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

2. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 2 Emerson Confidential Slide 2 Implement Site Management Optimize Unit Processes The Energy Improvement Process Survey and Measure Fix Devices and Loops Address Equipment Begin

3. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 3 Emerson Confidential Slide 3 Proper 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

4. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 4 Emerson Confidential Slide 4 What is Included in a Good Energy Measurement Plan? Accurately Measure All Utilities Establish Benchmarks for Energy In vs. Energy Out Automate Data Collection

5. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 5 Emerson Confidential Slide 5 Balance & 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 wont be used

6. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 6 Emerson Confidential Slide 6 Types 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

7. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 7 Emerson Confidential Slide 7 Balance & 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

8. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 8 Emerson Confidential Slide 8 Energy 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 Out Electrical Steam Chilled water Compressed air Gas Additional Utilities

9. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 9 Emerson Confidential Slide 9 Energy Management If you want to Manage it you have to Measure it

10. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 10 Emerson Confidential Slide 10 Application Fluid Properties PerformanceInstallation Economic Factors Environmental & Safety Meter Selected Liquid, Gas, Steam Conductivity Multi-phase Viscosity Pressure Temperature Wetted parts Accuracy Repeatability Temperature Effect Response Time Line Size Vibration Pipe Runs Submergence Cost Installation Reliability Maintenance Emissions Hazardous Waste Leak Potential Shut Down System? Control Monitor Indicate Batching Custody Transfer Flow Solutions Coriolis DP Flow Magnetic Vortex Other Select the Right Flowmeter for the Application

11. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 11 Emerson Confidential Slide 11 Energy Management Best Practices Minimize Pressure Loss Save on Energy Optimize Performance Correct Flowmeter Installation Automate Data Collection Line Size: 60 Weight: 300 lbs Cost: $68,000 VS. Line Size: 60 Weight: 50 lbs Cost: $17,000

12. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 12 Emerson Confidential Slide 12 Energy Management Best Practices Minimize Pressure Loss Save on Energy Optimize Performance Correct Flowmeter Installation Automate Data Collection Line Size: 60 Weight: 300 lbs Cost: $68,000 VS. Line Size: 60 Weight: 50 lbs Cost: $17,000

13. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 13 Emerson Confidential Slide 13 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 Liquids

14. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 14 Emerson Confidential Slide 14 Measure 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

15. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 15 Emerson Confidential Slide 15 * Per Crane Handbook Measure Mass Flow in Gas When Density Changes Measure Mass Flow in Gas When Density Changes 20 ft Manufacturers Specification 20 ft pipe 2 elbows Typical variation 0.55 psi 1.0% 0.44 psi 1.1% 0.5 psi 0.9% Total 1.49 psi3.0% Max Variation Regulator P = 40 psi P = 39.08 ± 1.05 psi Regulator Droop Pipe Friction* Barometric Variation % Error Pressure at the source does not equal pressure at the destination Density compensation improves flow performance Natural Gas Example: 2 inch pipe Flow rate = 10,000 SCFH 3.0% 1.5% <0.1% Flow = K * DP * ρ Flow = V * Constant ρ flow SQRT is to the 1/2 power Pressure and Temperature Variation Compensation MultiVariable Uncompensated DP Uncompensated Velocity 01234

16. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 16 Emerson Confidential Slide 16 Multivariable 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

17. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 17 Emerson Confidential Slide 17 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 Measurement Boosting Combustion Control Coriolis Elite Mass Flow Meters NG RFG

18. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 18 Emerson Confidential Slide 18 Energy Management Best Practices Minimize Pressure Loss Save on Energy Optimize Performance Correct Flowmeter Installation Automate Data Collection Line Size: 60 Weight: 300 lbs Cost: $68,000 VS. Line Size: 60 Weight: 50 lbs Cost: $17,000

19. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 19 Emerson Confidential Slide 19 Correct Installation of the Flowmeter is Critical for Accuracy VSVS Eliminate Impulse Lines Adequate Straight Pipe Run Orifice Plate Alignment & Pipe ID Uncertainty Proper steam conditioning

20. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 20 Emerson Confidential Slide 20 Typical DP Flow Straight Run Requirements 1 2 3 4 5 6 7 8 910 1 2 3 4 5 10 Diameters Upstream 5 Diameters Downstream

21. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 21 Emerson Confidential Slide 21 Required Straight Pipe for O-Plates Measurement of fluid flow in pipes using orifice, nozzle, and venturi ASME MFC-3M-2004

22. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 22 Emerson Confidential Slide 22 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 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

23. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 23 Emerson Confidential Slide 23 Conditioning 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%

24. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 24 Emerson Confidential Slide 24 Direct Mounting Reduces Maintenance …and Improves Consistency & Accuracy Eliminates inaccuracies Consistent installations Reduced complexity Leak points reduced No leak testing Traditional InstallationDP 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

25. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 25 Emerson Confidential Slide 25 Removing 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 Technologies www.oit.doe.gov/bestpractices *75 psig steam; 1/16 diameter leak; $10 per 1000 lb steam

26. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 26 Emerson Confidential Slide 26 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 Off

27. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 27 Emerson Confidential Slide 27 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?

28. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 28 Emerson Confidential Slide 28 Aluminum 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% 3 rd party out to calibrate twice & found no issues w/ xmtrs

29. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 29 Emerson Confidential Slide 29 Aluminum Recycler Flow Meter Audit Findings: 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% Correct20% low Fixing the issues corrected the plant energy balances.

30. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 30 Emerson Confidential Slide 30 Energy Management Best Practices Minimize Pressure Loss Save on Energy Optimize Performance Correct Flowmeter Installation Automate Data Collection Line Size: 60 Weight: 300 lbs Cost: $68,000 VS. Line Size: 60 Weight: 50 lbs Cost: $17,000

31. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 31 Emerson Confidential Slide 31 Flow 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 PL 1 PL 2 PL 3 PL 4 FT 1 FT 3 FT 2 PL 5 FT 4 FT 5 FT 6 FT 7 PL 6 PL 7 Energy In Use Point #1 Use Point #2 Use Point #3 Use Point n

32. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 32 Emerson Confidential Slide 32 Energy Savings Results Chilled water flows (7) 10 lines, 0-4000 GPM (7) 14 lines, 0-5000 GPM Existing DP/orifice plates

33. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 33 Emerson Confidential Slide 33 Energy Savings QBR (pros & cons) 14" Line ComparisonDP/O-PlateDP/AnnubarMagmeter Performance @ Normal Flow0.60%0.90%0.30% Turndown with +/- 2% Perf.6 to 15 to 133 to 1 Performance @ 10:1 Turndown8.25%5.00%1.00% PPL @ Normal Flow5.3 psi2.1 psi0 psi PPL Cost at Normal Flow$8,572$3,402$0 PPL Savings @ Normal FlowX$5,170$8,572 Required Straight Run56'16'8' Installed Cost$10,450$7,260$16,290 ROIX27.6 mo.29.4 mo.

34. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 34 Emerson Confidential Slide 34 Energy Management Best Practices Minimize Pressure Loss Save on Energy Optimize Performance Correct Flowmeter Installation Automate Data Collection Line Size: 60 Weight: 300 lbs Cost: $68,000 VS. Line Size: 60 Weight: 50 lbs Cost: $17,000

35. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 35 Emerson Confidential Slide 35 Energy 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

36. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 36 Emerson Confidential Slide 36 Powerhouse Steam Distribution Operating Units Desired Measurement Points

37. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 37 Emerson Confidential Slide 37 Process Today Only about 30% of engineers 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

38. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 38 Emerson Confidential Slide 38 Process 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

39. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 39 Emerson Confidential Slide 39 Achieving 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

40. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 40 Emerson Confidential Slide 40 Implementing Wireless: Integration Strategy An integration strategy is key to turning data into information into action Wireless data needs to be integrated into an EMS and then distributed to users as information Wireless can be integrated into any EMS –OPC, Modbus, AMS, Converters –DCS, PLC, Historians, anything Tips: –Involve applications administrator early –Plan for multiple users DCS PLC

41. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 41 Emerson Confidential Slide 41 Complete 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 Series Pressure, Level & Flow 848T Multi Input Temperature 6081C Conductivity Smart Wireless Gateway Create sustainable, sharable, repeatable solutions

42. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 42 Emerson Confidential Slide 42 Pulp & Paper Mill - Wireless Energy Monitoring Implementation Option 1Option 2 Total Measurement Points: 15 Total 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

43. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 43 Emerson Confidential Slide 43 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

44. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 44 Emerson Confidential Slide 44 Energy Management If you want to Manage it you have to Measure it Questions?