Do you know where
your energy is going

Emerson Energy Advisor

Monitoring

Measurement

Mapping

Management

Multiple energy sources
Lots of measurement devices
Data streams that converge into
software/analytics that create
alerts and reports

Emerson Energy Advisor

Energy Management
Information System (EMIS)

What is an Energy Management Information System?

  • Collects measurements and helps you manage energy
  • May be as simple as spreadsheets, or as powerful as a graphics-based system
  • Provides fundamental information for decisions affecting your energy use

Why Do I Want An EMIS?

Reduce total energy costs by 5% - 10%
(or usually more)

  • Gives you the information to make timely decisions about your organization's energy use
  • Establish, track and maintain real and achievable targets for energy reduction

Create an "Energy Culture" within your organization

  • Management
    • Set/enforce energy goals as a critical priority
    • Set key performance indicators (KPIs)
    • Set budgets for energy reduction
    • Prioritize energy projects
  • Operations
    • Establish accountability, contribution
    • Operate to energy KPIs
    • Know when your energy use is high, and why

Establish a reputation for sustainability

  • Implement a positive corporate social responsibility program for energy savings and emissions reduction

Why Do I Want An EMIS?

Create an "Energy Culture" within your organization

  • Management
    • Set/enforce energy goals as a critical priority
    • Set Key Performance Indicators (KPI's)
    • Set budgets for energy reduction
    • Prioritize energy projects
  • Operations
    • Establish accountability, contribution
    • Operate to energy KPI’s
    • Know when your energy use is high, and why

Why Do I Want An EMIS?

Establish a reputation for sustainability

  • Implement a positive corporate social responsibility program for energy savings and emissions reduction

Energy Advisor Advantages

Simple to Use

Scalable

Sustainable

How Does It Work?

Energy Advisor includes five modules for managing energy productivity.

View energy
performance
and KPIs

Drive energy
saving
behavior

Create
Dynamic
Energy Targets

Create a
unique energy
hierarchy

Verify
energy data
values

What Can I Expect?

Bleach or Steam?

How a paper mill determined the cost efficiency between fuel and chemicals.

Minding the Capacitor Banks

Above-target consumption prompts a facility to check whether capacity banks can be switched off.

Taking a Cold Hard Look

A petrochemical facility in a northern climate is able to calculate the effect of cold temperatures on the product stream.

A Tale of Two Boilers

A paper mill discovers how to get twice as much steam from the same amount of natural gas.

The Department of Redundancy Department

How many backup pumps does a facility really need?

Not the Usual Suspect

An over-pressurized header costs a refinery thousands of dollars a day until Energy Advisor shows them the real cause of the problem.

What is the value of Energy Advisor in your plant?

The default values in the table below represent a real world case of Energy Advisor software combined with top down management
commitment to reduce waste and emissions. Replace the values with numbers from your plant to estimate the value to your plant.

$

Enter total annual energy
spend (1,000’s of US$)

Enter estimated energy cost
(US$ per MMbtu)

Use this number or enter your
own value
(metric tons CO2/MMBTU)

Enter a value representing your
expected energy/emissions
reduction (%)

Your calculated CO2 reduction is (metric tons/yr):
Your calculated energy waste reduction (mmbtu/yr) is:
Value of energy you will not buy; 1,000’s of US$ to the bottom line:

Be advised total savings from an Energy Management Program are dependent upon a number of factors ranging from quality of measurements to management
commitment. Actual results may vary; the outcome from these calculations do not represent a commitment from Emerson Process Management.

EMIS Components

Hardware

Database

Software

EMIS Components

Hardware

Database

Software

Target

Monitor

Report

EMIS Components

EMIS Components

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PERFORMANCE REPORTS

HISTORICAL INFORMATION

ENERGY AND COSTS

OTHER SYSTEMS

Deliverables

  • Report energy key performance indicators (KPIs) at any level in the plant hierarchy (from plant floor to engineering to C-suite)
  • Effective performance reporting
  • Auditing of historical operations
  • Evidence of savings/reduction success
  • Energy data for other systems

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REDUCE UNPLANNED OUTAGES

SEE YOUR SAVINGS

Business Results

  • Get early detection of poor performance
  • Support energy budgeting and management accounting
  • Identify and justify energy projects
  • Understand patterns of overconsumption
  • Uncover energy saving opportunities and identify priorities
  • Make more informed decisions

ISO 50001 Energy Management System Standard

EU Emissions
Trading
Scheme

And the EU Emissions Trading Scheme (ETS):

  • Prepare and carry out a monitoring plan
  • Submit emissions reports
  • Buy (or sell) allowances
  • ETS rewards efficient plants with a potential revenue stream

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ISO 50001 Energy Management System Standard

ISO
50001

Achieve certification standards such as ISO 50001:

  • Framework for energy management system
  • Create an energy culture

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Compliance with European Climate Change Policy

EU
2020

What is it?

  • Legislative framework for European Union, to meet EU “2020” targets (20% reduction in greenhouse gas emissions, 20% of energy from renewables, 20% reduction in energy consumption.)
  • Encourages industry to implement energy management systems and undergo regular energy performance audits

Compliance with European Climate Change Policy

EU Energy
Efficiency
Directive

Energy Advisor helps you meet regulatory compliance, such as the EU Energy Efficiency Directive (EED):

  • Must do regular energy audits
  • Lead to energy saving projects
  • Implement energy management systems and adopt best practices

Compliance with European Climate Change Policy

EU Emissions
Trading
Scheme

And the EU Emissions Trading Scheme (ETS):

  • Prepare and carry out a monitoring plan
  • Submit emissions reports
  • Buy (or sell) allowances
  • ETS rewards efficient plants with a potential revenue stream

Compliance with European Climate Change Policy

ETS

EU Emissions Trading Scheme (ETS)

  • Industrial installations are required to monitor and report their annual emissions in accordance with legally binding guidelines adopted by the European Commission
  • Submit and carry out a monitoring plan
  • Prepare, verify, and submit an emissions report
  • Buy or sell “CO2 allowances” to comply with limits

ISO 50001 Energy Management System Standard

EU Emissions
Trading
Scheme

And the EU Emissions Trading Scheme (ETS):

  • Prepare and carry out a monitoring plan
  • Submit emissions reports
  • Buy (or sell) allowances
  • ETS rewards efficient plants with a potential revenue stream

Compliance with European Climate Change Policy

ISO
50001

ISO 50001

  • Provides a framework of requirements to monitor, target and report energy use
  • Specifies that an energy management system follows a systematic approach of continual energy performance improvement

Energy Advisor Advantages

SCADA

Process Control

Power Management

Enterprise Networks

AREAS

PROCESSES

UNITS

Simple To Use

  • Easy to set up and configure
  • Easy to use on a daily basis
  • Simple to get the information you need

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Energy Advisor Advantages

Scalable

  • View energy use throughout five levels of process hierarchy
  • Start small, then grow
  • Track all kinds of energy: Water, Air, Gas (Fuel), Electricity, Steam
  • Simple and affordable to add measurement points
  • Wireless

Energy Advisor Advantages

Wireless

  • Energy Advisor connects directly to the wireless gateway
  • Wireless installation makes it easy to add measurement points, even in difficult or remote locations
  • Emerson Smart Wireless field instruments automatically join the self-organizing wireless network
  • Wireless measurements include Flow, Temperature, Pressure, Amperage

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Energy Advisor Advantages

Sustainable

  • Future-proof
  • Easy to maintain by yourself
  • Far superior to a spreadsheet

Energy Advisor Advantages

Replace Your Spreadsheets

  • Save time and effort
  • Reduce dependency on the spreadsheet “owner” – expand the energy culture
  • Process hierarchy defines how energy use is aggregated up to higher levels automatically
  • Reduce errors
    • Eliminate manual data collection
    • Work with easy-to-follow calculations and reports
    • Get reports via web-based interface on demand or on a schedule
    • Standard reports include:
      • Cost Per Unit of Production
      • Energy Key Performance Indicator Status

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What Can I Expect?

BLEACH OR STEAM?

In a pulp mill, the inlet temperature to the oxygen de-lignification tower must be kept constant to ensure consistent bleaching of the pulp stock for a given application of bleaching chemical—in this case, oxygen.

The temperature target is determined by the process designer, but small fluctuations in control loop setpoint are up to operator discretion. Setting the temperature up a few degrees can save bleaching chemical, while setting it down a few degrees can save steam.

The pulp mill operation manager knows exactly how much bleaching chemicals cost, but the impact of steam is not as “real.” Even if there are internal charges from the powerhouse, they are typically done monthly and do not address incremental costs. The impact of operating temporarily away from the design inlet temperature is not readily apparent.

When the plant implemented Energy Advisor, the trade-off between bleaching chemicals and steam became apparent in real time.

It turned out that changing the temperature by even 2° Celsius could impact energy costs by $60 per hour when the incremental steam is generated by firing natural gas. The savings in bleaching chemicals by increasing inlet temperature can be completely eclipsed by the cost of steam, depending upon the fuel!

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What Can I Expect?

MINDING THE CAPACITOR BANKS

Facilities with large AC motors often must use banks of capacitors to keep the plant power factor closer to unity. These capacitor banks are typically turned on and off manually— rarely is the power factor controlled automatically.

A process facility using Energy Advisor had difficulty coming up with a single equation to develop the electrical target calculation. The dynamic gain of electric use vs. production rate was constant, but the offset (which represents the base electrical use with the plant down) seemed to differ depending upon the data set selected for analysis.

The process engineer thought the bias value should always be constant. How can the base level electrical use change from day to day?

He shared his finding with the operators, who pointed him to the capacitor banks used to adjust the power factor in the plant. They should only be switched on if the plant’s big motors are running, but with all that is going on when things are shut down, sometimes the operators would neglect to switch off the capacitor banks. No wonder the base level electrical use seemed to change from day to day!

Energy Advisor now acts as a not-so-subtle reminder to those operators. When energy use is above target, they look to see if any capacitor banks can be switched off. Without that real-time insight, the extra energy consumed due to excessive power factor correction is out of sight and out of mind.

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What Can I Expect?

TAKING A COLD HARD LOOK

The layout of many petrochemical facilities requires the transfer of product and/or utility streams between units. Often, the impact of heat loss due to changes in ambient temperature is overlooked.

A facility in a northern climate used Energy Advisor to create the calculations for steam usage in a blending process. The process engineer discovered that ambient temperature had a surprisingly high gain factor on the resulting equation.

A bit more digging revealed that the temperature drop on the product stream could be as high as 12° Celsius.

This information provided clear justification to upgrade the pipe insulation and to understand how to prioritize this project against other cost-saving initiatives.

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What Can I Expect?

A TALE OF TWO BOILERS

In Kraft pulping facility, the recovery boiler is used to process “black liquor” to recover the pulping chemicals and produce steam as a byproduct. Most pulping facilities also have a biomass boiler, and it is not unusual to operate for extended periods of time without having to fire auxiliary fuels such as natural gas or oil.

Although it is generally known that recovery boilers are more efficient than biomass boilers, the operating procedures for firing the auxiliary fuel may not reflect that knowledge.

Energy Advisor helped one facility truly understand the cost of firing natural gas on the biomass boiler instead of the recovery boiler when the process engineer found the gain factor on the recovery boiler to be twice that of the biomass boiler. Energy Advisor predicted twice as much steam from the same amount of natural gas when that gas was fired in the recovery boiler!

There are still legitimate process reasons to fire natural gas in the biomass boiler, but this facility is re-working their SOPs to favor use of natural gas in the more efficient unit, with immediate savings as a result.

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What Can I Expect?

THE DEPARTMENT OF
REDUNDANCY DEPARTMENT

Keeping a constant vacuum on a condensing unit is critical for operation within chemical processing facilities.

Losing the vacuum can mean not only the loss of condensate, but can cause a cascade effect, tripping multiple units.

One facility lowered the risk of this catastrophic event by running five vacuum pumps simultaneously. But during a maintenance window with only three pumps running, the true cost of running all five pumps (when three can do the job) could easily be determined.

Energy Advisor was used to quantify that significant savings could be had by even shutting down one pump. The new SOP is to have one spare pump online and one offline with immediate savings as a result.

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What Can I Expect?

NOT THE USUAL SUSPECT

The steam systems in an industrial facility can be quite complex, with multiple headers, let-down stations, boilers, and steam turbine generators used to balance generation and consumption.

And while steam vent valves often open to relieve pressure during process upsets, it’s neither desirable nor typical to have them open all the time. If a steam vent cannot be closed without the header over-pressurizing, then something is out of balance. But what?

This problem was costing a refinery in the Middle East several thousand dollars a day. As the problem occurred following a major controls upgrade, everyone blamed the controls.

But the culprits were actually mechanical failures: a failed check valve on the de-aerator receiver and a partially open let-down valve. Both failures caused steam to escape into the low pressure header, causing an imbalance. The purpose of the de-aerator check valve was to allow steam to flow only out of the header, so the impact of the failure was major.

Without the visibility provided by real-time energy monitoring, this problem went undiagnosed for several months, costing the facility many times the investment of an energy management information system.