Energy Measurement

Most of our lines have a energy measurement system. This article explains what we have to do in order to commission the energy measurement system.

1 Background information

Piping scheme (Rohrleitungsschema)

• For each category (except elecricity) there is a piping scheme. There you can find the location of the different sensors and the nominal values.
• Piping scheme can be found here:
  • Ask site manager
  • Get from SAP

What values are measured?

• Flowrate of water and thermal oil (some lines additionally have gas, steam and hotwater)
• Supply temperature of water and thermal oil to consumers (some lines additionally have gas, steam and hotwater)
• Return temperatur of water and thermal oil from consumers (some lines additionally have gas, steam and hotwater)
• Consumption of electrical energy

Where are the measuring points?

• Thermal oil
  • MDO
  • TDO
  • Optional: Additional consumers supplied by BMS (e.g. crystallizer, drier heated by thermal oil)
• Water
  • Total consumption of cooling water (e.g. for motors, switchboards)
  • Consumption of individual consumers of chilled water, e.g. chill roll, water bath, pull roll, regranulation.
  • Flow meter: FI
  • Temperature sensor: TI
• Electrical energy
  • Powermeters at each machine part (e.g. Mdo, Pur etc.)
• Gas
• Steam
  • MDO
  • TDO
• Hotwater

Why are temperatures and flow measured?

• Based on flow and temperature difference between supply and return, we can calculate the energy consumption.

2 Protocol

• The protocol is prepared in Siegsdorf so that it is matching for your line and only categories and sensor which exist on your line are mentioned.
• Path to protocol: \\KOM\projects\KOM\_engineering\public\documents\machine_data\XXXX_KOM_checklist_utility_measurements-EEC.xlsx
• Fill in the protocol while you commission the system. This way you will not forget anything and you have all the data available that you need for filling in the protocol (trends, set values etc.).
• After you have filled in this protocol, commit it to the SVN and send it to Siegsdorf
  • To: ibn.eec@brueckner.com.

3 Steps for commissioning

The energy measurement system measures, how much energy is consumed in several categories. There exist sensors for each category that we have to commission, calibrate and verify during the check up. Not every line has all of the below mentioned categories. Follow the protocol in order to see, which categories exist on your line.

• Water
  • PT100 temperature sensors (see section below)
  • Flow meters (see section below)
• Oil
  • PT100 temperature sensors (see section below)
  • Flow meters (see section below)
  • Oil type
    • Get the used oil type from customer or site manager and select in the panel
    • See also Checkup comment in Project_Types.SCL
    • Write into PROTOCOL.

File:Select oil type.png

Select the oil type

• Electrical Energy
  • Powermeters (see section below)
• Gas
  • Flow meters (see section below)
• Steam
  • Flow meters (see section below)
• Hotwater
  • PT100 temperature sensors (see section below)
  • Flow meters (see section below)

• What to do if sensors are not accessible, extra nozzles are missing or cables are too short for exchanging between supply and return line?
  • First, try to solve it on site together with the site manager.
  • If you cannot find a solution on site, take pictures and send an e-mail to Template:EEC-Support explaining the situation. If this issue gets reported repeatedly from many lines, we will try to improve the installation procedures.

First, perform the basic commissioning for each sensor. Make sure the assignment is correct and you get a proper value. Then perform the tasks described below for each sensor.

4 PT100 temperature sensors

The first sections describes the calibration procedure for most of the measuring points at the line. The second section describes the calibration procedure for the Casting Unit Hybrid Cooling System.

4.1 Calibration at ordinary measuring points

1. Check if the correct PT100 are installed

File:PT100 oil.jpg PT100 for oil

File:PT100 water.png PT100 for water

2. Put both PT100 for supply and return line in the same line (either supply or return line)

• An additional nozzle with immersion sleeve should be installed near each PT100.
• If the calibration is done during production ALARM/WARNING MIN/MAX have to be deselected temporarily

File:PT100 additionalNozzle.png

Additional nozzle for calibration

3. Open trend of supply and return temperature and check the deviation of both PT100 for at least 30 min

• The goal is, to have a deviation between supply and return that is smaller than 0.1 °C.
• Note: For calibrating the PT100 there has to be some flow of thermal oil/water!
• Leave the trend window open. Otherwise the trigger level of the trend is too high and you cannot see the small changes.
• Set one of the temperatures as master. Then both sensors will have the same scaling in the trend.

File:ThermErg PT100 WatOilTrendDiff.jpg Trend for calibration

File:Select master.png Select master for scaling

4. Change the value of "Offset" of return temperature according to the deviation

File:Offset.png

Adjust offset

5. Check again the trend of supply and return temperature for at least 15 min

• Now the deviation should be smaller than 0.1 °C. If not, readjust the value "Offset".

File:ThermErg PT100 WatOilTrendDiffOffs.jpg

Check again after calibration

• If the devation is smaller than 0.1 °C, add the final offset that you chose for the parameter panel and a screenshot of the trend to the PROTOCOL.

6. Put the PT100 back to the original position

4.2 Calibration at the Casting Unit Hybrid Cooling System

File:CastingUnit hybrid cooling panel.png Casting Unit Hybrid Cooling

File:CastingUnit hybrid cooling.png Sensors for Casting Unit Hybrid Cooling

• Hybrid cooling system: Cooling with tower water and chilled water. See also Private:CastingUnit Hybrid HCU
• There are no additional nozzels at the cooling units with hybrid-cooling.
• In order to calibrate the sensors the line has to be stopped.
• Close the manual valves at tower water and chilled water supply (to close control valves is not sufficient)
• Open the trends of the three sensors and start the pump
• All sensors should show the same temperature as they are in the same line and there is no cooling or heating in between
• If not, put an offset as described above. Do not enter the offset into the datapoint which is used for the controller (StrCas.Tmp*Ctl). Instead enter the offset in one of the other sensors marked in red on the screenshot above.

5 Flow meters

• Check that the flow meter is installed in flow direction

File:Promag Flow orientation.PNG

Check installation

• Check that the value shown on the display of the flow meter is matching with the value in WinCC.
  • If not, then the value for 20mA at the flow meter is not matching with the range set in the WinCC parameters.

• Check that the serial number of the transmitters is matching with the serial number of the receiver.
  • The flow meter consists of a transmitter and a receiver. Each receiver can only show correct results, when connected to the dedicated transmitter. Therefore check that the serial number of the transmitters is matching with the serial number for the receiver. If the serial number is not matching, the transmitter-receiver pairs were probably mixed up during installation. Look for the matching partner at other positions along the line.

File:Prowirl D 200 transmitter.png

Check serial number

• Check the measuring range
  • The sensors are set to the values from the BMS Mat.-Nr. specification by the subsupplier but we need to check if the measuring range is big enough.
  • If the measuring range is exceeded (i.e. output signal > 20 mA) there is an error message on the display and in WinCC (currently alarm max, in future sensor fault). In that case, expand the measuring range at the sensor and in WinCC.
    • The measuring range should be at least 20% larger than the expected flow.
    • The extended measuring range should not be identical to the standard measuring range of the next larger sensor (so that you can immediately see that the measuring range was intentionally extended here and not just by mistake that an incorrect measuring range was entered).
  • Follow the instructions in the article for the specific device linked below for changing the measuring range.
  • After changing the measuring range, write the new values into the PROTOCOL.

Water

• Details for the water flow meter can be found here Promag .

Oil

• Check whether the flow meter is installed in the supply or in the return line
  • There is the Bit StrGnl.OilFlwSenRtuPos.Bit in StrGnl.SCL together with a Checkup comment.
  • Check if the flow meter is installed in supply or return line, set the Bit accordingly and resolve the Checkup comment.
  • Write into PROTOCOL.
• On most lines we are using the Prowirl flow meter. In some cases however we are using the old setup with the orifice.
• Details for the Prowirl oil flow meter can be found here Private:Prowirl (Oil).
• Details for the oil flow meter using the orifice can be found here Fischer DE38.

Steam

• Details for the steamflow meter can be found here Public:Prowirl (Steam).

Gas

• TODO: Currently no article exists for the gas flow meter.

6 Electrical energy

• Follow the instructions in Public:Siemens AI Energy Meter.
• Take a screenshot of the power meter overview panel when all power meters are under load and add it to the PROTOCOL.