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Financed Case: Industrial EE Financing: EE VSD’s Werner Bouwer, Director, Enoveer
Citation preview
IDC/KfWShowcase on
Industrial Energy Efficiency
ENOVEEREngineering Innovation
Thank You
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Overview
o Company Profileo Enoveer Offero Implementation Processo Case Study
Variable Speed Drives
o Challengeso Success Factors
Company Profile
o Enoveer Engineering Innovation - 2010o Partners
• Deon Arndt (PhD Eng) • Werner Bouwer (PhD Eng) (Pr Eng)
o Services Energy Optimisation (Energy Management) Thermo-hydraulic design, simulation and analysis
o Industries Nuclear Mining Industrial Commercial
o Total Partner Experience of 30 yearso Quality vs. Quantity
Enoveer Offer
o Enoveer primarily focuses on establishing energy savings partnerships, through energy efficiency interventions with medium to large industrial energy consumers.
o Enoveer offers energy savings partnership financially incentivised by the ESKOM Integrated Demand Management (IDM) Standard Offer Programme (SOP).
Enoveer Offer
o Enoveer conducts the investigations, develops savings strategies, acts as ESKOM IDM project developer, designs the systems, appoints the contractors, manages the installation and manages the energy savings for three years.
o Enoveer funds up to 100% of the total project capital (partner in energy savings).
o Enoveer takes all the ESKOM IDM rebates and all the energy cost savings until a 100% return on investment is realised.
o The savings are calculated against a pre-determined baseline by an independent Measurement and Verification (M&V) group.
o Exit point for client if the investigation outcome not feasible, no cost for client , IP of investigation stays with Enoveer.
Implementation Process
1. The client signs the letter of intent/contract to initiate the project.
2. Enoveer conducts the energy savings investigation.
3. Enoveer presents the findings to the client for approval (exit point, no cost).
4. The client and Enoveer sign an Energy Services Agreement.
5. Enoveer submits a formal proposal to ESKOM IDM for approval.
6. Independent Measurement and Verification (M&V) measures and proposes energy baselines.
7. Enoveer manages the tender process.
8. The client and Enoveer sign the Project Scope Agreement.
9. ESKOM IDM and Enoveer sign the Standard Offer Contract.
10.Enoveer appoints the installation contractors.
11.Enoveer manages the installation of the energy savings strategies.
12.Enoveer manages energy savings over the three year period.
Case Study
o Enoveer was contracted by Xstrata Alloys to assist with energy savings investigations of the excess gas fans of the Premus plant located at the Lydenburg site.
o The investigation was conducted under the ESKOM IDM Standard Offer Program where Enoveer acts as the project developer.
Xstrata Alloys – Excess Gas Fans
Case Study
Xstrata Alloys – Excess Gas Fans
Case Study
Xstrata Alloys – Excess Gas Fans
Case Study
Xstrata Alloys – Excess Gas Fans
o The excess gas fans are responsible for drawing hot gas through Kiln A and Kiln B of the Premus plant.
o The gas moves through two cyclones for dust removal before entering the fans. The gas finally exhausts to the atmosphere through a bag filter plant.
o Inlet fan dampers are controlled to maintain the required gas mass flow rate through the kilns. Fan electrical motor power is used as control feedback signal.
Case Study
Xstrata Alloys – Excess Gas Fans
From Kiln A
93 kg/s
-5.56 kPa
115 °C
To Start UP FCE
To Filter Plant
-3.63 kPa 45% 1.00 kPa1453 kW
Cyclones
Control
50%
41%63%
Case Study
Excess Gas Fan Kiln A
o Actual measurements from the plant was taken to ensure high fidelity for accurate energy saving predictions.
o Simulation models for Kiln A and Kiln B were configured in Enoveer’s own developed Transient Computational Fluid Dynamics Code Enoflux to calculate the potential for energy savings.
Case Study
Investigation Measurement
Case Study
Investigation Simulation
o The fan inlet air dampers of Kiln A and Kiln B are currently on average 45% and 31% open respectively.
o These dampers induce an additional pressure drop over the system of 1.9 kPa and 4.9 kPa respectively.
o Opening these dampers completely and reducing the fan speeds to achieve the required gas mass flow rate will result in fan energy consumption savings.
Case Study
Investigation Results
Case Study
Total Excess Gas Fans Proposal
o Install Variable Speed Drives (VSDs) on the two excess gas fans of Kiln A and Kiln B.
o Ensure that one of the two dampers is always completely open.
o Control the speed of the fans to maintain an average mass flow rate of 85 kg/s using fan motor power as control feedback.
Case Study
Investigation Proposal
From Kiln A
85 kg/s
--2.79 kPa
115 °C
To Start UP FCE
To Filter Plant
-2.69 kPa 100% 0.81 kPa788 kW
Cyclones
50%
100%
Open dampers
Open damper
VSD
Install VSD and reduce speed
Case Study
Excess Gas Fan Kiln A Proposal
Case Study
Variable Speed Drives
o No loss of existing installed capacity.o Generally can be installed within existing infrastructure.o Commissioning times are generally shorter.o Wide range of make and models available.o Cost of installed VSDs in the order of R 2000 – R 2500 per kW.o For Medium Voltage (MV) VSD drives lead times are generally
24 weeks.
Case Study
Variable Speed Drives
Item Description Parameter
1 General
1.1 Make and Model Allan Bradley PowerFlex 7000. 1 500 kW, 6.6 kV
1.2 Manufacturing and Testing Standards
ISO 9001:2008, IEC 61800-3, IEC 61800-4, IEC
61800-5-1, EMC Directive 89/336/EEC and
92/31/EEC, General Product Safety
Directive (GPSD), 92/59/EEC, UL 508C,
UL 347, UL 347A, IEC 61800-5-1, NEMA
61800-4, IEC 61800-3,
1.3 Drive Topology Current Source PWM Topology
1.4 Total VSD Weight (kg) Estimate of 9006 kg
1.5 Availability (%) The VSD system shall be designed for a
minimum availability of 99%.
1.6 Mean Time Between Failures (hours)
Greater than 100,000 hours
1.7 Designed Life Expectancy (years)
Minimum life expectancy of 20 years
Case Study
Environmental Analysis
o Enoveer funds 100% of the total project capital (partner in energy savings).
Case Study
Financial Analysis
*Project Cost excludes engineering consulting fees.
Investment(R)
Energy Savings(kWh)Return
(R)
Energy Savings(kWh)
Return(R)
Rebates(R/kWh)
Investment(R)
Case Study
Role PlayersSupplier(s)
Capital(R)
Equipment(R)
o Initiation Meeting(s)
o Application Proposal
o Basic Assessment Questions & Answer(s)
o Due Diligence Detail business model assessment Termsheet
o Approval Letter
o Legal Agreement(s)
o Execution
Case Study
IDC GEEF Funding
(2) Investigation Report(9)Tender Evaluation Report
(1) Letter of Intent/Contract(3) Service Agreement
(12) Project Scope Agreement
(4) Proposal(6) Baseline Report
(10) Proposal
(5) Letter of Approval(7) SOP Contract
(11) Loan Agreement
Challenges
Time & IntegrationSupplier(s)
(8) RFQ(13) Order Agreement
M&V
(14) Installation
Success Factors
Quality & Systems
Thank You
Enoveer Engineering Innovation
Contact Person: Werner BouwerCell: 082 497 5716Email: [email protected]
Contact Person: Deon ArndtCell: 082 2560 907Email: [email protected]
For more information please visit
www.enoveer.co.za