Japan Tobacco’s worldwide energy monitoring initiative takes shape in South Africa.
Japan Tobacco International (JTI) is a manufacturer with 30 factories located in 23 countries around the world. The company recently embarked on a worldwide project to monitor energy usage at all operations, in order to reduce energy consumption across the group. This involves 27 sites around the globe, including South Africa and Tanzania.
The Wadeville operation, east of central Johannesburg, is well advanced in the process together with Endress+Hauser. Endress+Hauser United Kingdom is supplying the energy management software, with Endress+Hauser South Africa providing the products and services required to obtain the information for the system.
First, a complete site audit was conducted to determine the measurement requirements for the overall system. This audit was conducted by flow and energy specialist, Chris Gimson, seconded from the flow production facilities in Switzerland and Evan Dent, business development manager for energy. The audit identified the measurement requirements including electricity, boiler steam, fuel and feed water and a variety of flow and temperature measurement points.
After the audit the following instruments were purchased from Endress+Hauser to calculate steam mass and energy flow rates:
* Prowirl 72F Vortex flowmeters.
* TR10 temperature transmitters.
* RMS621 steam computer measurement.
For the boiler and burner gas consumption supply measurements, Endress+Hauser T-mass 65F Thermal mass flow meters provide a direct measurement of mass flow into the system. Boiler feed and hot water consumption is measured by Endress+Hauser Promag 50 Magnetic flowmeters. Temperature measurement is also supplied for each water line allowing energy to be calculated as well as consumption.
All the signals from the meters are communicated via Modbus directly to the JTI control system and are automatically transferred via Internet to the Endress+Hauser web-based eSight energy monitoring software hosted in the UK. Reports relating to specific energy consumption as well as gas, steam and water usage are generated to provide the factory with accurate baselines and production profiles. From these, energy trends can be monitored and the success of the energy initiatives can be reported in real-time.
Ultimately, the eSight software will collect data from 27 international sites and generate reports to give corporate management a global view of the organisation’s energy profiles and usage. Local sites can log in to view their user specific reports as required.
Benefits of the project can be summarised as follows:
* Single supplier for measurement devices as well as energy management software.
* Consultation on software, measurement technology and installation.
* Extended warranty on instruments based on commissioning being done by E+H personnel.
* Global energy reporting across all JTI factories with the ability to drill down to individual sites and components.
* Hosted global energy measuring and reporting in real-time.
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