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2010/TEL42/DSG/WKSP2/007
Energy-Saving Activities by Green IT Initiative in 2009
Submitted by: Yokogawa Electric Co.
Green ICT SeminarBandar Seri Begawan, Brunei Darussalam
3 August 2010
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Energy-Saving ActivitiesBy Green IT Initiative in 2009
August 3. 2010
Yokogawa Electric Corporation
Kazuro Ito
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Copyright 2009, Green IT Promotion Council 2
Contents
1. DATA Center by NTT DATA Intellilink Corp.
2. Public Facilities by Panasonic Corp.
3. Plant-1 by Yokogawa Electric Corp.
4. Plant-2 by Toshiba Mitsubishi-Electric
Industrial Systems Corp.
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Data Center-Singapore-
NTT DATA Intellilink Corporation
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Survey Items
1. Power Usage Effectiveness (PUE) Survey
PUE=Total Energy Consumption/Energy Consumption of ICT
◆ PUE means energy efficiency level in Data Centers based on DC power.
◆ PUE suggests the existence of power loss.
◆ PUE is useful to find out when the air conditioners and power facilities
should be renovated.
2. Assessment of thermal environment
(Ambient temperature by thermo cameras, temperature loggers, flow
meters and Computational Fluid Dynamics (CFD) Analysis etc.)
3. Analysis of PAC operation
*PAC: Package Air Conditioner
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Target
・ Target: A data center in Singapore
・ Surveyed Items
◆PUE Survey : Sector2 , Sector1◆Thermal Environment Survey : Sector2 , Sector1◆CFD Analysis : Sector2
Sector2
Sector1
Data Center Area (Top View)
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Temperature distribution of the room was obtained. Center and upper part of the machine room was higher in temperature than other places.
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Image of measurement
Racks
Shield
Support bar
Cable racks
30℃
15℃
16
18
20
22
24
26
28
Thermal Environment Survey
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FL+1.8m
Horizontal
A
B
C
A
B
C
Vertical
A-A
B-B
C-C
①
②
A
B
C
A
B
C
①Improvement hot air recirculation
②Improvement of over suction
【Capping】
Installation of cold isle cappings
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0
0.5
1
1.5
2
2.5
3
0 20 40 60 80 100Capacity rate of PAC[%]
Syst
em
CO
P o
f P
AC
[-]
*Electrical power consumption was
calculated by the current of A/C-1
~7,10,11
and measured by the kWh meters of
A/C-9~6.
COP is lower than that of the latest systems. Renovation is recommended.
A/C No.
Survey area of thermal environment
A/C-1
A/C-2
A/C-3
A/C-4
A/C-5
A/C- 6
A/C-7
A/C- 8
A/C- 9
A/C-10
A/C-11
A/C
0
10
20
30
40
50
60
70
80
A/C-1 A/C-2 A/C-3 A/C-4 A/C-5 A/C-6 A/C-7 A/C-8 A/C-9 A/C-10 A/C-11
0
0.5
1
1.5
2
2.5
3
3.5
4
Syst
em
CO
P o
f P
AC
[-]
Electrical power consumption
Cooling capacity
System COP
Ele
ctri
cal p
ow
er
and
co
olin
g ca
pac
ity[
kW]
Capacity rate of A/C[%]
Sys
tem
CO
P o
f A/C[-]
Thermal Environment Survey
Performance rate of A/C : 40 to 80%, System COP : 1.5 to 2.7
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Expected effect
Electric Power Reduction = 841,000KWh / 1Year
・CO2 Reduction460 t-CO2 / 1Year
・3.5% improvement on PUE
Sector1 Sector2
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Public Facilities-Chulalongkorn University in Thailand-
Panasonic Corporation
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Our target is a building of the faculty of engineering at Chulalongkorn University.
Introduction of candidate
His and Her Majesty receiving wreath from students when arriving at Chulalongkorn University.(from Imperial Household Agency HP)
http://ja.wikipedia.org/wiki/%E3%83%95%E3%82%A1%E3%82%A4%E3%83%AB:Main_auditorium_of_Chulalongkorn_University_IMG_0338.jpghttp://www.chula.ac.th/index_eng.htm
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Both equipments and operations were found to be improved in air-conditioners (A/Cs) and lightings.
Summary
The temperature setting of
air conditioners
Targets
Increase the standard temperature setting by 2 degrees to 77℉(25℃), and encourage people to abide by the rule.
Effective countermeasures
Air Conditioners Reduce cost and CO2 emission by installing multi-air conditioning system
FL stabilizers Replace the current copper steel type stabilizers
with inverter type models.
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In some areas, A/Cs had been operated at lower temperatures.
Case1 -Increase temperature setting of A/Cs
75°F⇒ 77°F
If set at too low, like 70°F, then an error message comes out.
Although pre-defined temperature was 75°F, it had not been well managed to be so.The target value has been newly set at higher temperature of 77°F and well monitored.
10% of energy reduction is expected by changing temperature set shown above.
That will be equivalent to around 95.6 CO2-ton/year.
Increase the temperature setting of air conditioners.
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Multi-air conditioning systems have yet to be used.
Case2 -Use High Efficiency A/Cs
BEFORE AFTER Building multi-air conditioning system
The air conditioners were not recent models and their COPs were not high.
Due to lack of the functional flexibility of the systems, the places where
temperature control was not required have wastefully been air-conditioned.
We estimate the annual energy consumption of air conditioner will be 595,886kWh/year.
By implementing multi-air conditioning system, annual energy reduction
is expected to be 305,210 kWh/year.
That will be equivalent to around 167.9 CO2-ton/year.
Use building multi-air conditioning systems
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Current copper steel stabilizer consumes more electricity than inverter stabilizer.
Case3 -Use Inverter type stabilizers in FL-
Currently, copper steel stabilizer, 4,630 units in use, consumes 13% more electricity than inverter stabilizer.
Current annual electricity consumption is 327,243kWh/year
Electricity consumption by current equipment:40WElectricity consumption by improved equipment:35W2908 lamps can be replaced to reduce CO2 emission of 22.5 ton/year.
Replace FL stabilizers with inverter models
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Expected effect
CO2 Reduction424 t-CO2 / 1Year
Increase temperature setting
of air conditioners
Use high efficiency air conditioners
Use inverter stabilizers
By other miscellaneous improvements
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Plant -1 -Rayong Olefins Co., Ltd. (ROC)&
Thai Acrylic Fibre Co., Ltd. (TAF)-
Yokogawa Electric Corporation
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• Step 1
-Target selection (Oct.)“Heat exchanger” &“Ethylene cracking furnace”
-Related operation and maintenance analysis (Oct.)
• Step 2
Frame work study for energy saving (Dec.)
• Step 3
Energy saving proposal to ROC management (Jan.)
Survey Process - ROC
Quoted from Web sites.
Fig-1: Heat exchanger Fig-2 Fouling
Fig-3: Ethylene cracking furnace Fig-4: Tubes
Sample images,not at ROC
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Current status and issuesHeat exchangers (HEXs) - ROC
• No heat performance monitoring tools had been available for hundreds of HEXs, thus maintenance targets were listed up based on human experiences. (Time Based Maintenance; TBM)
• Suppose current one HEX performance is as blue line on the right, it will trace red dotted line if it is not cleaned or trace green dotted line if it is cleaned at next turn around. And the difference between the two lines is energy loss.
Heat transferefficiency
Time
Turn around Turn around
Cleaned
Not Cleaned
Operationcycle
Current HEXperformance
• Cleaning needs to be judged keeping balance between the loss and maintenance cost. But without performance monitoring the judgement is difficult to made.
Differenceof energyconsumption
Fig-1: Heat transfer efficiency
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Current status and issuesEthylene cracking furnaces - ROC
• No tool had been available for uneven coking tube detection.
• Thus constant volume steam was supplied for de-coking. Even tubes were relatively clean.
• It is likely that this leaves some coking areas after de-coking and it lowers heat transfer efficiency and shorten the next cycle length.
Constant steam feedfor de-coking
Steam
Condition of Heat exchanging tubes
Relatively clean tubeDirty tube
Moderately dirty tube
24 tubes
Fig-1: Constant de-coking steam feed
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Survey process (Detail)Ethylene cracking furnaces - ROC
Red bar shows worst 5 severely coking tubes.• Coking status survey of 24 tubes
was done at a cracking furnace by newly developed MVSA (Multi variable statistical analysis) based InsightSuiteAE’s
“Smart fault diagnostician”
---Fig-1
• Optimum de-coking steam supply methods were studied based on the severity
Fig-1: Smart fault diagnostician
Tube & related process
Coking rate
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Expected effect - ROC
Electric Power Reduction = 807,000KWh / 1YearSteam Reduction = 290 t-CO2 / 1YearFuel = 300 t-CO2 / 1Year
CO2 Reduction1400 t-CO2/ 1Year
Heat Exchanger Ethylene Cracking Furnace
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• Step 1
-Target selection (Oct.)
“Dryer temperature control loops” & “Control valves of entire plant”
-Related operation analysis(Oct.)
• Step 2
Frame work study for energy saving (Dec.)
• Step 3
Energy saving proposal to TAF management (Jan.)
Survey Process
Survey Process - TAF
Fig-1: Dryer and control equipment
Fig-2: Control valve
Temperature sensors Control valves
Air
Air
Air chamber
SteamPlug
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Energy-saving proposals and the Effect Control loops @ dryers details - TAF
Proposals• Execution of tuning of control valves
and loops at surveyed dryer by tuning simulator “TuneVP” Fig-1,2
• Introduction of InsightSuiteAE’s“Control loop diagnostician”, “Control valve diagnostician” & “TuneVP” to all other dryers for more savings through plant life-time
Effect• Drying steam saving by lowering zone
temperature pattern• Air compressor power saving
(Indirect effect: Less product quality variance)
Target temperature
Actual temperature
(1) Minimize fluctuation
(2) Lowering set point
(3) Expand to all zones
Fig-1: TuneVP (Tuning simulator)
Fig-2: Expected tuning result
Time
Temp
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Energy-saving proposal and the Effect Control loops @ dryers details - TAF
Fig-1: Control loops tuning trial (Before)
Fig-2: Control loop tuning trial (After)
Disturbance: Line speed change(+ interference from up stream zones to down stream zones.)
Dryer temperaturesZone 1, Zone 2Zone 3, Zone 4Zone 5, Zone 6
Time
Temperature/Line speed
Time
Temperature/Line speed
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Electric Power Reduction = 6,400KWh / 1YearSteam Reduction = 490 t-CO2 / 1Year
CO2 Reduction494 t-CO2/ 1Year
Control loops Stable valve controls
Expected effect - TAF
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Plant -2 -Rayong Olefins Co., Ltd. (ROC)&
Thai Acrylic Fibre Co., Ltd. (TAF)-
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Summary
ROC
Cooling water pump etc
Targets
Inverter type speed control for motors in
pumps especially with medium voltage
motors
Effective countermeasures
TAF
Water pump for chiller etc
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Survey Process (Detail)PUMP Q-H CurveP
um
p H
ead
; H
Pump Flow ; QQ1
H1
Flow loss Curve
R = Q2
H = A-(A-1)Q2
REQUIRED MOTOR
POWER
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Survey Process (Detail)Valve Control vs Speed control
Pu
mp
H
ea
d ;
H
Pump Flow ; QQ1
H1
Flow loss Curve
R = Q2
H = A-(A-1)Q2
REQUIRED MOTOR
POWER
A
0.7x Q1
Pu
mp
H
ea
d ;
H
Pump Flow ; QQ1
H1
Flow loss Curve
R = Q2
H = A-(A-1)Q2
REQUIRED MOTORPOWER
A
0.7x Q1
Valve Control Speed Control
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Target item at ROC
Item No. : PM-2400C
Equipment : Cooling water pump
Motor rating : 10P-1850kW-6600V-50Hz-F eG3
6.6kV-2600kVA TMdrive-MVG is applicable.
(*The existing eG3 motor shall be replaced
with a new explosion-proof motor
in order to get variable speed motor
explosion-proof certificate.)
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Inverter -TMdrive-MVG 6.6kV-2600kVA-
6.6kV-2600kVA
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Expected effect
Electric Power Reduction = 7,266,000KWh / 1Year
CO2 Reduction4,032 t-CO2 / 1Year
ROC
Electric Power Reduction = 1,204,000KWh / 1Year
TAF
CO2 Reduction668 t-CO2 / 1Year
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Conclusion
The Japanese companies engaged in this survey assured
themselves of its business models through these activities.
Japan’s Energy Saving Products and Solutions by IT will contribute
to energy-saving in ASEAN countries and world wide.
Thank you very much for the cooperation of the partner companies
and the great help from the Japanese Government (METI).
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Green IT The best practices collection 2009
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