re con

RECON

PURPOSEReCon: A PI Global Tool which

supports Sustainability and Reduces Cost

Focused on Water and Energy Usage Reductions

Support and Enable PepsiCo in the world

OBJECTIVES WHY DO THIS?

Optimize Water and Energy Usage at the Source, in the Process and at Discharge

Minimize Impact of Water and Energy Usage on the Communities in which we operate

PRINCIPLESHOW DO WE WANT TO DO

THIS?

Developed Globally – Implemented Locally Enable the Accurate and Calibrated Tracking of

Performance Provide both Process Tools and Project Based

Solutions Linked to PepsiCo Sustainability Initiative Incorporate Reward and Recognition

PROCESSES WHAT WILL CHANGE?

Keeping Score – Finding Solutions Standardized Scorekeeping

Globally Benchmark-able MetricsSite Level Scorecards

Operating Best Practices Project-Based Technical Solutions

TOOLSSOFTWARE, HARDWARE,

MANUALS Plant Energy Profiler

Source and Demand Profiles ReCon Diagnostic

AssessLearnPlan

Standard Scorecard Project Library

Standard FormatsGlobally Shared

PLANT ENERGY PROFILER

RECON DIAGNOSTIC

STANDARD SCORECARD

Period 1 2 3 4 5 6 7 8 9 10 11 12 13 YTD YTD/PLN YTD/YAG PLN/YAG Diff Diff(MM$)

Electricity (KWH/Lit) 660.78 644.37 663.66 745.93 779.44 802.44 830.91 795.23 709.57 637.19 555.53 597.91 454.04 683.96 166.9% 97.8% 58.6% -39.2% ($0.765)

Fuel Oil (KWH/Lit) 23.59 31.25 26.38 27.87 23.75 24.23 21.75 19.92 16.77 16.02 16.30 20.57 14.13 21.59 54.0% 88.8% 164.4% 75.7% $0.148

Nat Gas (KWH/Lit) 1,871.07 2,459.36 2,086.27 2,208.14 1,893.85 1,932.89 1,744.55 1,600.14 1,351.12 1,287.04 1,301.47 1,633.54 1,125.69 1,719.38 214.9% 89.0% 41.4% -47.6% ($0.124)

LP Gas (KWH/Lit)

Propane (KWH/Lit)

Water (Lit/Lit) 0.41 0.37 0.38 0.44 0.43 0.45 0.42 0.38 0.32 0.27 0.22 0.23 0.14 0.34 68.4% 85.4% 124.9% 39.5% $0.257

Sewage (Lit/Lit) 0.43 0.39 0.42 0.47 0.34 0.44 0.24 0.34 0.22 0.17 0.19 0.24 0.13 0.31

Production (Lit) 10,484,486 10,076,512 12,001,679 10,409,979 10,378,481 10,867,236 9,185,537 12,502,901 11,932,659 13,895,763 16,910,226 13,952,247 4,620,980 147,218,686 11.3% 96.9% 855.6% 758.7% ($0.484)

Week 1 2 3 4 PLN

Electricity 557.24 602.89 562.26 747.27 409.80

Fuel Oil 16.31 20.82 17.91 34.47 40.00

Nat Gas 1,302.46 1,653.16 1,426.22 2,715.87 800.00

LP Gas

Propane

Water 0.21 0.25 0.22 0.25 0.50

Sewage 0.32 0.21 0.19 0.25

Production 4,161,898.00 3,647,711.00 4,142,151.00 2,000,487.00 25,000,000

Water Sewage Production

(Lit) (Lit) (Lit)

Period 12 3,224,732 3,412,785 13,952,247

LEGEND: Electricity Fuel Oil Nat Gas Water Sewage PLN STR YAG

2005 PepsiCo International Resource Conservation Scorecard

Period 12

Comments

31,420,825,124

(KWH)

Energy

0.00

20.00

40.00

60.00

80.00

100.00

0.00

200.00

400.00

600.00

800.00

1,000.00

1,200.00

1,400.00

0.00

500.00

1,000.00

1,500.00

2,000.00

2,500.00

3,000.00

0.00

0.30

0.60

0.90

1.20

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

IMPLEMENTATIONWHO IS INVOLVED?

Robust and Flexible Identify Regional Captains and Expert Trainers Train and Develop Captains and Trainers Establish Lead Sites in Each Region Expand to Broad-Scale Implementation across

PI

SUCCESS WHAT DOES SUCCESS LOOK

LIKE?

Regional ReCon Targets are in PlaceGlobal Metrics reflect true improvementRegional Targets Achieved

Prepare Reward and Recognition CriteriaCreate Centers of Excellence Awards for Best

of Best in PI

FOUR STAGES IN RECON

PrerequisitesProcessesPracticesProjects

PREREQUISITESAchieve Sponsorship & Awareness

Establish Common MetricsSet Priorities

ACHIEVE SPONSORSHIP & AWARENESS

Build Sponsorship and Awareness From Executives to Frontline Personnel

Establish the Fundamentals Global Benchmark Metrics Site Level ReCon Scorecards

Prioritize Opportunities Find the Baseline Source and Use Profiles Diagnose Opportunities Execute Action Plan

Involve Employees Early Apply Smart Tools

ESTABLISH COMMON METRICS

Establish formulas to calculate important value to report and diagnostic.Water ConservationEnergy Usage

From the value calculated and base on Tools to make a tables to tracking energy using.

Assume: 75kW (100 HP) motor using the 1.15 service

factor 93% motor efficiency 8760 operating hours $.10/kWh rate

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(75 kW) x (1.15 SF) x (8760 hrs.) x ($.10/kWh) = $81,242.00

.93 motor efficiency

OR

(100 hp) x (.746 kW/hp) x (1.15 SF) x (8760 hrs.) x ($.10/kWh) = $80,809.00

.93 motor efficiency

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Period 1 2 3 4 5 6 7 8 9 10 11 12 13 YTD YTD/PLN YTD/YAG PLN/YAG Diff Diff(MM$)

Electricity (KWH/Lit) 660.78 644.37 663.66 745.93 779.44 802.44 830.91 795.23 709.57 637.19 555.53 597.91 454.04 683.96 166.9% 97.8% 58.6% -39.2% ($0.765)

Fuel Oil (KWH/Lit) 23.59 31.25 26.38 27.87 23.75 24.23 21.75 19.92 16.77 16.02 16.30 20.57 14.13 21.59 54.0% 88.8% 164.4% 75.7% $0.148

Nat Gas (KWH/Lit) 1,871.07 2,459.36 2,086.27 2,208.14 1,893.85 1,932.89 1,744.55 1,600.14 1,351.12 1,287.04 1,301.47 1,633.54 1,125.69 1,719.38 214.9% 89.0% 41.4% -47.6% ($0.124)

LP Gas (KWH/Lit)

Propane (KWH/Lit)

Water (Lit/Lit) 0.41 0.37 0.38 0.44 0.43 0.45 0.42 0.38 0.32 0.27 0.22 0.23 0.14 0.34 68.4% 85.4% 124.9% 39.5% $0.257

Sewage (Lit/Lit) 0.43 0.39 0.42 0.47 0.34 0.44 0.24 0.34 0.22 0.17 0.19 0.24 0.13 0.31

Production (Lit) 10,484,486 10,076,512 12,001,679 10,409,979 10,378,481 10,867,236 9,185,537 12,502,901 11,932,659 13,895,763 16,910,226 13,952,247 4,620,980 147,218,686 11.3% 96.9% 855.6% 758.7% ($0.484)

Week 1 2 3 4 PLN

Electricity 557.24 602.89 562.26 747.27 409.80

Fuel Oil 16.31 20.82 17.91 34.47 40.00

Nat Gas 1,302.46 1,653.16 1,426.22 2,715.87 800.00

LP Gas

Propane

Water 0.21 0.25 0.22 0.25 0.50

Sewage 0.32 0.21 0.19 0.25

Production 4,161,898.00 3,647,711.00 4,142,151.00 2,000,487.00 25,000,000

Water Sewage Production

(Lit) (Lit) (Lit)

Period 12 3,224,732 3,412,785 13,952,247

LEGEND: Electricity Fuel Oil Nat Gas Water Sewage PLN STR YAG

2005 PepsiCo International Resource Conservation Scorecard

Period 12

Comments

31,420,825,124

(KWH)

Energy

0.00

20.00

40.00

60.00

80.00

100.00

0.00

200.00

400.00

600.00

800.00

1,000.00

1,200.00

1,400.00

0.00

500.00

1,000.00

1,500.00

2,000.00

2,500.00

3,000.00

0.00

0.30

0.60

0.90

1.20

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

SET PRIORITIES Understand the Balance between Supply and

the Demand for each Resource Objectively Verify the Demand Distribution at

the Site Categorize Demand by Priority and

Opportunity Calculate “ Supply “ and “ Demand “ then

post on the Tools

Make a Hotlist and set Priorities from A-B-C

HOTLIST

Diagnostic

Identifies

Opportunity

Priority AHigh Opportunity

Low Difficulty Short Result

Cycle

Priority CLow Opportunity

Low Difficulty High Visibility

Priority DHigh OpportunityHigher Difficulty Longer Results

Cycle

Priority BHigh OpportunityHigher Difficulty Longer Result

Cycle

Profiler

Quantifies

Opportunity

ReCon

Tea

m

Asses

ses Diffi

culty

& V

isib

ility

Select 20 Balanced Objectives

PROCESSES

Engage the Workforce Make sure every one joint, priority to frontline. Every Member are Trained : Safety Training, Data Collection

Training, Focused Improvement Training Rewards & Recognition

Develop ReCon Discipline : Develop a Discipline and make sure do it every day, every shift.

ReCon Integrates with Existing Deployment Platforms

Organize ReCon Teams, Tools and Projects within your Busines

ReCon should be part of the Business Productivity Plan

PRACTICES Apply System Evaluation Technology

Use high technology to evaluate systems to determine waste and make projects to fix them.

Best Practices focus on the Periodic Evaluation of Specific Systems

Involve Utility Partners : ask Partners Help to improve Practices.

Improve Individual and Overall System Performance

Ultrasonic Compressed Air, Leak Evaluations Infrared Electrical Network Inspections Lighting Systems Analysis Utility Bill and Vendor Reviews Combustion Burner Tuning Infrared Building Scans

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PROJECTSDeploy Projects were made in Practices.

Tracking and Evaluate the Efficiency.Leverage new Technology.Extend Expertise to the Community and

Supply Chain

WHAT NEW OCEAN CAN HELP ?

Technical Options.Practices

Tracking and Evaluate Systems.Consultant for Projects.

Projects Provide Solutions for Energy Saving.Provide Equipments and Tools.

WITH NEW OCEANMonitoring and data collectionData analysisRecommendationsImplementation

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OPPORTUNITIES

Five Areas :Electric MotorsCompressed AirSteamFurnacesHeat Recovery

Electric Motors

Why ? Electric motors usually account for almost half of total industry

energy consumption, and represent a significant opportunity for financial savings from energy consumption.

Four Areas :energy efficient motors (T2)variable speed drives (T2)correctly size motors (T2)regular maintenance (T1)

ENERGY EFFICIENT MOTORS

Most energy efficient motors are less waste energy reduced vibration, noise and heat.

The potential for long-term savings.May be taken five to ten years in the

future.Saving potential up to 5 - 8 percent. Typical payback time one to two years

CASE STUDY Steelworks in Italy Renew old motor by Efficiency Motor.

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Cutting 3,000

MWh/year

Saving $560,000/

year

CO2 Reduced1,288

tons/year

Efficiency Motor

VARIABLE SPEED DRIVES

VSDs are ideal for situations where a motor, or the device the motor drives, does not operate at full capacity during its entire operation.

 Typically Saving around 30 percent The main advantage is when the speed of the fluid

fluctuates.

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A 250kW fanThree 132 kW fans

saving $210,000/

year

Energy saving 3,300

MWh/year

CO2 reduction 1,500 tons/year

CORRECTLY SIZE MOTORS VS

REGULAR MAINTENANCE Ensure components are clean and free from dust

and oil. Operating at peak performance as compared to

the manufacturers specifications Identify areas of wear or damage before the

performance of the motor is degraded Saving potential: 1 – 5 percent. Typical

payback time two to three years.

COMPRESSED AIR SYSTEMS Compressed air systems consume a large

component of energy use and hence offer the potential for large financial savings.

Compressor unit (T2) Distribution system (T1/T2)

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Portion of Electrical Input Converted to Useful Work

Lost Energy

Useful Energy

Com

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ir Basics

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ONLY ONE KW OF WORK FOR 7.5 KWS INPUT

02468

Input Power to Compressor Motor

Compressed Air Useful Work

KW

Useful

7.5 Kw Electric power input is required for 1 Kw output of Compressed Air work

COMPRESSOR UNIT Compressor Motor Compressor Element.

Rotary screw, rotary vane, reciprocating or centrifugal.

20% between the styles.Control Systems

Microprocessors has had an important effect on the efficiency of air compressors

savings of up to 45% may be possible

MAINTENANCE

THE DISTRIBUTION SYSTEM

Important Part of Compressor Air .

Saving 25 – 35 %.

Air In

CompressedAir and Oil

Air/Oil Separator

CompressedAir Out

BOILERS In maximising the efficiency of boilers two key

principles : the level of excess air a large part of the heat that was produced in the boiler will go

up the chimney In boiler plants, there are typically four areas of potential

savings: Monitoring equipment (T1/ T2) Load management (T1) Condensate return (T1/T2) Fuel selection (T1)

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-40 -20 0 20 40 60 80

16.0

14.0

12.0

10.0

8.0

6.0

4.0

2.0

0.0

% Excess Air

% G

as

Conce

ntr

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y V

olu

me

85%

75%

80%

70%

Com

bust

ion E

ffici

ency

(Eff

)

%CO2

%O2

%CO

Eff

Excess AirIncomplete Combustion

Efficiency

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NN

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NNO

O

NN

NN

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NNO

O

OO

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OHH

+HotHot NitrogenNitrogen

NN

NN

NN

NN

NN

NN

NN

NN

Waste H

eat

(Methane)

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BurnerAirIn

GasIn

Process Heat User

Control Processor

CombustionGas O2 Sensor

O2

Signal fromTemperature orPressure control

Motorized Valves

Monitoring EquipmentBoilers are a potential source of energy savings since

they are frequently adequately monitored, even at the simplest level.

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3 Meters are Critical to Monitor Boiler KPIs

Fuel Input Steam Output

Totalizing Fuel

Meter

Totalizing Steam Meter

Boiler

Water Softener

Deaerator

Totalizing Water Meter

Load Managementoperating the number of boilers to produce the

required amount of gas/steamadvance warning of changes in the gas/steam

load

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LOAD MANAGEMENT

50

Example:

Measured100,000 KJ/Hour

Fuel input

Measured 80,000 KJ/HourSteam output

Totalizing Fuel

Meter

Totalizing Steam Meter

Totalizing Water Meter

Efficiency%80100000,100

000,80Efficiency

Condensate Return there will always be some efficiency losses as result of

condensate Condensate traps, which collect and remove moisture

Fuel Selection

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Feedwater

Flash Tank

FlashSteam

BoilerDeaerator

(DA)

End UsersSteam to Users

CondensateReturn

Blowdown

PreheatedMake upWater

Liquid blowdownHeat Recovery Hx

Make upWater

To Drain

Heat Recovery Hx

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SAVING FROM FURNACE

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GrossEnergy Input

AvailableEnergy

Chimney GasLosses

DryWet

Wal

l Los

ses

Energy toProcess

Fuel FiredHeater

EXCESS AIR

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Mount of Heat used

Air to Fuel (A/F) Ratio

Insulation

Chimney

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NN

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NNO

O

NN

NN

NN

NNO

O

OO

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OHH

OHH

+HotHot NitrogenNitrogen

NN

NN

NN

NN

NN

NN

NN

NN

Waste H

eat

(Methane)

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BurnerAirIn

GasIn

Process Heat User

Control Processor

CombustionGas O2 Sensor

O2

Signal fromTemperature orPressure control

Motorized Valves

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Exhaust Gas

Chimney Exhaust Fan

Multiple Burners and Zones

1. Tune Burners for Combustion Efficiency2. Adjust the Draft (Exhaust Flow) for OVEN

Efficiency

Oven

Damper

Chimney save

CONCLUSIONWITH NEW OCEAN

Monitoring and data collectionData analysisRecommendationsImplementation

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