Overview
This case study outlines the strategic implementation of water and energy efficiency improvements in a large, complex production facility consisting of three production sites. The facility faced significant challenges in meeting environmental compliance standards due to inefficient use of resources. With a control and instrumentation device count exceeding 1500, the project required precise planning, innovation, and collaboration to achieve substantial efficiency gains.
Challenge
The production complex was under scrutiny by environmental regulatory bodies for excessive water usage. An initial scope document from the client highlighted the risks associated with current practices and identified potential solutions for improving efficiency. However, a detailed review and request for clarification by our consultants led to the discovery of design challenges that required innovative thinking and strategic planning to address effectively.
Solution Development
Despite compliance, one of the two solutions presented a significant challenge due to long lead times for component delivery. Our team performed a comprehensive design Risk Assessment for both solutions to evaluate the technical and operational risks in line with the company's Quality Management System (QMS).
After stakeholder consultation, including client solution engineers, process support, project managers, site operations, and an internal multidisciplinary team of EC&I and software engineers, our experts implemented the solution which involved managing the obsolescence impact of the PLC and SCADA components on the existing system, with expert consultations from Schneider Electric and the client's Process Support department.
This approach leveraged the reuse of production waste and by-products, heating multiple contents in parallel through effective heat exchangers with flowrates automated to match desired temperatures. This design ensured compliance with environmental standards and optimized resource use.
Implementation and Results
Following a successful software testing phase and simulation of results, trial dry testing was conducted. The innovative solution not only mitigated the risk of penalties from the regulatory body for excessive water use but also achieved a remarkable saving of a minimum of 65 cubic meters of water over 12 production batches.
A comprehensive technical report was produced to guide future operations. An Operator and Maintenance Manual (O&MM) was compiled by our technical author, consolidating various supplier datasheets and manuals into a single, cohesive document.
Conclusion
This project showcases the power of strategic planning, stakeholder collaboration, and innovative engineering in overcoming environmental and operational challenges. The successful implementation of water and energy efficiency measures not only ensured compliance with regulatory standards but also demonstrated a commitment to sustainable and efficient production practices.
