Download - Energy Savings in Foundries
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Computerization in the Foundry Industry (Panel 14-132)
Energy Savings and Productivity Improvements using Computer Controlled,
Remotely-Monitored, Smart Sensors
• James Wiczer, Sensor Synergy Inc., Barrington, IL• Brad Tidd, North Vernon Industry Corp., North Vernon, IN• Michael Wiczer, Sensor Synergy Inc., Barrington, IL
• Case studies described in this presentation were funded by the American Foundry Society under R&D project #12-13#03 and by the Collaborating Foundries including NVIC
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Today’s Talk
• Background on Energy Savings & Monitoring
• Project 1 – V-Process Pumps• Project 2 – Shakeout Table & Dust
Collector• Project 3 – Induction Furnaces• Analysis Tools• Conclusions
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
What we want to talk about• Real-world application of Technology to
Foundry Issues
• Millions of Measurements
• Data shared in the Cloud & the Foundry
• Application of High-Tech Software Tools to Analyze Lots of Data
• Create Actionable & Meaningful Recommendations
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Project #1 - Vacuum Pumps for V-Process Molds – Energy Saving Opportunities?
• Up to 4 Large Electric Motors Driving Vacuum Pumps to Supply Vacuum to the Pouring Floor and Shakeout area– Motors Include 250hp, 250hp, 250hp & 200hp
• Monitor Power Used by Motors and Vacuum Pressure Measured at Pouring Floor and Shakeout Floor
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Measure Electric Power Consumed by 3 Connected
Motors –
Pouring Floor Vacuum Pressure Monitor
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Unexpected Motor Failure During Measurements Revealed Excess Capacity
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Vacuum System Energy Savings Opportunities
DatesHours “On” Past
Ideal Turn Off time
Approx. Extra kW-hr usage
Potential Savings if turn-
off time optimum
Total Potential Savings from 6 weekends
10,280 kW-hr $1028
Total Potential Savings from
1 year (50 wks) if these 6 weekends are
typical
85,570 kW-hr $8,570
Potential Savings by Reducing
Extra Vacuum
Capacity
No Capital Expenditure
Expenditures per
Building ($12,000)
Estimated Annual Failure Costs Due to
Reduced BackUp Vacuum Capacity
Measured in Bldg. 2 $80,000 $100,000 to
$130,000 $0 / $7,500
Estimated Total for both Bldg. 1 & 2
$160,000 $200,000 to $260,000 $0 / $15,000
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Results from Vacuum Pump Monitoring
• Excess Capacity for “Design Margin” Can Be Costly in the long term
• Identified $50,000/Yr to $90,000/Yr at Each Facility Extra Capacity Energy Costs
• Effort Needed to Identify Extra Capacity (if any) and to Achieve Savings
• Cost vs. Savings Trade-Off
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Project #2 – Monitor Dust Collector and Shakeout Table
• Monitor the Synchronization of the Shakeout Table and a Dedicated Dust Collector
• Opportunities for Savings with Better Synchronization
• Use 2-second Measurements to Monitor Operations of these two Power Hogs
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Project #2 Conclusions
• Improved Synchronization of Shakeout Table and Dedicated Dust Collector Drive Motor can Save– $38,000/year in Electricity
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Project #3 – Induction Furnaces #4 & #5 @ NVIC
• Install Power-Use Measurement Equipment on 2, 4MW induction furnaces ---- #4 and #5
• Make 1-Measurement/second, 24/7 for the duration of the project
• Send Data to Cloud Server to Share Data with all Interested Stake-Holders
• Correlate Power-Use Measurements with Activities at Foundry
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Key Features of Induction Furnace Monitoring Project
• Over 16 Million Power Measurements during the first 3-months on 2 Furnaces
• Correlated Weight of Metal Heated During Each Furnace Heat with the Amount of Electricity Used for a Portion of the 3-month Study Period
• Correlated Run Sheet “Time of Day” Information with Power Measurements Time of Day Data
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Equipment Installation
PC Data Viewer located in Foundry
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Web Browser Data Viewer on the Internet
Power measurements for the same time duration during normal operations and during problem operations
Red area shows when
furnace is using
electrical power
White area shows when
furnace is not using electrical
power
Furnace Electrical Power
Usage is as expected – Start at ½ power then go to full power and finally off while tapping
Furnace Electrical Power Usage Profile is
unexpected – Long periods of “Off Time” while
equipment is repaired and other issues.
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Cost of Electricity/Heat per Ton
12:00 AM 4:48 AM 9:36 AM 2:24 PM 7:12 PM 12:00 AM 4:48 AM0
20
40
60
80
100
120
140
160
Electricity Costs/Heat per 2,000 LB --- Costs Measured for Duration from Tap to Tap time)
Cost per 2,000 LB
Electricity Cost per Ton per HeatAverage $53.15Std. Dev $19.29Coefficient of Variation 0.363
Associating the amount of electricity used (costs) for a single heat with the amount of metal heated does not result in a strong correlation. In fact the Coefficient of Variation is Greater when we tried to compensate for the different amount of metal being heated during each furnace run.
Average Cost/Ton
$53.15
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Observations from Project #3
• Power Data is a High Resolution Indicator of Induction Furnace Activity
• Knowing the Costs of “Issues” may help a foundry determine which ones to Remedy – Equipment in need of Frequent Repair– Shift Change Issues– Hold Power Usage
• Power Setting During Hold Times• What Events Cause a Shift to Hold Power• Total Energy Expenditures after Ready Time
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Costs with Worst 25%
9/4/13 12:00 AM 9/4/13 12:00 PM 9/5/13 12:00 AM 9/5/13 12:00 PM 9/6/13 12:00 AM 9/6/13 12:00 PM 9/7/13 12:00 AM 9/7/13 12:00 PM$0.00
$50.00
$100.00
$150.00
$200.00
$250.00
$300.00
$350.00
$400.00
Tap to Tap Costs/Heat ($'s) for 3 Day Sample / Orange - Lower 75% / Lt. Blue = Upper 25%
Tap to Tap CostsUpper 25% of Tap to Tap Costs
Date and Time of Day
Tap
-to
-Tap
Co
sts
($'s
)
Average Costs
including Lt. Blue Values
Average Costs Excluding Lt. Blue Values
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
If we could do this, then ….
• The average electricity costs/heat for operating the induction furnaces would decrease from
•$200.18 … to … $178.11
• This would create and Annual Electricity Savings of …
•$466,400
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Data Analysis Tools
• Build tools to study data specifically for foundry applications
• Goal: Extract the best information for those most knowledgeable about the operations & demands of a particular foundry– Experts + data can learn the most about
improving their operations
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Generating Furnace Operation Logs
• Let’s focus on one example of a data analysis tool we’re working on– Problem inspired by this project with
NVIC• In this project, we focused on
correlating energy with operations.– This required accurate logging that is
difficult to achieve over extended periods of time
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Generating Furnace Operation Logs (cont.)
• Challenges to getting accurate operations logs / run sheets:1. Manual logging is time-consuming
• Inaccuracies may result from the many tasks performed by furnace operators at tap time
2. Additional instrumentation for electronic detection of melt start / end times is often complex and costly
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
• Use the power data we collect to estimate when operation events (e.g. tap time, melt ready time, etc) occur
• But first…
Furnace Operation Logs – A Third Option
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Some preparation for a little bit of computer talk
• Algorithm: A calculation or procedure a computer program uses
• Parse: Splitting up data into pieces• Score: The algorithm’s evaluation of
some data.• Sigma (σ): Standard deviation. The
“spread” of some data.
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Software identification of melt start & stop events
• Computer prediction can sacrifice some accuracy in favor of ease-of-implementation– Algorithmic approach– Get lots of data and treat them
statistically– Enable operators to focus on core
duties
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
How the algorithm works• Manually log times during
“training” period– We used 3 days & 82 melts for this
example• Learning based on Principle
Component Analysis (PCA)– Most notably used in face
recognition algorithm “eigenfaces”– Think of a 15 min window around
each event as a “face”(Photo: AT&T Labs Cambridge)
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Sliding windowPower measurements
Prediction score
Window (prediction input)
Evaluate a window and predict how likely start of tap event is at the center.
15 Minutes
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Sliding window scoresPower measurements
Prediction score
The power curve gets a corresponding curve for likelihood of tap start.
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Algorithm processes scores and generates melt start times
Power measurements
Predicted event times
Take the highest scores in a neighborhood and get discrete tap time predictions.
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Repeat for “melt ready” events
Apply the same algorithm to melt ready times and combine the results.
Power measurements
Predicted start times
Predicted ready times
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Exploratory Analysis
Tap to Ready Time (min)
Ave
rage
Pow
er (
KW
)
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Exploratory Analysis
Tap to Ready Time (min)
Ene
rgy
Con
sum
ed (
KW
Hr)
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Improved Metrics
Mean = 42.1 minσ = 12.4 min
Mean 11.7 minσ = 4.3 min
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Improved Metrics
• Analyze furnace usage from “Ready time” to “End-of-Tap time”:– Average energy: 24 KW Hr– % of Tap-to-Tap energy: 2.4%– Average time: 11.8 min– % of Tap-to-Tap time: 23.7%
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
Conclusions• These Projects Improved Energy Costs and
Operational Efficiencies by Applying High-Tech Monitoring Hardware & Software
• Foundry Operations Experts & Energy Analysts Exploit these Tools to Identify and Quantify Issues
• In each Case, Monitoring & Analysis Generated Actionable Recommendations
118th Metalcasting Congress April 8-11, 2014 – Schaumburg, IL USA
For additional information:
James (Jamie) Wiczer, PhD Sensor Synergy, Inc. – Barrington, IL
[email protected] / Ph. 847-353-8200
Brad Tidd, Senior Kaizen Manager North Vernon Industry Corporation, North Vernon, IN
Brad.Tidd@NVIC-CWT / 1-812-346-8772 x 1288
Michael Wiczer, Senior Software Engineer
Sensor Synergy, Inc. – Barrington, [email protected] / Ph. 847-226-0687