KERO Energy Saving Projects 2015 – 2019

KERO Energy Saving Projects 2015 – 2019

The contribution to the powerplant is:  131,3 kWp

Kimball Electronics Romania started activity in a green field facility in Remetea Mare, Timis County, Romania, in November 2015.

Since then we work to improve and certify our work environment obtaining:

  • ISO 9001:2015, 12/2015

  • IATF16949:2016, 04/2016

  • ISO 14001:2015, 04/2017

  • ISO 50001:2011, 05/2018

  • ISO 45001: 2018, 06/2019

Energy saving was a priority for us since beginning, targeting to operate in a green / safe environment and, as well, to reduce our spending related to energy consumption. 

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Energy Saving Best Practices

1.      Temperature and humidity set points optimization

In 2018, in order to reduce energy consumption, we implemented the following changes:

  • during the summer time we increased the temperature set point with 1⁰C in the production area from 23⁰C to 24⁰C

  • we increased the temperature of the chilling water with 1⁰C, from 7⁰C to 8⁰C

  • during the winter time we decreased the temperature set point with 1⁰C in the production area, from 23⁰C to 22⁰C

  • we increased the humidity set point in the production area from 50%RH to 55%RH.

After implementation we monitored closely the effects of the changes, consulting with production people about how they feel it. There was no negative impact at all.

By doing this we were able to save 256MW (21.94TEP) per year due to electrical energy saving (summer time temperature and chiller) and 500MW (42.84TEP) per year due to gas energy saving (winter time temperature and humidity).

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2.      LED LIGHTING

Since beginning in 2015 we implemented LED lighting instead of standard fluorescent lamps. In our plant we use over 600 lamps, a simple math showing us a saving of about €16,000/year.

# of lamps: 610

LED lamps power: 38W/h

Fluorescent lamps: 72W/h

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Power saving:

per hour: 20.7kW

per year: 119.2MW

Cost of LED lamps: €75 each

Cost of fluorescent lamps: €30 each

Yearly energy cost saving: €16,330

Pay back years: 1.7

Contribution to the Virtual Power Plant:

·         Total Energy Saved: (where TEP equals to 11,36 MWh)

o   Electricity:  48,7 TEP= 553,232 MWh

o   Heating and gas: 90 TEP=  1.022,4 MWh

o   Total: 1.575,632 MWh

 

PVPPP= QVE x η / τCS

 

Where: 

PVPPP – Energy Saving accounted in the Virtual Power plant

QVE – The full energy  saving, meaning the basis of the calculations

η – average powerplant efficiency

τCS - annual peak hours of the power plant

The contribution to the powerplant is: 131,3 kWp

Complex Energy efficiency investments at ETA2U

ETA2U

Complex Energy efficiency investments at ETA2U

Contribution to the Virtual Power Plant 131,3 kWp 

ETA2U is the main Romanian IT systems and solutions integrator, IT products and services provider and one of the most certified companies on the Romanian IT market (technical, business and quality).

The company has the following certifications:

  • SR EN ISO 9001:2015 Quality Management Systems

  • SR EN ISO 14001:2005 Environmental Management Systems

  • SR OHSAS 18001:2008 Occupational Health and Safety Management Systems

  • ISO/IEC 20000-1:2011 Information Technology - Service Management

  • ISO 22301:2012 Societal Security - Business Continuity Management Systems

  • SR ISO/CEI 27001:2013 Information Technology — Security Techniques — Information Security Management Systems

Obtaining ISO 50001 certification is one of the short-term goals. In this line, energy managers have started two major projects at the company's branches:

  • Lighting modernization – 2018/2019;

  • Data Center energy consumption optimization – 2019/2020.

These two projects were preceded by the installation of an energy consumption monitoring system. Monitoring devices were installed at key points (main distribution boards) and where needed monitoring was carried out at lower levels of consumption (secondary distribution boards – e.g. lighting circuits). Graphics from a monitoring device can be seen below.

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Fig. 1. Current monitoring – main distribution board

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Fig. 2. Active power – main distribution board

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Fig. 3. Reactive power – main distribution board

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Fig. 4. Current monitoring – secondary distribution board – circuit 1

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Fig. 5. Current monitoring – secondary distribution board – circuit 2

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Fig. 6. Current monitoring – secondary distribution board – circuit 3

Lighting modernization – 2018/2019

By investing at the headquarters, 200 fluorescent light fixture (fig. 7) were replaced (4 x 18 W), maximum total output 14.4 kW. This means 42 MWh energy consumption per year, if we consider an average of 8 work hours per day.

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Fig. 7. Fluorescent light fixture

Installing LED lighting panels (fig. 8) and optimizing the number of luminaires achieved part of the efficiency. As a result of the optimization the number of luminaires was reduced by about 20% (from 200 to 160).

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Fig. 7. LED lighting panel

Following the implementation in the office area, we saved about 19.6 MWh/year

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By mounting motion and twilight sensors (bathrooms, outside), we saved about 9.7 MWh/year.

Energy efficiency investments at ETA2U contributed 29.3 MWh to the Virtual Power Plant.

Data Center energy consumption optimization – 2019/2020

This ongoing project focuses on energy consumption optimization in our Data Center (45 kW). Within this project network equipment will be replaced and HVAC will be optimized, also a reactive power compensation system will be installed.

Total energy savings- contributed to the VPPP:

Electricity: 553,2 MWh

Heating energy: 1022,4 MWh

PVPPP= QVE x η / τCS

 

Where: 

PVPPP – Energy Saving accounted in the Virtual Power plant

QVE – The full energy saving, meaning the basis of the calculations

η – average powerplant efficiency

τCS - annual peak hours of the power plant

The contribution to the powerplant is: 131,3 kWp

Energy program in dalli Timisoara Plant

Contribution to the Virtual Power Plant

Energy program in dalli Timisoara Plant

The contribution to the powerplant is: 88,6 kWp

Timisoara Plant is a recent addition to dalli company, since 2015, as it has been acquired from P&G company.

Our core business has remained in the same area of Fast Moving Consumer Goods, House & Fabric Cleaning Products adding to Brands also the Discount Market.

The need for a sustainable and efficient plant from energy consumption point of view already existed in P&G and was taken over by dalli as well in day to day business.

Several challenges have been solved during this 10 years program:

  • LED installation for all new projects cutting the constant need for work at height in heavy production areas to energy consumption improvement.

  • Heating in several warehouse areas was also solved with minimal investment and zero on-going cost of utilities by re-using existing resources from compressor units.

  • Plant logistic flow was massively redesigned, reducing from 25000 km annual cumulated distance, to less the 10000 km.

  • Invertors for all motors/pumps in all production departments

  • Condensate recuperation from the steam system throughout the plant

  • Civil upgrade on insulation and windows

  • Sensors on all lighting which can be used via daylight/movement sensor

  • Compressed air leakages audit

  • Master control on compressor room to increase efficiency on equipment utilization

  • LED lighting upgrades on several areas in the plant

  • Infrared camera audit on all electrical cabinets in the plant

  • HVAC automation & monitoring

The program has achieved 40% improvements in energy consumption overall in the plant.

A major reconstruction project started in the last 2 years providing opportunities to upgrade the existing standards with the latest technologies:

  • LED lighting in all the new area constructed:

    • Mixing area

    • Filling area

    • Tank-farm area

    • Palletisation/Distribution Centre area

    • Offices Building

  • Compressor room designed to re-use hot air in order to heat during winter, warehouse areas.

  • Logistic flow major redesign

  • Transformers station & site layout preparation for future energy saving projects

1.     Upgrade on LED lighting

Depending on each area, there were several types of luminaires used:

  • 164W, 25.000lm, 4000K, Wide beam – projector type of LED light (replacement of 400W projector)

  • 30-46W, 4300lm-6400lm, 4000k, Wide beam – 150cm - replacement of T26 -2x36W traditional lighting

  • 35-53W, 5240lm-7900lm, 4000K, wide beam – 150cm - replacement of T26 -2x36W traditional lighting chemicals/steam resistant

  • 36W, 3600lm -  4x18W replacement (600mm x 600mm)

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This project concludes an annual saving of approximately 394 MWh with about 47KW saving in output.

2.     Compressor room designed to re-use hot air in order to heat during winter, warehouse areas

As a new compressor room has been built and it is known that 85% of the energy consumed by a compressor is dissipated energy through heat, several projects have been put in motion in order to bring as much efficiency as possible.

There are several areas where projects are addressed:

  • Old generation compressors replaced with new generation ones - done

  • Using hot air generated by compressor units to increase temperature by 10 degrees Celsius on adjacent warehouse areas - done

  • New master control system to optimize use of all compressors units - planned

  • Generate hot water with heat exchanger incorporated in the compressor unit and re-use it on offices building – planned

The needed system to heat up the adjacent area of the warehouse would have a capacity of approximately 170 kW and it is no longer necessary due to this project.

The annual saving is about 490 MWh.

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The system diverts hot air from compressor exhaust, into the Warehouse, for 3-5 months per year, depending on temperatures.

3.     Logistic flow major redesign

The logistic flow redesign has reduced from 25000 km annual cumulated distance or forklift travel, to less the 10000 km.

This gives a saving in energy consumption of forklift fleet of about 180 MWh.

4.     Transformers station & site layout preparation for future energy saving projects

All new buildings have been designed to accommodate future photovoltaic panels that generate electricity.

The area that can sustain this is about 5000 sqm.

Transformers station is built with new generation efficient dry transformers and with back-up capacity for future projects.

5.     Total savings and contribution to the VPPP:

  • LED lights:  394 MWh

  • Compressor room: 490 MWh

  • Logistics redesign: 180 MWh

  • Total savings: 1.064 MWh

 

PVPPP= QVE x η / τCS  

 

Where: 

PVPPP – Energy Saving accounted in the Virtual Power plant

QVE – The full energy saving, meaning the basis of the calculations

η – average powerplant efficiency  

τCS - annual peak hours of the power plant

The contribution to the powerplant is:  88,6 kWp

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