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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
pre
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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
ati
on b
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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OO
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NN
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NN
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
Monitoring EquipmentBoilers are a potential source of energy savings since
they are frequently adequately monitored, even at the simplest level.
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MONITORING EQUIPMENT PI R
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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
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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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OO
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NN
NN
NN
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)
AIR TO FUEL (A/F) RATIO PI R
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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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