IBM - Energy Efficiency Recommissioning: Improving Buildings Systems Efficiency Jean-Pierre Boulianne, Pierre Lefèbvre, Yves Veilleux ICEBO 2013

Transcription

1 IBM - Energy Efficiency Recommissioning: Improving Buildings Systems Efficiency Jean-Pierre Boulianne, Pierre Lefèbvre, Yves Veilleux ICEBO 2013

2 IBM Bromont - Recommissioning IBM Manufacturing Plant Bromont, Qc, Canada Environmental / Energy Management System Recommisioning Program Conclusion 2

3 Bromont Located on a 1000 acres in industrial park in Bromont, Quebec, Canada square feet MicroTeq10 (Consortium of microelectronic companies - research and development in manufacturing technologies) 3

4 Our mission Bromont Second level packaging and electrical testing of the most advanced semiconductors in the world for the entire IBM product line and for some OEM customers. Bromont Wafers Carriers Packaging Electrical Testing Boards Products 4

5 Bromont Groupe Systèmes et technologie Environmental Management System Management Review Environmental Policy Verification Corrective Actions Planning Execution 5

6 IBM Bromont: Energy Efficency Results ESL-IC a Bromont Groupe Systèmes et technologie Energy Conservation (Corporate) Target: 4% Year after Year Energy Savings: 5 M$ over 10 years Incentives Program Utilities Competitive Advantage 6

7 Recommissioning: Buildings Systems Efficiency Central Utillity Plant Boilers Revision of boilers sequence of operation including boilers staging based on priority and efficiency; Reset schedule on the main steam pressure set point according to outside air temperature ranging from 110 to 50 psi minimum; Feed water pressure controlled with VFD to 50 psig above drum pressure (PID tuning); Micro-modulation controls implemented on 2 boilers for optimal combustion efficiency; Calibration of sensors and revision of calibration process; and Tuning of PID control loops. 7

8 Boilers: Steam pressure optimization Before After 8

9 Chilled Water System Overview 9

10 Central Utillity Plant Chilled Water System Chiller staging according to the variable speed drive chiller demand (VFD) Building chilled water supply temperature set point reset according to the HVAC valves demand Modulating the VFD chiller at highest temperature as possible Maintain chillers load to 85% by modulating the leaving water temperature set point and the evaporator flow control; Optimization of the glycol temperature to maximize Direct Free Cooling; Automate start/stop of the Free Cooling with cooling towers to maximize free cooling; Reduction of supply pressure set point from 80 psig to 60 psig; Cooling towers staging and temperature set point according to the Wet Bulb temperature and electrical peak shaving control 10

11 IBM Bromont Recommissioning Program: HVAC HVAC Systems Optimization Key Activities HVAC systems recommissioning. The recommissioning and optimization program for the HVAC systems was established and based on the following activities: 11

12 IBM Bromont Recommissioning Program: HVAC ESL-IC a Identify systems with the higher energy use reduction potential to prioritize the efforts Complete assessment and a plan to cover all systems for each type of improvement HVAC systems recommissioning. The recommissioning and optimization program for the HVAC systems was established and based on the following activities: 12

13 IBM Bromont Recommissioning Program: HVAC ESL-IC a Review of control sequences and implementation of new control strategies to optimize the operation of the systems Temperature, Humidification, Static pressure, Economizer mode Existing instrumentation reviewed and new instruments added to deliver enhanced control capabilities to support project needs. PID control loop tuning was performed for optimal operation HVAC motor fans: Vriable speed drives (VFD) installation on air supply and return fans. Humidification System Optimization Before After Plot-0 Plot TEMP-HUM:M2: pv 35,99 % HR HVAC:M2-RDC-PLA:VLV-HUM.pv 63,01 % SPECS HUMIDITÉ MINIMUM.V alue TEMP-HUM:M2: pv 31,92 % HR HVAC:M2-RDC-PLA:VLV-HUM.pv 48,61 % SPECS HUMIDITÉ MINIMUM.Value :00:00 2,50 jours :00: :00:00 2,50 jours :00:00 13

14 Operational dynamic dashboards Energy Efficiency: Sustainability is Key Operational limits are dynamics and may change on operating and environmental conditions Provide key energy performance indicators Operators to identify and apply correctivesto systems out of specification Maintain optimal energy efficiency Example of the dynamic operational dashboard for HVAC systems 14

15 Conclusion From 2007 to 2012, the recommissioning program has contributed in a total of 2.8 M$ of cumulative energy savings and reduced by more than 7% the related system energy cost for the same period. For The Future we are now evaluating, among other opportunities; HVAC VAV Boxes recommissioning and retrofit. A Chilled Water Demand Flow project Compressor energy efficient technologies Boilers efficiency losses modeling/dashboard Manufacturing equipment economy mode (Code 75) These improvement projects should provide additional benefits over the next several years and support our site efforts to meet or exceed the corporate goal of 4% annual energy conservation. 15

16 Bromont Groupe Systèmes et technologie Energy efficiency The work is never done A cost effective approach A competitive edge A leverage for the pride and the engagement of the employees 16

17 Merci! Thank you! 17