Heads Up CIPEC – Volume 19, Issue 1

Volume 19, Issue 1

Note to our readers: This is the first of what will now be a Volume/Issue-based newsletter in lieu of a monthly issue.

As always, we welcome any feedback you may have. Send us an e-mail and let us know what you think.

ISO 50001 Lead Auditor certification

Canada and the United States are the leaders of a worldwide project under the Global Superior Energy Performance Partnership to develop a certification scheme for the ISO 50001 Lead Auditor that meets the requirements of ISO/IEC 17024 accreditation.

In support of these efforts, CSA Group and Natural Resources Canada will host a special five-day ISO 50001 Lead Auditor training course and examination during the week of March 23, 2015. This training session will be held at CSA Group’s training facility located at 5060 Spectrum Way in Mississauga, Ontario.

Candidates who meet the educational and experience requirements and who successfully complete the examination will earn the designation of ISO 50001 Lead Auditor. Groups or individuals interested in attending are encouraged to register for the training via CSA Group’s website at www.shop.csa.ca or by calling 1-800-463-672.

For further information please contact Olivier Cappon, Portfolio Manager, Sustainability and Electricity, CSA Group at olivier.cappon@csagroup.org.

Upstream oil and gas process integration workshop is a success

Process Integration (PI) training is garnering increasing interest in the upstream oil and gas sector now that it has been tailored to the industry. The first such customized PI workshop, held in November 2014 in Calgary, was sponsored by CIPEC, Suncor and Alberta Energy Efficiency Alliance. The event drew 15 participants from Suncor, Devon Canada, Canadian Natural Resources Limited, ConocoPhillips and SNC-Lavalin.

“Providing our employees with access to training on process integration techniques supports Suncor’s quest for operational excellence. By participating in NRCan’s training sessions and using the associated tools, we expect to find new ways to make our operations more efficient, with reduced energy costs and fewer greenhouse gas emissions,” says Doug Evans, general manager, technical services at Suncor.

Philippe Navarri, Senior Project Manager, Process Integration, CanmetENERGY, and one of the workshop trainers, notes that session topics included the steps necessary for a successful process integration study from plant data collection to project definition as well as energy performance assessment, waste heat recovery from utility systems, and pinch analysis concepts to analyse and optimize industrial process heat use. The workshop also covered case studies from the oil and gas sector and provided hands-on training. Each participant also had the opportunity to use and leave with a copy of the INTEGRATION software developed by CanmetENERGY.

Maureen Pellettier, leader of the Energy Efficiency Suncor Technical Excellence Network (STEN), explains that the impetus for hosting the Calgary-based workshop came from feedback about NRCan’s process integration training attended by several engineers from the Suncor refinery in Montreal. Jean-Simon Bourret, the facility’s process engineering manager, says that “the process integration training has been beneficial. Since our training in 2012, we’ve implemented new heat exchangers at our Montreal refinery using CanmetENERGY’s INTEGRATION software.” 

Offering PI workshops to the upstream oil and gas sector is an important step in increasing awareness and building process integration capacity within the industry, notes Navarri. “PI provides a systematic approach that can greatly benefit the sector in terms of energy savings and GHG reduction.”

Calgary workshop participants value these potential benefits. “We received very positive feedback; they could see the advantages of the approach for their facilities,” says Navarri. Attendees also appreciated the combination of theoretical and practical aspects of the INTEGRATION software, as the tool allows users to quickly analyze the performance of existing heat exchanger networks, identify heat recovery opportunities and evaluate various scenarios to optimize heat use across facilities and promote greater efficiency.

In addition, a four-hour introductory PI session was arranged in December 2014 for those STEN energy advisors who were unable to attend the November workshop, to provide them with an overview of the topics covered.

Pellettier summarizes both the success of the November workshop and the introductory session as “having the potential to further advance Suncor’s energy efficiency efforts.”

Planning is already underway for another PI workshop for the upstream oil and gas sector in March 2015.

Visit the Natural Resources Canada website to learn more about how your facility could benefit from process integration.

Photo of workshop attendants
Participants at the November 2014 process integration (PI) training workshop.

Redesigned compressed air system leads to savings at Boeing Canada Winnipeg

A new compressed air system at Boeing Canada Winnipeg has helped the facility save significantly on operating costs. The project also garnered the facility recognition within the worldwide Boeing enterprise for the best improvement project.

Gerry Glor, the facility’s manufacturing engineer, explains that composite parts are baked in large autoclaves that are pressurized with compressed air. A compressed air audit found that the existing centrifugal compressors supplied only 3,000 cubic feet of air per minute (cfm) even though two additional autoclaves have increased the demand to 5,500 cfm.

Moreover, the existing system resulted in high peaks and low valleys during normal production. Furthermore, when not in production mode, the two compressors entered a very inefficient blow-off mode. The additional autoclaves would have required the use of a third compressor and the purchase of a fourth.

Glor notes that the capacity issues with the centrifugal compressors presented an opportunity to redesign the system. Installed in early 2014, the new system features four rotary screw compressors (two 225-hp VSD [variable speed drive] and two 100-hp base) and two booster compressors (50-hp high pressure) to provide sufficient air for both the plant and the autoclaves.

Instead of the compressors running continuously  to supply the autoclave, the required air is now stored at a pressure of up to 280 psi in two large 25,000-U.S. gallon (USG) receivers located outside of the compressor room. When the compressed air is needed, up to 5,500 cfm of air, or the equivalent of 1,375 hp of air compressor capacity, is delivered from the receivers.

Additionally, a demand management system, designed by Manitoba Hydro and intended to monitor power peaks, turns off the booster compressors when they would lead to increased peak demand charges. The system reduces the cost of the stored air by about 25 percent. Moreover, oversized compressor piping was installed to reduce piping pressure losses across the system.

An innovative sequencing system controls the compressors as does the accurate regulation of the VSDs on the compressors. Usually only one of the four main compressors is running while another one supplies fill air for the autoclave, which is supplemented by stored air as needed. Moreover, staff at Boeing Winnipeg also dealt with compressed air leaks and inappropriate end-use levels to reduce average air flow from 750 cfm to 425 cfm.

The new system consumes about 669,000 kilowatt hours (kWh) with a peak of 285 kilovolt-ampere (kVA). “This system allows for greater flexibility and is much less maintenance and energy intensive,” states Glor. It also allows the autoclaves to be pressurized about three times faster than the old system, which reduces run-time. The compressed air is also used to operate other pneumatic equipment in the plant without a loss in pressure.

Glor says that current and future projects include eliminating single-pass process water cooling and optimizing autoclave nitrogen pressurization systems. The autoclave nitrogen and compressed air systems may also be upgraded again in the near future to support another autoclave that is currently being constructed.

Layfield Group embraces VFDs

Layfield Group, a manufacturer of environmental products located in Richmond, British Columbia, is sold on variable frequency drives (VFDs). “It’s an upfront investment, but we have seen payback periods as short as one year,” says Maintenance and Project Manager Dave Brandle as he explains that the facility’s compressed air, chilled water, extrusion and blower systems have been or will be VFD retrofitted.

A 2012 energy audit of the 50,000-square-foot facility allowed the company to target certain areas for efficiency improvements. As a result, several single-speed air compressors were replaced with one single-speed compressor and one VFD model – the latter responding to demands above the baseline. This retrofit, supported by a BC Hydro PowerSmart incentive that paid 75 percent of the costs, led to savings of around 130,000 kWh annually. "The upgraded compressed air system now matches the load we need, so we're not wasting money or energy to make compressed air we don't use," Brandle says.

Moreover, three out of four water-chiller motors were retrofitted with variable speed drives for savings of around 60 percent; the facility’s extruder was also upgraded to run at variable speeds. Additionally, all the blower motors in the facility will be replaced with VFD motors over the next ten years. Brandle notes that the company has again partnered with BC Hydro PowerSmart to achieve its significant energy savings.

Layfield’s success with VFDs is highlighted in a new VFD Fact Sheet published by the Consortium of Energy Efficiency as part of their Motor Decisions Matter campaign, which points to the potential savings that VFDs can deliver by reducing motor speed to match a driven load.

The fact sheet helps business decision-makers simplify options to invest in energy efficiency and states that most facilities that move air or water would benefit from taking the time to assess the costs and benefits of installing VFDs. It summarizes equipment that would benefit most from VFD upgrades keeping in mind that VFDs must be paired correctly with existing equipment to achieve the maximum benefit.

The Layfield Group has decided that the benefits far outweigh the costs. “We plan to spend $10 million in plant upgrades, and all of these will incorporate high efficiency drives and the latest technology,” says Brandle. He points out that the company is “in the environmental business, so we also have an obligation to reduce our environmental footprint; our goal is to use the fewest resources at the lowest cost.”

To read the fact sheet, visit www.motorsmatter.org/index.asp.

CEO of Resolute Forest Products named to Canada’s Clean50

“Sustainability principles and objectives are reflected in our vision, corporate values and the way we do business across the company every day," says Richard Garneau, President and CEO of Resolute Forest Products Inc. Garneau was recently named to Canada’s Clean50 in the manufacturing and transportation sector.

Clean50 is a group of leaders recognized by the Delta Management Group for having contributed significantly to sustainable development or clean capitalism in Canada. “The Clean50 award and similar designations speak to our ongoing efforts to be a sustainable supplier for our customers and a strong civic partner in the communities where we live and work,” says Garneau. He adds that “this designation represents an important endorsement of Resolute's approach to our business and sustainability strategies, which are directly linked and interdependent." 

Resolute Forest Products manufactures a diverse range of products, including newsprint, specialty papers, market pulp and wood products. The company has 20 pulp and paper operations in Quebec and Ontario as well as nine power generating plants in Quebec and Ontario.

Garneau notes that sustainability principles and objectives are reflected in the company vision and its corporate values. Fueled by this philosophy, by the end of 2013, the company achieved significant energy savings as well as a 67.5-percent reduction in GHG emissions from a year 2000 baseline.

These achievements are the result of substantial investments in switching to more environmentally friendly fuel sources and improving energy efficiency. For example, Resolute FP funded the $10-million conversion of their mill in Saint-Félicien, Quebec, from heavy fuel oil to natural gas. Last year, the company ramped up four power generation assets, including a $65-million 51-megawatt (MW) capacity cogeneration facility in Thunder Bay, Ontario. “In addition to producing revenue from the external sales of some of this power, cogeneration allows us to optimize the use of a renewable energy source,” notes Garneau.

Garneau notes that the company uses SMART (specific, measurable, attainable, relevant and time-bound) targets to ensure continuous improvement. Plans for the future include a 65-percent absolute reduction in GHG emissions by 2015 compared to the 2000 baseline, and the development and offering of low-GHG footprint products to Resolute’s customers.

He sums up the company’s view of long-term sustainability: “Carefully balancing environmental, social and economic priorities strengthens our competitiveness, making Resolute a supplier of choice for our customers, and an engaged civic partner in the communities in which we live and work.”

New tool offers one-stop-shop for energy efficiency training and education

“We expect a career in energy efficiency to be a growing area as governments and the public realize that energy efficiency is the most effective way to save energy and the environment, and education is essential to being part of that trend,” says Elizabeth McDonald, President and CEO of the Canadian Energy Efficiency Alliance (CEEA).

McDonald’s forecast is supported by the U.S. Alliance to Save Energy (ASE), which projects that energy efficiency could create 1.3 million jobs by 2030. That future workforce needs to be prepared, and the CEEA’s new EE Education Tool is designed to address that need as a one-stop-shop for energy efficiency-related courses, certificates and degrees from across Canada. “The tool, launched at the end of September 2014, brings together all of the educational resources – universities, colleges and technical training opportunities – in one handy place,” says Rebecca Isowa, CEEA Board member and Manager of Program Services at Toronto`s Seneca College.

“We knew that courses were being offered all over Canada and we wanted to make sure anyone interested – no matter where they lived – had access to the courses and training to make a career in energy efficiency more accessible,” says Isowa. “The online tool will help Canadians understand the benefits of energy efficiency and how it can positively affect the bottom line of a company, country or individual,” adds McDonald.

The Education Tool has listings for post-secondary colleges and universities and upgrading and training programs for professionals and individuals. The tool features hundreds of courses, certificates and degrees focused on energy efficiency and can be sorted by institution, location, and credential.

To find out more about the EE tool, visit http://energyefficiency.org/educational-resources/.

Workshop hosted by the Coalition for Eco-Efficient Comminution offers collaboration opportunities

“CEEC provides a forum to engage the mining sector in collaboration,” says Craig Haight, Energy Coordinator at Teck Highland Valley Copper Operations, after a recent, two-day workshop in Vancouver, British Columbia, hosted by the Coalition for Eco-Efficient Comminution (CEEC).

CEEC is a global initiative that works to accelerate the implementation of eco-efficient comminution practices through the promotion of research and industry benefits. To this end, the organization offers industry access to the most current technical scientific papers and field studies.

CEEC’s mission fits well with the sustainability goals of Teck Highland Valley Copper Operations, says Haight, adding that his company has been tackling the issue of energy performance metrics for the comminution circuit. “The classic metrics that are used for benchmarking energy performance don’t tell the whole story. By attending the CEEC workshop, we found out that we are not the only mine working to develop more comprehensive metrics.”

Gareth Clarke, Mining Sector Manager at BC Hydro, and another attendee at the CEEC workshop, says that “given our interest in reducing electricity energy consumption in the mining sector, CEEC’s work on new comminution technologies is very important.” He adds that BC Hydro’s rough improvement estimates in the comminution process suggest that an existing mine can save at least 10 percent, and a newly designed mine could cut energy costs by 50 percent.

Haight appreciated the workshop saying that “with its focus on comminution, the CEEC event allowed participants to share more detailed information than would otherwise be possible at a larger conference or within an association with a larger mandate. Participants were able to focus on relevant obstacles and potential technologies.” 

Haight said that the largest single message from the workshop was the importance of developing metrics and methodologies for energy performance benchmarking. Given the many factors that affect the comminution process, appropriate, comparable metrics are important to be able to benchmark within and across companies. Clarke adds that workshop participants identified challenges and opportunities in the comminution process that will provide direction and priorities for CEEC for the next two years.

According to Haight, CEEC is a vehicle for supporting sustainability in the mining industry by sharing principles of operation excellence and best practices. “The more companies can be part of CEEC and partake in workshops like this, the more collaboration will occur and positive change will ensue.”

Clarke also notes that CEEC can be an important player in market transformation and that BC Hydro will closely follow CEEC’s activities that align with BC Hydro’s industrial energy management goals and will look for opportunities to collaborate. “We hope that CEEC will push leading-edge change.”

CIPEC Webinar: Combined Heat and Power (CHP) systems

Date:  February 26 – English Session – French session T.B.D.
Time: 13:00 EST
Location: Online, delivered through your Web browser
Duration: 90 minutes
Cost: Free

 

Take advantage of this opportunity to hear first-hand about how combined heat and power (CHP) systems offer great efficiency opportunities.

Conventional methods of producing usable heat and power separately have a typical combined efficiency of 45 percent, while CHP systems can operate at levels as high as 80 percent.

Join us for this webinar to hear first-hand how St. Marys Cement uses CHP to improve the efficiency of their operations and how your company could benefit from implementing CHP. 

 Agenda

  1. Introduction and Overview of NRCan’s CIPEC program
  2. CHP: What is it and what are the benefits?
  3. Industrial Case Studies – St. Marys Cement
  4. Conclusion and Q&A

Speakers

Bruce Clements, Group Leader, Advanced Controls and Simulation, Natural Resources Canada 

Martin Vroegh, Director, Environmental Affairs, St. Marys Cement

Craig Clydesdale, President and CEO, MCS Energy

Register Online HERE

For more information please contact Natalie Bourdeau-Legris at 613-944-4782 or e-mail natalie.bourdeau-legris@nrcan-rncan.gc.ca.

Priority will be given to CIPEC Leaders. For more information about becoming a CIPEC Leader, click here.

Dollars to $ense Energy Management workshops – winter and spring schedule

Energy Management Information Systems
Date: February 28
Location: Vancouver, British Columbia
Offered in collaboration with Langara College

Recommissioning for Buildings
Date: March 14
Location: Vancouver, British Columbia
Offered in collaboration with Langara College

Energy Efficiency Financing
Date: March 28
Location: Vancouver, British Columbia
Offered in collaboration with Langara College

To register, call the Langara College’s Continuing Studies Registration Office at 604-323-5322

Notice: Please allow eight to 10 weeks from the planning to the delivery of a customized Dollars to $ense workshop.

Complete list of industrial events

Call for story ideas

Has your company implemented successful energy efficiency measures that you would like to share with Heads Up CIPEC readers? Please send your story ideas for consideration to the editor, Jocelyne Rouleau, by e-mail at jocelyne.rouleau@nrcan-rncan.gc.ca.

If you require more information on an article or a program, contact Jocelyne Rouleau at the above e-mail address.

You can also use the subscription page to update your contact information, or to unsubscribe or subscribe to the Heads Up: Building Energy Efficiency newsletter, our sister publication for commercial, institutional and federal government buildings. If you are experiencing difficulty accessing the subscription page, send an e-mail to info.ind@nrcan-rncan.gc.ca.