ROSEMOUNT ENERGY MANAGEMENT SOLUTIONS
Measure energy to manage energy
How
much could
you save?
MAKE BETTER, MORE INFORMED DECISIONS
ABOUT ENERGY MANAGEMENT
Energy use accounts for 30 percent of the
operating budget in a typical plant.1
management. The right information helps you optimize
fuel-to-air ratios…handle changing BTU content in
with unreliable measurement devices in place. Or worse
fuel…and identify which piece of equipment is running
yet, no measurements at all.
most efficiently. You can now determine the amount
measurements that help identify precisely where energy
is being consumed throughout plant operations. Devices
for measuring temperature, pressure, level and flow
can be readily installed in the best locations to provide
Small devices reveal BIG opportunities
wireless devices, can provide even more measurement
points at a lower installed cost. You’ll be able to analyze
FLEXIBLE SOLUTIONS
energy use by each operating unit, and make better,
the untapped energy savings that are hidden within
Process measurement is the foundation of any ongoing
those processes? Measurement instrumentation.
energy management effort focused on sustainable
Because you can’t manage what you don’t measure.
improvement. If you’re planning a large-scale efficiency
overhaul following industry standards such as ISO
Rosemount measurement products, installed in all
50001, measurement and benchmarking will play an
the right places, enable the detection of process
important role. Rosemount product lines include all the
inefficiencies as quickly as they develop. Distinctively
instrumentation you’ll need.
of large process plants. But knowledge is power, and
You don’t have to undertake a major energy initiative to
Rosemount measurement products give you the power
make a serious dent in operational costs and emissions.
to control energy use and emissions like never before.
However, best practices for energy management may
be implemented as time and budget allow, one process
1
5
Re-assess/
set new goals
Best practice
for energy
improvement
energy management strategy to a much deeper level.
Most industry experts believe that of all the possible
energy-saving process improvements, only about half
have been implemented.
with a larger cushion than necessary to accommodate
variability caused by underlying issues.
steps to implement next.
COMPLY WITH INCREASING REGULATORY
AND ENVIRONMENTAL REQUIREMENTS
Large fines and bad press triggered by non-compliance
issues can be devastating for business. Staying compliant
with ever-changing regulatory requirements is no
easy task. With the broad Rosemount instrumentation
MEET YOUR ENERGY BUDGET DESPITE RISING
OR UNCERTAIN COSTS
It is possible, however, to manage energy costs more
portfolio, you can measure energy use for virtually any
application in any process area. Rosemount devices are
simple to install, and they network easily so you can
quickly comply with new regulations.
effectively by identifying—and correcting—areas of
Confused about how to meet current regulatory require-
chronic waste. The savings potential is particularly
ments? Emerson Measurement and Flow Consultants can
significant in plants with aging infrastructure.
recommend solutions to help you stay in compliance.
Not sure where to begin?
Measure
performance
types of inefficiencies, in all areas of your plant. Because
THINK
SMALL
insight needed to ensure operations are not running
savings, and it doesn’t take long to notice the results.
improvement. Rosemount devices help you detect all
not resolved. Rosemount products help you take your
leaks and losses. Rosemount devices provide the
area at a time. Small improvements can add up to big
When it comes to energy use, there’s always room for
significantly driving up cost and emissions—if they’re
informed decisions about which energy optimization
No one can accurately predict the future cost of energy.
blue devices seem almost insignificant in the context
even seemingly minor problems become important—
of energy that’s lost through inefficient operation,
the information you need, when you need it. Installing
energy use in a process plant. What’s the key to finding
TRANSFORM YOUR ENERGY PROFILE
of the guesswork that goes into effective energy
Effectively managing energy use is virtually impossible
Rosemount instrumentation provides highly accurate
Hundreds of big and small problems prevent optimal
Rosemount measurement devices eliminate much
2
Ask us. We can help you determine what measurement
Set goals and
prioritize process
changes
you need, where you need it—and the best technology
4
3
Measure
results
Implement
process changes
to provide it—for each application within your facility.
Consultants from Emerson Process Management will
work with you to devise an effective measurement
strategy that enables you to continuously refine the
applications and equipment that consume energy
throughout your facility.
You’ll gain a whole new level of insight that reveals
opportunities beyond the most common energy fixes.
2
1 U.S. Department of Energy, Energy Efficiency & Renewable Energy, http://www1.eere.energy.gov/manufacturing/tech_deployment/pdfs/39156.pdf (accessed Sept. 2013).
3
Optimize your plant
Wherever energy is used there’s an opportunity for waste.
Temperature, pressure, level or flow measurements can
indicate operational efficiency, or inefficiency. Understanding
where—and why—to measure these variables is absolutely
essential to running an optimized plant.
Take a look at some of the places where Rosemount
measurement products can provide the data you need to
reduce energy costs, and comply with emissions regulations.
BOILER
FURNACE OR FIRED HEATER
The main source of energy for many
processing plants—a key area to focus
on for efficiency gains.
Furnaces and fired heaters consume a
great deal of energy providing heat to your
processes. Inefficient combustion can be
caused by the wrong amounts of fuel and air
entering the furnace or fired heater.
Some boiler fuel efficiencies may run as
low as 60 to 70 percent.
EnergyWire: August 2, 2013.
COMPRESSOR ROOM
TURBINE
Compressors use a great deal of electricity,
making the compressor room a prime
target for significant energy improvement
Extreme conditions make it difficult to take
the accurate measurements that are needed
to precisely control and protect the turbine.
Air systems over five years old may waste up
to 30 percent of compressed air output.
5
DOE/GO-102004-1964. Revised August 2004. Compressed Air Tip Sheet #3.
CHILLERS
It takes a lot of energy to chill water. Poorly
controlled chillers demand more electricity
to produce the same tons of cooling,
driving up operational costs.
COOLING TOWER
Cooling efficiency varies with outdoor
conditions; it’s important to monitor how
much cooling each cell can provide.
Water used by cooling towers can account for 20
to 50 percent or more of a facility’s water use.
North Carolina Department of Environment and Natural Resources,
http://www.ncdenr.gov.
HEAT EXCHANGERS
With the large amount of energy consumed
here, heat exchangers are a critical area of
potential energy waste. Over time, fouling
reduces the heat transfer efficiency of
heat exchangers, subsequently increasing
energy consumption.
DISTRIBUTION PIPING
Distribution piping factors into energy efficiency in so
many places, in a variety of ways. The importance of
strategic measurement here can’t be overstated.
About 20 percent of a plant’s steam traps fail each year.
U.S. Department of Energy Federal Technology Alert, DOE/EE-1093.
4
LEARN MORE ABOUT PROCESS ENERGY SAVING OPPORTUNITIES
Take our Virtual Plant tour and see how to better analyze energy use at your facility. Get the information
you need to develop more effective energy management strategies. Visit: www.rosemount.com/energy
5
What’s your next energy project?
THINK
SMALL
Plants with energy management programs in place can often save 10–15 percent
by implementing additional best practices to increase energy efficiency.2
Plant efficiency programs typically start by addressing the obvious fixes, including the
replacement of aging, inefficient equipment and machinery. However, continuous gains can only
be sustained through total system optimization. Considerable efficiency can be lost or gained
between the areas where steam, compressed air and chilled water are generated and the places
where they are actually consumed.
Rosemount measurement devices identify where waste is occurring faster and easier than manual
detection methods, and more reliably than other installed devices.
“It’s only one little steam leak…”
Think a little leak doesn’t really matter? Think again.
In just one hour, a blowing steam trap at 300 pounds
per square inch (psi) with an orifice diameter of 3/16
inches will waste 267 pounds of steam. Using an average
cost of steam at $10 per 1,000 pounds, one blowing
steam trap will waste $64 per day—which adds up to
$23,426 per year in avoidable energy cost. And that’s
just one trap: About 20 percent of steam traps fail each
year in a typical plant.
Under a manual inspection method in a plant with
hundreds of steam traps, a faulty trap could go
undetected for almost a year. Rosemount wireless
acoustic steam trap monitors provide the information
you need to detect, pinpoint and resolve failed traps
quickly. Use the formula below to calculate your
estimated losses.
TYPICAL COST OF STEAM TRAP FAILURE
17 Bar (~ 250psi)
4 Bar (~ 50psi)
Orifice
Size
# of Traps
Cost of
Failure
3 mm
5 mm
7.5 mm
12.5 mm
93
78
7
4
$1,292
$3,590
$8,077
$22,437
Orifice
Size
# of Traps
Cost of
Failure
3 mm
5 mm
7.5 mm
10 mm
12.5 mm
4
77
2
2
1
$4,643
$12,899
$29,022
$51,594
$80,616
2 U.S. Department of Energy, Energy Efficiency & Renewable Energy, http://www1.eere.energy.gov/manufacturing/tech_deployment/pdfs/39156.pdf (Accessed Sept. 2013).
6
7
A better device leads to
compressed air savings
BEFORE:
Compressed air system using orifice plates
Compressors
160 mbar
Compressed air system leaks and pressure losses drive
Main Line Measurement
up energy costs because the compressor must use
6.5 Bar
Driers
6.0 Bar
5.7 Bar
electricity to generate compressed air that never gets
100 mbar
used. Using orifice plates to measure output at the
compressor, and flow through the main line, actually
contributes to permanent pressure loss. Replacing
Pressure Loss
300 mbar
210 mbar
orifice plates with Rosemount Annubar Flowmeters
virtually eliminates pressure losses by creating less
blockage in the pipe, which reduces the amount of
pressure drop.
AFTER:
Compressed air system using Rosemount
Annubar Flowmeters
Compressors
These illustrations demonstrate how one chemical
8 mbar
manufacturing facility in Brazil reduced electricity costs
Main Line Measurement
by $750,000 a year simply by replacing orifice plates
6.5 Bar
with Annubar Flowmeters. This solution also increased
Driers
6.0 Bar
6.0 Bar
Rosemount measurement technology can provide more
5 mbar
the efficiency of the compressed air system by 10
Rosemount technology
extends the project budget
measurement per dollar. Here’s one example: A large
percent, thereby improving line pressure at even the
U.S. pulp and paper mill wanted to study energy use
most remote locations.
Pressure Loss
16 mbar
10 mbar
throughout its facility. Preliminary project work identified
the need for 60 new flowmeters to understand systemwide usage of compressed air, process water and steam.
Working under a strict budget, it initially appeared the
customer would only be able to afford 15 flowmeters.
Rosemount wireless technology saved the project:
Annual Operating Cost
HP
50
100
300
SCFM
225
500
1,500
Total Cost*
$35,134
$69,818
$205,502
Its inherent low installed cost enabled all 60 points of
interest to be measured within the budget constraints.
Further savings in installed cost were realized9by using
non-intrusive Rosemount Annubar Differential Pressure
Pressure Drop, PSI
$176
$349
affordable way to add measurement points. It’s
the ideal solution in places where running wire to
devices would be cost-prohibitive; for example, in
challenging or remote areas and in places where
safety is a concern.
$1,028
and larger. Once the meters were installed, numerous
WHY WORK WITH EMERSON?
sources of waste were identified and fixed.
3
$527
$1,047
$3,083
5
$878
$1,745
$5,138
Savings that could easily be documented amounted to
measurement products. Our devices are extremely
7
$1,230
$2,444
$7,193
$350,000 in the first year, achieved by reducing steam
accurate and offer long-term reliability under
9
$1,581
$3,142
$9,248
demand by 4,000 pounds per hour (assumes steam cost
extreme plant conditions. We can help you select
of $10/1,000 lbs.).
the right product, and the right place to measure, to
*24/7 Operation (8760 hrs. /yr.), $0.10/kWh, TEFC Standard-E motor.
Emerson offers a full selection of Rosemount process
support your energy reduction activities.
Source: Studebaker, Paul (2008), Compress Efficiently. Plant Services Magazine.
Retrieved from http://plantservices.com
THINK
SMALL
8
Wireless instrumentation provides an easy,
Flowmeters on nearly all lines six inches in diameter
Annual Additional Cost of Pressure Drop
1
Wireless solutions
Air systems older than five years may waste up to 30
percent of compressor output.3
3 U.S. Department of Energy, Compressed Air Tip Sheet #3, (DOE/GO-102004-1964. Rev. August 2004).
9
See the bigger energy picture
Rosemount measurement solutions integrate seamlessly into an Energy Management Information System (EMIS)
by Emerson. This valuable software tool delivers a real-time picture of energy performance to operations and
management personnel.
Local service, local supply
02.133
Factory-trained Rosemount Service technicians will
ensure your measurement instrumentation is properly
Rosemount process sensors
and measurements
installed, calibrated and maintained. We’ll provide the
technical expertise you need to gain the full potential
Data historian
Visualization tools
Components of
a turnkey EMIS
Reporting and
user displays
010010
111010
010101
001001
Data analysis
routines
of the diagnostics embedded in our devices. Only
Rosemount Service technicians are qualified to make
sure our devices continue to provide the data you rely
on to maintain optimal energy efficiency.
0100101110
1001010100
1001110101
0011100010
1010010101
0100101101
0100101011
Data validation
algorithms
Process and unit
energy models
Rosemount Service delivers support through a network
of service centers and technicians strategically
located throughout the world. When speed is critical,
Rosemount service technicians, products and parts can
arrive at virtually any facility within hours, not days—
even in remote locations.
Emerson Certified
At Emerson, we operate our own dedicated Rosemount
service organization, hiring and training the best
technician talent available. Only Rosemount Certified
field technicians are qualified to ensure the measurement
products installed in your facility maintain the OEM
THINK
SMALL
10
Nearly one-ninth of the total energy use in the United States is consumed by steam systems. In a typical
specifications that are critical to safety and efficiency.
industrial steam system, operational improvements can reduce energy-related costs by 10–15 percent.4
4 U.S. Department of Energy, Energy Efficiency & Renewable Energy, http://www1.eere.energy.gov/manufacturing/tech_deployment/pdfs/39156.pdf (accessed Sept. 2013).
11
Enlist our experts
Whether you’re undertaking a comprehensive energy
overhaul to ISO 50001 standards, need help finding
ways to reduce energy costs, or simply want advice on
how to stay in compliance, consultants from Emerson
Process Management can provide the support you need.
Invite our professionals to assess your operations.
You may be surprised by the big and small energysaving opportunities that are revealed. Our
professionals will collaborate with you to make sure
the right measurements are in place to help you meet
your energy-related goals. Consultants from Emerson
Process Management also provide long-term support
to ensure installed devices stay accurate and reliable
for years to come.
LET’S FIND OUT WHERE YOU CAN SAVE ENERGY
Request a technical consultation today: 1-800-999-9307
Or email us: [email protected]
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