50001…) + Several ongoing projects in N-A and Europe Energy audit in 20+ mills with focus on data availability & quality, monitoring capability and performance gap Par?cipa?on in Energy Blitz at 15+ mills with significant and sustainable cost reduc?ons 2 EMIS implementation in mills with different situation, motivation, and culture High level monitoring models implemented in 5+ mills
- 8. Slide | 8 WHY SO LITTLE IMPLEMENTATION IN P&P? Strengths Challenges ?
- 9. Slide | 9 LET’S LOOK AT TYPICAL ENERGY MANAGEMENT SYSTEM GAP ANALYSIS
- 10. Slide | 10 GAP ANALYSIS REVEALS LOW LEVERAGE OF ABUNDANT DATA AND IT INFRASTRUCTURE
- 11. Slide | 11 LOW CAPEX REQUIRED BECAUSE OF EXISTING INFRASTRUCTURE good level of metering $ S E G D historian DCS control room engineering management corporate PLC / server server link to real time external data high level of automation most of the mills have a data historian access to data and information data analysis software reporting system ✔ ✔ ✔ ✔ ✔ ✔✔
- 12. Slide | 12 ENERGY IS ALREADY IN PEOPLE MINDS managers engineers supervisors operators Big cost monitored (ex TMP) Energy audits Energy projects Awareness campaign Eyes on benchmarks High level reporting Energy manager
- 13. Slide | 13 MILLS HAVE GOOD ORGANIZATIONAL ASSETS Corporate task force Energy team/ manager Green belt programs Process knowledge Continuous improvement Operation challenges Capability building Performance management
- 14. Slide | 14 P&P: GOOD ASSETS FOR EMIS IMPLEMENTATION Strengths Challenges Organization Eyes on energy Hardware/ software
- 15. Slide | 15 COMPLEX PROCESS INTERACTIONS CREATE A GAP BETWEEN DATA AND ACTIONS • Energy account centers • EAC definition is easy… Effective EAC are challenging to define! • Targeting • Rootcauses of variability are difficult to identify • Targeting can become very complex • Simple regression with production is ineffective • Baseload definition does not really make sense • Actions – “So what?” • Lack of targets and actionable parameters • Risk of displacing energy use
- 16. Slide | 16 WHO'S ACCOUNTABLE FOR WARM WATER SYSTEM? PM1 shower water tank PM1 showersT Steam makeup Variability reduction can represent up to a $500,000/year savings L Fresh water PM1 condenser PM1 economizers Hot water tank Kraft mill hot water TMP water heater TMP cooling duties mill excess warm water PM2 economizers PM cooling duties PM effluent heat exchanger T
- 17. Slide | 17 TYPICAL TARGETING IS NOT PRACTICAL Predicting performance during start-ups or shutdowns is irrelevant Predicting “baseload” is irrelevant for continuous process This is the only area where we need performance equation
- 18. Slide | 18 HUMAN CHALLENGES FOR EMIS IMPLEMENTATION • Focus on production • Operations are production-oriented, not cost-focused • Accountability for energy costs • Problem solving culture • Problem solving is based on opinions and experience rather than on facts • Lack of targets and actionable parameters • Resources • Competition with other energy project for $ and people • Lean - “Not another hat”
- 19. Slide | 19 ELECTRICITY VS. STEAM Thermal Electrical – without TMP / GWD Electrical TMP / GWD KPI structure Complex Groups of EAC Often in place Metering vs. EAC and KPI Good Not complete Not consistent Good Targeting Complex More typical APC with focus on quality EMIS implementation Complex (interactions) Complex (actionable param.) Complex (culture) Variability reduction opportunity High Low Medium to high Load management opportunity Depends on marginal fuel Depends on the market Part of it already captured
- 20. Slide | 20 WHAT CAN WE DO NOW? Strengths Challenges Gap between data and actions Operation culture Problem solving culture Resources Organization Focus on energy Hardware/software
- 21. Slide | 21 SUCCESS IS A MIX OF PROCESS EXPERTISE, TECHNOLOGY AND PEOPLE ENGAGEMENT The right tool to the right person at the right time
- 22. Slide | 22 “TURNING EVERYONE INTO A DECISION MAKER. PUSH DECISION-MAKING DOWN TO THE LOWEST LEVEL” -NUCOR OperatorsSupervisorsManagers Impactofdecisiononday-to-dayenergycost Top management commitment with global view on cost control Focus on actionable parameters in the control room
- 23. Slide | 23 EAC IS THE WAY YOU COUNT ENERGY BUT KPI STRUCTURE IS THE WAY YOU MANAGE IT Strategic goals reduce cost by X M$, be energy self sufficient in 5 years, … EAC#2 EAC#3 EAC#4EAC#1 M M M M KPI KPI KPI KPI KPI KPI KPI KPI Tactical level OperatorsSupervisorsManagers Impactofdecisiononday-to-dayenergycost mill manager: $ vs. budget for the last 3 days on his blackberry operator: % valve opening vs. target every hour on DCS
- 24. Slide | 24 LEVERAGE HISTORICAL DATA TO BRING FACTS IN OPERATOR HANDS Actual value of KPI Predicted regimes based on 3+ process variables > 1.1 < 1.1 KPI>1.1 KPI<1.1 A: Performance is good and we know why C: Performance is good “but we do not know why” B: Performance is bad “but we do not know why” D: Performance is bad and we know why Insight to solve the problem 1. CO pre-heater > 15% 2. Temp heating tower < 84,5°C Previously unseen situation! Operator alerts energy team for more investigations
- 25. Slide | 25 CLASSICAL EMIS IMPLEMENTATION SCHEME… Upfront investment for mill wide measurement, IT system, software + service cashflow implementation HEAVY ON RESOURCES AND CASHFLOW
- 26. Slide | 26 IMPLEMENTATION BY PROJECTS PROVIDES BETTER CHANCE OF SUCCESS cashflow implementation Upfront investment for service and minor IT development FIRST PROJECT FOCUS ON AREA WITH THE BIGGEST POTENTIAL Investment for service and some IT, required measurement, software Kickoff project sub-project #2 sub-project #3
- 27. Slide | 27 APPROACH TO SOLUTION – TYPICAL PROJECT Kick off session • KPI structure • Workshops with operators and stakeholders • Process understanding • Data collec?on Data analysis • Explora?on • Rootcause analysis (mul?variate data analysis) • Modeling Implementa3on prepara3on • Test and valida?on of the model off line • Programming of equa?ons and dashboard • Repor?ng structure Implementa3on • Operators training • Stakeholder training • Closing session Immediate actions taken based on performance gap analysis • Awareness • Capability building of plant people • First decisions, first savings • Better knowledge of operation • Optimization rules of the process $$$ $$$ $$$
- 28. Slide | 28 SUCCESS FACTORS ① You’re richer than you think Meters, historian, display, analysis software… ② Top-down approach, bottom-up implementation No accountability without actionable parameters ③ Start implementation with an energy optimization project Pilot: people readiness, potential, data available
- 29. Slide | 29 SUCCESSFUL IMPLEMENTATION! DECISION SUPPORT TOOLS PERFOR- MANCE MONITORING
- 30. Slide | 30 THANK YOU! Visit: www.myenergymaestro.com Sebastien Lafourcade – slafourcade@pepite.ca +1-5124-571-9118