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

Energy ManagementEnergy ManagementBuilding your Foundation with Energy Measurement

Joel Lemke

Flow Specialist

[File Name or Event]Emerson Confidential27-Jun-01, Slide 2

Emerson ConfidentialSlide 2

Implement Site Management

Optimize Unit Processes

The Energy Improvement ProcessThe Energy Improvement Process

Survey and Measure

Fix Devices and Loops

Address Equipment

Begin



Proper Flow Metering is Part of All Energy Management ActionsProper Flow Metering is Part of All Energy Management Actions

Metering Needs:

Optimized Combustion Control to

reduce excess O2

Enhanced Compressor

Control

Reduce Pressure Losses

Flexible Fuel – Maximize use of

Low Cost

Loading Balance – Run

the Most Efficient

Equipment Fix Insulation Issues

Increase Condensate

Returns

Repair Leaks

Steam Trap Maintenance

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



What is Included in a Good Energy Measurement Plan? What is Included in a Good Energy Measurement Plan?

Accurately Measure All

Utilities

Establish Benchmarks for Energy In

vs. Energy Out

Automate Data Collection

BTUs

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Balance & BenchmarkBalance & 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



Types of EnergyTypes 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



Balance & BenchmarkBalance & 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



Energy BalanceEnergy 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 OutElectricalSteamChilled waterCompressed airGasAdditional Utilities



Energy ManagementEnergy Management

“If you want to Manage it you have to Measure it”



Application FluidProperties

Performance Installation EconomicFactors

Environmental& Safety

MeterSelected

Liquid, Gas, SteamConductivityMulti-phaseViscosityPressureTemperatureWetted parts

AccuracyRepeatabilityTemperature EffectResponse Time

Line SizeVibrationPipe RunsSubmergence

CostInstallationReliabilityMaintenance

EmissionsHazardous Waste Leak PotentialShut Down System?

ControlMonitorIndicateBatchingCustody Transfer

Flow Solutions

CoriolisDP FlowMagneticVortexOther

Select the Right Flowmeter for the ApplicationSelect the Right Flowmeter for the Application



Energy Management Best PracticesEnergy Management Best Practices

Minimize Pressure Loss

Save on EnergyOptimize Performance

Correct Flowmeter Installation Automate Data Collection









3 sources of error make traditional flow measurement inaccurate in Gas and Steam applications

Source #1: P&T Variation

Pressure & Temperature variation in Gas & Steam

Source #2: Primary Element

Flow Coefficients not constant

Source #3: Transmitter

Installed performance of transmitter over flow range

Mass Flow in Gas, Steam & Unstable LiquidsMass Flow in Gas, Steam & Unstable Liquids



Measure Mass FlowMeasure Mass Flow

40.9 gal(154.8 L)

42.0 gal(159.0 L)

60º F (15.6º C)20º F (-6.7º C)

342 lb (155.1 kg)

342 lb (155.1 kg)

2.7%

0.0%

Mass (Energy) is Conserved,

Volume is not



* Per Crane Handbook

Measure Mass Flow in Gas When Density Changes Measure Mass Flow in Gas When Density Changes

20 ft

Manufacturer’s Specification

20 ft pipe2 elbows

Typical variation

0.55 psi 1.0%

0.44 psi 1.1%

0.5 psi 0.9%

Total 1.49 psi 3.0%

Max Variation

RegulatorP = 40 psi

P = 39.08 ± 1.05 psi

RegulatorDroop

PipeFriction*

BarometricVariation

% Error

Pressure at the source does not equal pressure at the destination

Density compensation improves flow performance

Natural Gas Example:2 inch pipeFlow rate = 10,000 SCFH

3.0%

1.5%

<0.1%

Flow = K * DP * r

Flow = V * Constant ρflow

SQRT is to the 1/2 power

Pressure and Temperature Variation Compensation

MultiVariable

Uncompensated DP

Uncompensated Velocity

0 1 2 3 4

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Multivariable Mass Flow for Natural Gas, Steam, Air & other gasesMultivariable 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

YOU ENTER:• Process Fluid• Primary Element• Line Size

• Mass Flow• Energy Flow

• Volumetric Flow• Totalized Flow

• Process Temperature• Differential Pressure

• Static Pressure

YOU RECEIVE:

WE MEASURE:• Differential Pressure• Static Pressure• Process Temperature



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 plant capacity 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.

Gas MeasurementBoosting Combustion ControlGas MeasurementBoosting Combustion Control

Coriolis Elite Mass Flow Meters

NGRFG









Correct Installation of the Flowmeter is Critical for AccuracyCorrect Installation of the Flowmeter is Critical for Accuracy

VS

Eliminate Impulse Lines

Adequate Straight Pipe Run

Orifice Plate Alignment &

Pipe ID Uncertainty

Proper steam conditioning



Typical DP Flow Straight Run RequirementsTypical DP Flow Straight Run Requirements

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5

10 Diameters Upstream

5 Diameters Downstream



Required Straight Pipe for O-PlatesRequired Straight Pipe for O-Plates

Measurement of fluid flow in pipes using orifice, nozzle, and venturi

ASME MFC-3M-2004



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

Rosemount Conditioning Orifice TechnologyRosemount Conditioning Orifice Technology

Geometry conditions the flow profile across the entire pipe

The four orifice holes act as a flow conditioner and primary element in

one device



Conditioning Plate for Short Run ApplicationsConditioning 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%



Direct Mounting Reduces Maintenance…and Improves Consistency & AccuracyDirect Mounting Reduces Maintenance…and Improves Consistency & Accuracy

Eliminates inaccuraciesConsistent installationsReduced complexityLeak points reducedNo leak testing

Traditional Installation DP Flowmeter Installation

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



Removing Leak Points Saves Time and Money Direct Mounting Reduces Leak PointsRemoving Leak Points Saves Time and Money Direct Mounting Reduces Leak Points

All but 2 potential leak points factory leak-checked.

$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

*U.S. Dept. of Energy Office of Industrial Technologieswww.oit.doe.gov/bestpractices

*75 psig steam;1/16” diameter leak;$10 per 1000 lb steam



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

3-Year User-Study* Finds Implementing Direct Mount Technology Pays Off3-Year User-Study* Finds Implementing Direct Mount Technology Pays Off



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!

Why is Condensate Drainage Important?Why is Condensate Drainage Important?



Aluminum Recycler Flow Meter AuditAluminum Recycler Flow Meter Audit

¼” water leg imbalance = 12.5% flow rate error at 1 inH2O DP

DP xmtr

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



Aluminum Recycler Flow Meter AuditAluminum Recycler Flow Meter AuditFindings: 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.









Flow Meter Pressure Loss Potential Waste of EnergyFlow Meter Pressure Loss Potential Waste of Energy

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

.

.

.

Blowers

PL1

PL2

PL3

PL4

FT1

FT3

FT2

PL5

FT4

FT5

FT6

FT7

PL6

PL7

Energy In

Use Point #1

Use Point #2

Use Point #3

Use Point n



Energy Savings ResultsEnergy Savings Results

Chilled water flows

(7) 10” lines, 0-4000 GPM

(7) 14” lines, 0-5000 GPM

Existing DP/orifice plates



Energy Savings QBR (pros & cons)Energy Savings QBR (pros & cons)

14" Line Comparison DP/O-Plate DP/Annubar Magmeter

Performance @ Normal Flow 0.60% 0.90% 0.30%

Turndown with +/- 2% Perf. 6 to 1 5 to 1 33 to 1

Performance @ 10:1 Turndown 8.25% 5.00% 1.00%

PPL @ Normal Flow 5.3 psi 2.1 psi 0 psi

PPL Cost at Normal Flow $8,572 $3,402 $0

PPL Savings @ Normal Flow X $5,170 $8,572

Required Straight Run 56' 16' 8'

Installed Cost $10,450 $7,260 $16,290

ROI X 27.6 mo. 29.4 mo.






Correct Flowmeter Installation

Automate Data Collection



Energy Management InfrastructureEnergy Management Infrastructure

Strategic Business Decisions

Who are the big users?

Who is inefficient?

Over time, who is becoming inefficient?

ROI Driven Actions

Collect Data

Analyze Data (Btu/sq. ft. or Btu/ton, etc.

data)

Report Data (bldg. or

dept. ownership)

Production Unit 1

Production Unit 2

Production Unit n



Powerhouse

Steam Distribution

Operating Units

Desired Measurement Points



Process TodayProcess Today

Only about 30% of engineer’s wish list automated…

Points critical for control and safety are wired

Often just 4-20mA– No Diagnostics

High value monitoring points wired

Remaining points manually collected



Process PainsProcess Pains

In addition to process, automation needs exist for safety, reliability, maintenance, utilities, asset protection and more.

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



Achieving real-time dataAchieving real-time data

Emerging customer trend: wireless networks 3X larger than originally intended due to scalability.

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



Complete portfolio exists to solve problems in real-timeComplete portfolio exists to solve problems in real-time

Smart Wireless THUM Adapter

Hydrocarbon Leak Detection

648 Temperature

CSI 9420 Vibration

6081 pH

702 Discrete

2160 Vibrating Fork Liquid Level Switch

4300 Series Position Monitor

3051S SeriesPressure, Level & Flow

848T Multi Input Temperature6081C Conductivity

Smart Wireless Gateway

Create sustainable, sharable, repeatable solutions



Pulp & Paper Mill - Wireless Energy Monitoring ImplementationPulp & Paper Mill - Wireless Energy Monitoring Implementation

Option 1 Option 2

Total Measurement Points:

15Total Measurement Points:

60$5.5k / point

Wired Flowmeter Cost

Flowmeter $75,000

Wiring/Conduit $225,000

$20k / point!

Wireless Flowmeter Cost

Flowmeters $300,000

Gateways $12,000



Summary: What is Included in a Good Energy Management Plan?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



Energy ManagementEnergy Management

“If you want to Manage it you have to Measure it”

Questions?

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