Energy Management

1. Energy Management Building your Foundation with Energy Measurement Joel Lemke Flow Specialist

2. The Energy Improvement Process Begin Survey and Measure Implement Site Management Fix Devices and Loops Optimize Unit Processes Address Equipment

3. Proper Flow Metering is Part of All Energy Management Actions • More accurate & repeatable Fuel/Air (mass) flows • Flexible metering technology • Balance/know energy consumption by use point • Mass balance of utilities • Output flow measurement for each boiler, compressor, chiller

4. What is Included in a Good Energy Measurement Plan? BTUs

5. Balance & Benchmark • Objective: Benchmarking to identify areas for energy improvement • To benchmark, must energy balance first • Energy In = Energy Out • All energy (used or else) must be accounted for • If data is not reliable, it won’t be used

6. Types of Energy • Energy consuming systems & processes use: • Electricity, Fuel, Compressed Air, Steam, water • Each Energy System needs to be analyzed to identify opportunities for improvement • Each Process Unit needs to be analyzed to identify opportunities for improvement

7. Balance & Benchmark • Start by listing: • All major systems • All major processes/usage areas • Then develop Energy Envelopes for each • Boilers / steam • Electrical (includes lighting, motors, drives, controls) • CW systems • HVAC • Compressed air • Major Process Units

8. Energy Balance • Major process units • Pulp & Paper • Paper machine, • Coating • Pulp mill • Refining • Cat cracker • Coker • Hydrocracker • Steel Mill • Coke plant • BF • BOF • Caster • HSM Energy In = Energy Out Electrical Steam Chilled water Compressed air Gas Additional Utilities

9. Energy Management “If you want to Manage it you have to Measure it”

10. Select the Right Flowmeter for the Application Economic Factors FluidProperties Performance Installation Application Control Monitor Indicate Batching Custody Transfer Liquid, Gas, Steam Conductivity Multi-phase Viscosity Pressure Temperature Wetted parts Accuracy Repeatability Temperature Effect Response Time Line Size Vibration Pipe Runs Submergence Cost Installation Reliability Maintenance Environmental & Safety Meter Selected Emissions Hazardous Waste Leak Potential Shut Down System? Coriolis DP Flow Magnetic Vortex Other Flow Solutions

11. Energy Management Best Practices VS. • Line Size: 60” • Weight: 50 lbs • Cost: $17,000 • Line Size: 60” • Weight: 300 lbs • Cost: $68,000

12. Energy Management Best Practices VS. • Line Size: 60” • Weight: 50 lbs • Cost: $17,000 • Line Size: 60” • Weight: 300 lbs • Cost: $68,000

13. Source #2: Primary Element Source #1: P&T Variation Mass Flow in Gas, Steam & Unstable Liquids 3 sources of error make traditional flow measurement inaccurate in Gas and Steam applications Flow Coefficients not constant Pressure & Temperature variation in Gas & Steam Source #3: Transmitter Installed performance of transmitter over flow range

14. Measure Mass Flow 40.9 gal (154.8 L) 42.0 gal (159.0 L) 2.7% 20º F (-6.7º C) 60º F (15.6º C) 342 lb (155.1 kg) 342 lb (155.1 kg) 0.0% • Mass (Energy) is Conserved, • Volume is not

15. Flow = K * DP * r Measure Mass Flow in Gas When Density Changes Pressure at the source does not equal pressure at the destination Regulator P = 40 psi 20 ft P = 39.08 ± 1.05 psi Natural Gas Example: 2 inch pipe Flow rate = 10,000 SCFH Density compensation improves flow performance Pressure and Temperature Variation Compensation Max Variation <0.1% MultiVariable Regulator Droop Manufacturer’s Specification 0.55 psi 1.0% Uncompensated DP 1.5% SQRT is to the 1/2 power Pipe Friction* 20 ft pipe2 elbows 0.44 psi 1.1% Uncompensated Velocity 3.0% Flow = V * Constantρflow Barometric Variation Typical variation 0.5 psi 0.9% 0 1 2 3 4 * Per Crane Handbook Total 1.49 psi 3.0% % Error

16. Multivariable Mass Flow for Natural Gas, Steam, Air & other gases WE CALCULATE: • Density • Viscosity • Velocity • Beta Ratio • Enthalpy • Gas Expansion • Discharge Coefficient • Velocity of Approach • Reynolds Number • Compressibility Factor WE MEASURE: • Differential Pressure • Static Pressure • Process Temperature YOU RECEIVE: YOU ENTER: • Mass Flow • Energy Flow • Volumetric Flow • Totalized Flow • Process Temperature • Differential Pressure • Static Pressure • Process Fluid • Primary Element • Line Size

17. Coriolis Elite Mass Flow Meters Gas MeasurementBoosting Combustion Control • Challenge • Fuel gas composition varied considerably. • Fixed F/A ratio led to hot spots & NOx when fuel Btu rose. • Reduced production to 80% capacity to prevent the hot spots & NOx. • Overall plantcapacity reduced due to less steam production. • Solution • Coriolis direct mass meter installed on main fuel line. • Outcome • Better measurement enabled automatic cascade control. • Production increased to nearly 100% capacity. • Hot spots and NOx reduced greatly.   NG RFG 

18. Energy Management Best Practices VS. • Line Size: 60” • Weight: 50 lbs • Cost: $17,000 • Line Size: 60” • Weight: 300 lbs • Cost: $68,000

19. Correct Installation of the Flowmeter is Critical for Accuracy VS

20. Typical DP Flow Straight Run Requirements 10 Diameters Upstream 5 Diameters Downstream 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10

21. Required Straight Pipe for O-Plates • Measurement of fluid flow in pipes using orifice, nozzle, and venturi • ASME MFC-3M-2004

22. Rosemount Conditioning Orifice Technology • Ideal for both new and retrofit DP flow applications • Requires only 2D of straight pipe upstream and 2D downstream from any flow disturbance • Up to 90% reduction of piping from standard orifice installations The four orifice holes act as a flow conditioner and primary element in one device Geometry conditions the flow profile across the entire pipe

23. Conditioning Plate for Short Run Applications • Typical air to fuel ratio of 10:1 • 4” gas line typically has a 12 or 14” air line • After elbow, 60 pipe diameters (60 feet) required for a 0.6 beta o-plate • Performance degradation rule of thumb: • Installed perf. = Perf. / % of recommended straight pipe • 2% device has 50% of recommended straight pipe • Installed perf. = 2% / 0.50 = 4%

24. Direct Mounting Reduces Maintenance…and Improves Consistency & Accuracy Traditional Installation DP Flowmeter Installation Eliminates inaccuracies Consistent installations Reduced complexity Leak points reduced No leak testing • Instrument Tubing is 10 to 20 feet long, plus several elbows • Increased potential leak points and plugging • Transmitter is direct-mounted less than 1 foot from the pipe, with straight connections • Reduces potential leak points and plugging

25. Removing Leak Points Saves Time and MoneyDirect Mounting Reduces Leak Points • $1214/year energy* per leak PLUS: • Value of lost process fluid • Personal safety and risk • Environmental cost, impact • Cost of inaccurate measurement • Maintenance cost of repairing leaks All but 2 potential leak points factory leak-checked. *75 psig steam; 1/16” diameter leak; $10 per 1000 lb steam *U.S. Dept. of Energy Office of Industrial Technologies www.oit.doe.gov/bestpractices

26. 3-Year User-Study* Finds Implementing Direct Mount Technology Pays Off • 3000 applications over 3 years resulted in only 6 work orders • 90% reduction in work orders • 46% reduction in total maintenance cost * Copy of study available from Rosemount. Document 00802-0100-2071

27. Why is Condensate Drainage Important? • Flow meters designed for single-phase (liquid or gas, not both) • Condensate in steam reduces effective pipe area • Water hammer possible if too much liquid build up • Water heat transfer terrible compared to steam!

28. DP xmtr Aluminum Recycler Flow Meter Audit Background: • North Plant • reverbs 1, 2, 7 & 8 • 2 burners/reverb • Air & gas flows on each reverb (except #2) • Є Calculations > 100% • 3rd party out to calibrate twice & found no issues w/ xmtrs ¼” water leg imbalance = 12.5% flow rate error at 1 inH2O DP

29. Aluminum Recycler Flow Meter Audit Findings: • XMTRs mounted below pipe - moisture accumulated • (2) Orifice plates installed backwards • Some O-plates sized for flange tapping, but installed as D, D/2 • Not one air meter had enough straight pipe • Sizing based on nominal pipe size, not actual pipe ID • 1 sized for a 3.5” pipe instead of a 4” • flow error = 6.5% • All natural gas sizings used SG = 0.87 • Correct specific gravity = 0.60 • flow error = 20.4% Correct 20% low Fixing the issues corrected the plant energy balances.

30. Energy Management Best Practices VS. • Line Size: 60” • Weight: 50 lbs • Cost: $17,000 • Line Size: 60” • Weight: 300 lbs • Cost: $68,000

31. Flow Meter Pressure Loss Potential Waste of Energy Blowers FT4 Use Point #1 FT2 PL4 FT5 PL2 FT1 Use Point #2 Energy In PL5 FT6 PL1 Use Point #3 FT3 . . . PL6 FT7 PL3 Use Point n PL7 • Copper Smelting Example: • Orifice plate pressure losses (PPL) were bottleneck to proper air delivery to “converters” (remove impurities from molten Cu) • Replacement with alternate meters maintained control and nearly eliminated PPL • Required Blower discharge pressure dropped from 21 to 16.5 psi $500k annual reduction in electricity to blowers

32. Energy Savings Results • Chilled water flows • (7) 10” lines, 0-4000 GPM • (7) 14” lines, 0-5000 GPM • Existing DP/orifice plates

33. Energy Savings QBR (pros & cons)

34. Energy Management Best Practices VS. • Line Size: 60” • Weight: 50 lbs • Cost: $17,000 • Line Size: 60” • Weight: 300 lbs • Cost: $68,000

35. Energy Management Infrastructure Production Unit 1 • Strategic Business Decisions • Who are the big users? • Who is inefficient? • Over time, who is becoming inefficient? Report Data (bldg. or dept. ownership) Analyze Data (Btu/sq. ft. or Btu/ton, etc. data) Collect Data Production Unit 2 ROI Driven Actions Production Unit n

36. Powerhouse • Steam Distribution • Operating Units • Desired Measurement Points

37. Process Today • Points critical for control and safety are wired • Often just 4-20mA • No Diagnostics • High value monitoring points wired • Remaining points manually collected Only about 30% of engineer’s wish list automated…

38. Process Pains • Wired Points • ROI justification is high due to installation costs • Diagnostics are often missing due to legacy host systems • Automation is limited by the economics of wires • Corollary: Process efficiency, safety, uptime, are limited by the economics of wires. • Manual Points • Exposes user to process environment • Exposes measurement to human error • Fatigue, double entrees, repeatability • Time consuming • Mundane routines, wasted human capability collecting data instead of solving problems In addition to process, automation needs exist for safety, reliability, maintenance, utilities, asset protection and more.

39. Achieving real-time data • Wireless is a truly scalable instrument technology • Start as small as a single gateway and 5 instruments • Gateway • Capacity for 100 points • 4 second to 60 minute updates • IEC 62591 wirelessHART standard • Ideal for (energy) monitoring applications Emerging customer trend: wireless networks 3X larger than originally intended due to scalability.

40. Hydrocarbon Leak Detection 702 Discrete 6081C Conductivity Smart Wireless Gateway Smart Wireless THUM Adapter 6081 pH 648 Temperature 848T Multi Input Temperature 2160 Vibrating Fork Liquid Level Switch 4300 Series Position Monitor CSI 9420 Vibration 3051S Series Pressure, Level & Flow Complete portfolio exists to solve problems in real-time Create sustainable, sharable, repeatable solutions

41. Pulp & Paper Mill - Wireless Energy Monitoring Implementation Option 1 • Option 2 • Total Measurement Points: • 15 • Total Measurement Points: • 60 • $5.5k / point • $20k / point!

42. Summary: What is Included in a Good Energy Management Plan? • Balance & benchmark: Energy envelopes for energy systems and process units • Accurate sub metering of all utilities: Electric, steam, water, compressed air, gas) • Take into account all factors that affect performance • Consider turndown • Install flowmeter correctly, maintain flowmeter • Select flowmeters with minimal PPL: Reduce energy consumption • Real-time, cost effective information: Wireless

43. Energy Management “If you want to Manage it you have to Measure it” Questions?