News
News from year: 2018
19/10/18
Pursuing the Energy Efficiency with Q3-DEMS
Energy efficiency is not only important for environmental sustainability but also in terms of operating costs reduction.
For this purpose, Danieli Automation has designed the Danieli
Energy Management System, an integrated solution based on an edge-computing architecture that allows an easy and smooth implementation as well in brownfield scenarios.
For this purpose, Danieli Automation has designed the Danieli
Energy Management System, an integrated solution based on an edge-computing architecture that allows an easy and smooth implementation as well in brownfield scenarios.
Danieli Automation has developed an energy-management and monitoring system called "Q3 Danieli Energy & Monitoring System", whose acronym is Q3-DEMS. Q3-DEMS is a flexible and scalable solution that can be adapted to the needs of the customer for achieving energy-saving targets and managing energy flows without waste.
It is aimed at collecting the greatest possible volume of information relating to the energy carriers from the field, in order to achieve greater energy efficiency by perfectly integrating the existing processes and application programs, and creating a simple interface
between people and collected data.
It collects data in a way similar to the methane gas delivery point up to the single user in the plant to be monitored. Likewise, it is possible to monitor other consumptions, such as those of noble gases (used in electric furnaces) and water consumption. Continuously recording and monitoring consumption makes it possible to discover possible anomalies with respect to optimal consumption, by detecting the signs of wear and malfunctioning before a failure occurs. This predictive analysis can be very helpful for defining a preventive maintenance time-schedule.
It is aimed at collecting the greatest possible volume of information relating to the energy carriers from the field, in order to achieve greater energy efficiency by perfectly integrating the existing processes and application programs, and creating a simple interface
between people and collected data.
It collects data in a way similar to the methane gas delivery point up to the single user in the plant to be monitored. Likewise, it is possible to monitor other consumptions, such as those of noble gases (used in electric furnaces) and water consumption. Continuously recording and monitoring consumption makes it possible to discover possible anomalies with respect to optimal consumption, by detecting the signs of wear and malfunctioning before a failure occurs. This predictive analysis can be very helpful for defining a preventive maintenance time-schedule.
The monitoring system allows to identify the most profitable energy efficiency enhancement actions and notifies anomalies when they are taking place.
Example of return of Investment:
Q3-DEMS was installed to monitor the electrical consumption of some pumps belonging to the water treatment plant (WTP) of a 1.2-Mtpy meltshop for special engineering steels.
From a preliminary analysis, it was calculated that the electrical consumption of the water pumps of the plant under examination corresponded to approximately 7 to 8 % of the total electrical consumption of the plant.
In particular, the analysis was focused on the energy consumption of 24 pump motors of power ranging from 55 to 110 kW, making part of the WTP system intended for one of the two 100-t electric arc furnace and one of the three conticasters for round blooms, in relation to the water-flow rate managed by a single pump.
The pumps in question work continuously, i.e., approximately 7,000 hours per year.
From the monitoring performed, it could be noticed that the
pumps did not work properly nor in an optimal way. In the meantime, the motors of some pumps had been replaced with some more powerful ones.
Therefore, other pumps that were not supplying any additional flow worked all the same, and so absorbed electric power. For this project, monitoring instruments were installed in the existing
power switchboards for each outgoing line. Some pressure measuring devices were installed too, the communication
network was laid down and an ad hoc Q3-DEMS software
was developed, suited to the customer's needs. Data were collected, analyzed, and made available to all the
designated users.
Without carrying out any invasive interventions, but simply by modifying the working logic of the pumps under examination, the payback time in relation to the achieved energy saving was
approximately five months.
Starting condition
Four pump groups, totaling 20 pumps. Annual consumption is around 12GWh/y
Monitor analysis
2 GWh/y in idle phase
700 MWh/y wasted
Final condition
20% Active saving: -2.4 GWh/y
The conclusion is that 18-20% of total energy can be saved by changing only the logic pumps run cycles without adding inverters to the monitors.
Example of return of Investment:
Q3-DEMS was installed to monitor the electrical consumption of some pumps belonging to the water treatment plant (WTP) of a 1.2-Mtpy meltshop for special engineering steels.
From a preliminary analysis, it was calculated that the electrical consumption of the water pumps of the plant under examination corresponded to approximately 7 to 8 % of the total electrical consumption of the plant.
In particular, the analysis was focused on the energy consumption of 24 pump motors of power ranging from 55 to 110 kW, making part of the WTP system intended for one of the two 100-t electric arc furnace and one of the three conticasters for round blooms, in relation to the water-flow rate managed by a single pump.
The pumps in question work continuously, i.e., approximately 7,000 hours per year.
From the monitoring performed, it could be noticed that the
pumps did not work properly nor in an optimal way. In the meantime, the motors of some pumps had been replaced with some more powerful ones.
Therefore, other pumps that were not supplying any additional flow worked all the same, and so absorbed electric power. For this project, monitoring instruments were installed in the existing
power switchboards for each outgoing line. Some pressure measuring devices were installed too, the communication
network was laid down and an ad hoc Q3-DEMS software
was developed, suited to the customer's needs. Data were collected, analyzed, and made available to all the
designated users.
Without carrying out any invasive interventions, but simply by modifying the working logic of the pumps under examination, the payback time in relation to the achieved energy saving was
approximately five months.
Starting condition
Four pump groups, totaling 20 pumps. Annual consumption is around 12GWh/y
Monitor analysis
2 GWh/y in idle phase
700 MWh/y wasted
Final condition
20% Active saving: -2.4 GWh/y
The conclusion is that 18-20% of total energy can be saved by changing only the logic pumps run cycles without adding inverters to the monitors.
Autore: JD