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HONEYWELL'S ENERGY EFFICIENCY AND ENVIRONMENTAL CAPABILITIES

2000 Edition

Prepared by: Corporate Government Relations International Affairs Washington, D.C. November 2000

Table of Contents
I.

Introduction and Capabilities Overview Honeywell in Power Generation


Parallon 75TM Microturbine for On-site Power Generation (Bensenville, IL) North America Louisville Gas & Electric Retrofit (Kosmosdale, KY) Otter Tail Power Plant Automation (Big Stone, SD) Western Europe Akzo Delesto II Delfzijl (The Netherlands) Central & Eastern Europe Bobov Dol Thermal Power Station (Bulgaria) The Komoany Heating Plant (North Bohemia, Czech Republic)

4 9 10 12 14 16 17 19 22

II.

III.

Honeywell in Power Transmission


Asia Andra Pradesh Rural Electrification (India) Electrical System Distribution Efficiency Improvement (Japan)

23 25 27

IV.

Honeywell in District Energy


Central & Eastern Europe Varna District Heating (Bulgaria) st Nad Labem District Heating Plant (Czech Republic) Otrokovice District Heating Plant (Moravia, Czech Republic) Bonyhd ESCO District Heating Project (Hungary) Sikls District Heating Project (Hungary) Katowice District Heating Plant (Poland) District Heating Improvements in Krakow (Poland) Martin District Heating Network (Slovakia) District Heating Boiler House Revamp (Romania) District Heating Substations Control (Romania) Murmansk District Heating (Russia) Tver District Heating (Russia) Moscow: Tushino-3 (Russia) Pozniaky Heating Plant (Ukraine) Kiev Institutional Buildings Assessment Project (Ukraine) Asia Beijing District Heating (China) Yantai TRV Demonstration Project (China) Sangmu District Heating (Korea)

28 31 33 35 39 42 44 49 51 53 55 57 59 61 62 64 65 67
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V.

Honeywell in Process Industries


North America Amoco Chemicals (Decatur, AL) Gulf States Lime Kiln Optimization (Demopolis, AL) Asia South Australia Water Optimization - SCADA (Australia)

68

69 71 73 76 77 79 82 85 87 90 92 94 96 98 100 102 104 105 107 109 111

VI.

Honeywell in Buildings and Residences Western Europe


Performance Contracting for Ford (Belgium) Performance Contracting for Samsonite (Belgium) Performance Contracting for Norton (France) Performance Contracting in the University of Cologne (Germany) Performance Contracting for Schools (Germany) Performance Contracting for Poste Italiane (Italy) Performance Contract for Willem Alexander Hospital (The Netherlands) Performance Contract for Groot Ziekengasthuis Hospital (The Netherlands) Energy Site Monitoring - Ford Espaa S.A. (Spain) Performance Contracting for Ford Espaa S.A (Spain) Performance Contracting in Crawley Hospital (West Sussex, England) Performance Contracting for Havering Hospitals NHS Trust (Essex, England) Performance Contracting for Glan Hafren NHS Trust (Newport, Wales) Asia Hanvit Bank Intelligent Building System Project (Korea) Immanuel Methodist Church (Korea) Inland Revenue Authority of Singapore Air Quality Project (Singapore) Honeywell Asia-Pacific Headquarters (Singapore) Latin America Positive Pressurization of the Paint Shop at Ford Motor (Mexico) Lighting Retrofit and Control Project at Ford Motor (Mexico)

112 115

VII.

Honeywell in the Aerospace Industry


Honeywell Flight Management Systems AS900 Series Turbofan Engines

117
118 120 122 123 125

VIII.

Honeywell in the Automotive Industry


Garrett Turbochargers Automotive On-Board Sensors

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IX.

Honeywell in the Carpet Industry


Infinity Nylon (Evergreen Recycling Plant: Augusta, GA)

126 127 130 131 134 135

X.

Honeywell in the Chemical Industry


Genetron Environmentally Safer Refrigerants and Foam Blowing Agents

XI. XII.

For Further Information Acknowledgments

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Honeywell Energy Efficiency and Environmental Capabilities INTRODUCTION


Honeywell is a US$24-billion diversified technology and manufacturing leader, serving customers worldwide with aerospace products and services; control technologies for buildings, homes and industry; engines and power generation systems; specialty chemicals; fibers; plastics; and electronic and advanced materials. Headquartered in Morristown, NJ, Honeywell employs approximately 120,000 people in 95 countries. While a diversified company, there is a common thread that runs through many of the products, solutions and services that we offer our customers and that is that they improve energy efficiency and offer environmental benefits. This report is intended to provide interested readers with a comprehensive view of Honeywells capabilities from this energy efficiency and environmental perspective. You may be surprised by the breadth of technologies that we deploy, the range of markets to which we deliver these capabilities, and the impressive benefits financially and environmentally - that they bring to our customers. Following this overview are specific examples from around the world of illustrative projects and customer relationships that span the full range of Honeywells energy efficiency and environmental capabilities. For further information on the information provided in this document, please refer to the contact information at the end of the brochure. We welcome your interest and comments.

Capabilities Overview
Power Generation
Honeywell brings efficiency and environmental benefits to power generation in two major ways. One, we provide technologies, services and products that improve the operating performance and therefore energy use and related emissions output within a range of power production facilities from industrial power users to independent power producers. Secondly, we have developed and now manufacture high efficiency stand-alone power generation units that can operate either on or off an electrical power grid. Electric Utilities Deregulation and privatization in this industry are having a major impact on the way plants operate in this historically slow-changing industry. This restructuring will require utilitygenerating companies to respond to a dynamic global business environment; they will need to increase revenues and reduce the cost of a delivered product from aging fossil-fuel-fired steam power plants. At the same time, they must maintain safety and reliability while meeting ever-changing environmental regulations.

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As one of its primary markets, Honeywell Industrial Automation and Control (IAC) has been providing electric utilities with system and product solutions that improve the operation of plants through automation and advanced control applications. Systems solutions are delivered through the Power Generation Center of Excellence. IAC has also helped utilities respond to organizational changes by providing support and assistance to replace skills lost during these reorganizations with the TotalPlant employee development program. Benchmarking the organizational process and improving the productivity of the plants can be a very important step in the deregulation process and is another service available from Honeywell IAC. Industrial Energy Honeywell does not take the traditional view that the power house is strictly an allocated cost center. Too often, utilities such as steam, electricity, compressed air and chilled water are treated as an unavoidable overhead, or an allocation rather than a manageable variable cost. Honeywell believes that energy is often a hidden and neglected variable cost that can be managed and controlled by production managers with a direct impact on profitability. Controlling these hidden costs can be a major source for product cost reduction, profit improvement, and/or a means to differentiate your product on price. Honeywell has developed a family of solutions to address the needs of regulatory control, advanced monitoring, and optimization designed to specifically minimize energy costs while maximizing availability and reliability. It has been Honeywells experience that implementation of industrial energy management and control projects reduce energy expenses from 2 to 6 percent. Independent Power Producers Deregulation is spawning an increasing number of non-utility power generators whose goal is to provide the lowest-cost energy. Recent surveys of the industry indicate that the instrument and control systems originally installed in these plants have not been sufficiently reliable; they do not incorporate the advanced design elements necessary to ensure the availability or performance expected from these generator sets. Honeywells proven reliability and advanced control applications provide the ideal suite of solutions that this highly competitive industry needs to continue to be competitive. On-Site Power Generation Honeywell offers the Parallon 75, a compact, self-contained unit that uses a microturbine to convert a wide variety of gaseous and liquid fuels into electricity for onsite power generation, to small and mid-sized businesses. Capable of providing energy solutions from 75 to 1 KW, the system is designed to operate parallel to the utility grid or as an independent source of power for the customer. It helps to reduce energy bills, improve power quality and reliability, and minimize the risk of power outages.

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Power Transmission & Distribution


Honeywell helps electric utilities reduce their operating costs and improve energy savings through its new generation METGLAS amorphous metal distribution transformers (AMDTs). These transformers can achieve up to 80% lower core loss than conventional transformers. When you consider that 10% of all electricity generated by utilities today is lost in the transmission and distribution process, the potential savings through reductions in core loss can be significant.

District Energy Systems


Honeywell is the only company that can provide a complete solution for every part of a District Heating System achieving energy savings at each level of operation up to a total of approximately 45%, and thereby reducing CO2, NOx and SO2 emission. Honeywells approach offers integrated automation of the generation plant, integrated control of the heat distribution systems, and local user comfort control.

Process Industries
Substantial amounts of energy and power are utilized in the process of manufacturing many of the materials and products that consumers and businesses consume each day. Honeywell is a world leader in automation solutions for a wide range of process industries, including oil & gas, chemicals and petrochemicals, pulp & paper, mining, metal and minerals, pharmaceuticals and other consumer goods. By providing advanced control and information management software and industrial automation systems and related field instrumentation and control products, Honeywell helps industries optimize their manufacturing processes and in so doing, achieve greater energy efficiency in the plant operations. As noted above, Honeywells control systems can also be applied within a plants powerhouse, thereby achieving improved energy efficiency in both the process and power generation aspects of the industrial facility .

Buildings
A substantial proportion of the energy consumed worldwide goes to power and heat homes and buildings. Honeywell is a global leader in control systems and products that can improve the operating performance of key systems (heating, cooling, lighting and security) within homes or apartment buildings, factories, schools, hospitals, airports, commercial buildings, and military installations. In fact, Honeywell offers comprehensive energy retrofits for all of these kinds of facilities, enabling the homeowner, building owner or operator to enjoy greater comfort and easier management while also achieving energy and thereby cost savings. Performance Contracting Honeywell also offers Performance Contracting to many of its customers. Performance Contracting or Comprehensive Technical Service (CTS) is a service that Honeywells Home and Building Control division offers to owners of building complexes, particularly to hospitals, industrial plants, schools and universities. Working with the customer, Honeywell identifies a range of infrastructure improvements that will significantly reduce

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the customers operating costs. Honeywell then formally guarantees that the cost of the improvements will be completely covered by energy and operational savings.

The Aerospace Industry


Honeywell offers a variety of systems and solutions designed to improve aircraft environmental performance and reliability. These products include flight management systems that assist the flight crew in selecting the most efficient flight path and aircraft operating settings to maximize fuel efficiency and noise reduction, and more fuel-efficient engines and power systems. Flight Management Systems (FMS) Honeywell has become the world leader in Flight Management Systems. Airlines and corporate operators worldwide rely on Honeywell FMS systems for en route and terminal area navigation. Honeywell flight management systems are based on proven Honeywell technology, while incorporating many of our customers' requests for advanced capabilities. Many of Honeywell's FMS products are designed to control for lowest fuel burn and to allow the crew to fly the airplane in the most cost efficient way, thus reducing the energy consumed and the emissions created by the aircraft. FMS products achieve this by providing cockpit level control of the airplanes including variables such as determining the right altitude to fly and predicting arrival times. Honeywell has developed patented algorithms for several performance and economy functions that offer the flight crew choices impacting environmental issues. Honeywell has also developed self-tuning performance capability for optimum efficiency, Autopilot Coupled Vertical Navigation for maintaining a desired flight profile, and Noise Abatement Departures features. Engines and Systems - A900 Series Turbofan Engines The AS900 Series Turbofan Engine was designed to provide main power for new technology regional airliners and corporate aircraft being manufactured and delivered over the next twenty years. The AS900 has been designed to increase fuel savings and reduce direct maintenance costs (DMC). The AS900 utilizes 15% less fuel than current engines in the same thrust class and has DMC guaranteed to be 20% less than comparable engines.

The Automotive Industry


Honeywell brings higher fuel economy and helps reduce automotive-related emissions through our Garrett Turbocharger engines and on-board automotive sensors. Engines outfitted with Turbochargers give a small engine the same horsepower as a much bigger engine and make bigger engines more powerful, up to 40% more powerful than it would have been without the turbocharger. Because a turbocharger delivers more air to the engine, combustion of fuel is more complete and cleaner, which helps reduce emissions. Fuel economy is increased as small, turbocharged engines turn more of the fuel energy they consume into power and waste less of it through heat loss and friction.

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Honeywell Sensing and Control is a leading supplier of active cam, crank, transmission, body systems, and wheel speed sensors for applications that require high accuracy, extreme temperatures, or specialized packaging to survive rugged environments. Our cam and crank position sensors are most often used to help customers enhance their system's pollution control, fuel efficiency, and ignition timing. Transmission speed sensors help automatic transmissions shift smoothly.

The Carpet Industry


Evergreen Nylon Recycling, our joint venture with DSM Chemicals, is the first of its kind in the world. Opened in November 1999, the facility will process 200 million pounds of normally landfilled carpet into high-quality caprolactam, the basic building block chemical used to make nylon. Honeywell's Type-6 nylon has inherent properties that allow it to be broken down into its base components with the company's proprietary recycling process. Competitive types of nylon are more difficult to work with and involve more cost and complexity. With the new facility fully operational, it is now possible to turn your old carpet into the door handle on your next new car with no loss of performance or vibrancy of color.

The Chemical Industry


Honeywell is a leading developer and producer of environmentally safer fluorocarbons used to replace ozone depleting CFCs (chlorofluorocarbons) and HCFCs (hydrochlorofluorocarbons). These products, sold in many regions of the world under the Genetron trade name, are used in commercial refrigeration (supermarkets, warehouses, grocery stores), stationary (residential and commercial) and automotive air conditioning and foam insulation for building construction and appliances.

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Selected Environmental and Energy Efficient Capabilities for

POWER GENERATION

Honeywell brings efficiency and environmental benefits to power generation in two major ways. One, we provide technologies, services and products that improve the operating performance, and therefore energy use and related emissions output. These solutions can be deployed within a wide range of power production facilities from industrial power users to independent power producers. Secondly, we have developed and now manufacture high efficiency stand-alone power generation units designed to operate either on or off an electrical power grid. Honeywell offers a large portfolio of products, services and solutions to many markets within the power generation sector. The markets served most intensively by Honeywell are electric utilities, industrial energy, independent power producers, and on-site generation. This section contains an overview of Honeywell products and solutions, as well as specific project examples. The activities represented in this section are as follows:

Parallon 75TM Microturbine for On-site Power Generation Louisville Gas & Electric Retrofit (Kosmosdale, KY) Otter Tail Power Plant Automation (Big Stone, SD) Akzo Delesto II Delfzijl (The Netherlands) Bobov Dol Thermal Power Station (Bulgaria) The Komoany Heating Plant (North Bohemia, Czech Republic)

North America

Western Europe

Central & Eastern Europe


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Capability: Business Unit: Product: Customer Example: Significance:

Power Generation - On-Site Transportation & Power Systems The Parallon 75 Turbogenerator Power System The Energy Efficient McDonald's in Bensenville, Illinois expects energy cost savings of at least 10% On-site power generation with increased reliability, lower energy costs, and reduced emissions

Introduction
The Parallon 75 turbogenerator is a compact, on-site power generation system that is designed to help small-to mid-sized commercial, industrial and institutional facilities reduce their energy bills, improve power quality, and minimize the risk of power outages. A single unit generates 75 kW of power, and multiple units can be configured to work together to deliver more than 600 kW of power. The Parallon 75 is more versatile than conventional generators because models are offered that can generate electricity with liquid or gaseous fuels, including alternative fuels like flare gas and landfill gas. In addition to serving as a primary fuel source, the unit can be used for combined heat and power (cogeneration), enabling a business to use exhaust heat created during the power generation process as a second source of energy to heat water, or even cool or heat a building. The benefits are both economic and environmental: Businesses get more use from the original fuel source, and emit fewer greenhouse gases into the atmosphere. The Parallon 75 can operate parallel to the utility grid or as a stand-alone power source. When used parallel to the grid, as a second source of power, the Parallon can begin generating power whenever it's needed, such as at peak demand times when energy costs are highest. It also protects from grid-related power outages. Customers: The Parallon 75 is ideal for stand-alone sites such as supermarkets, fast-food restaurants, call centers, banks, big-box retailers, office buildings, apartment buildings, small- to mid-sized industrial plants, schools, and other facilities with similar power requirements. In addition, the Parallon 75 can generate electricity using flare gas from oil production facilities, or methane gas from landfills. It also provides affordable and reliable power to rural customers.

Resulting Benefits
Increased reliability: More than ever, small and mid-sized businesses depend on electrical equipment that requires a non-stop, reliable source of energy. While it is difficult to quantify power outage related costs such as lost sales and missed deadlines, a recent survey of small business owners estimated the damage caused by power outages at approximately $7,500 a day. A reliable source of power is essential to the success of many small businesses. The Parallon
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75 can neutralize grid-related power outages by satisfying the customer's energy needs through on-site generation. Lower energy costs: When used parallel to the utility grid, the self-contained Parallon system has controls that monitor the grid around the clock, and determine exactly when to start producing power. Whenever this system can generate electricity for less than the utility company, it starts up automatically, and replaces electricity from the grid with electricity that costs less. During high-energy demand periods, energy rates peak. Because the energy produced by the Parallon 75 system will, in many cases cost less than energy generated during peak demand periods, businesses can seamlessly switch to this more efficient source whenever needed. This is commonly called "peak shaving." The customer will never know which source their power is coming from, but they will notice measurably lower energy costs each month. Environmental benefits: As an on-site power source, the Parallon 75 uses an advanced new technology that makes it an extremely efficient source of power. It is low-cost, fuel-efficient, low in emissions, and almost maintenance-free. The Parallon 75 can run on a variety of fuels which can be burned with lower emissions than a typical diesel generator set, including natural gas and propane, making it a cleaner alternative to traditional on-site generators. In addition, the Parallon 75 can generate electricity using flare gas from oil production facilities. In this case, the Parallon 75 offers increased energy efficiency and environmental performance by making use of a fuel the flare gas rather than emitting the gas into the environment. At oil production facilities, the newly generated electricity can be used on-site or sold back the power grid. The system reduces greenhouse gas emissions that would have resulted from the flaring of excess gas, in addition to lowering energy costs and/or providing additional revenue.

The Parallon 75 at Work A Customer Example


Energy Efficient McDonald's in Bensenville, Illinois: Expected energy cost savings of at least 10% In January 1999, The Energy Efficient McDonalds quick service restaurant in Bensenville, Illinois, became the first commercial customer to use the Parallon 75 turbogenerator. Using low-cost natural gas and the Parallon 75 system, McDonald's generates electricity on-site to power its restaurant on weekdays from 9 a.m. to 6 p.m. -- times when the utility's electric rates are high. Because the Parallon 75 system operates parallel to the utility grid, McDonald's can choose when and from which source it powers its facility based on lowest cost. With the Parallon 75 turbogenerator system as its cornerstone, the Bensenville McDonalds also features energy efficient lighting, cooling, kitchen ventilation, an energy management control system, and building monitoring. Designed to optimize the application of complementary conservation systems, a 10 25 percent reduction in energy consumption is projected as well as additional savings from the elimination of power outages. The Bensenville McDonalds is one of four energy efficient McDonald's restaurants in the world.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Power Generation - Electric Utilities Industrial Automation and Control Louisville Gas & Electric Unit 1 Retrofit Louisville Gas & Electric Kosmosdale, Kentucky 1998-1999 Unit has greatly improved emergency forced outage rate and lowered NOX emissions

Introduction
This retrofit project at Louisville Gas & Electric in Kosmosdale, Kentucky included a 321-MW, combustion Engineering (CE) coal fired boiler with 4 Raymond bowl coal mills. The retrofit project design was aimed at achieving a better heat rate and higher availability, and reduced maintenance. Honeywell Solution The Honeywell solution began with a data-acquisition system in 1993. This gave operations a trendable view of the process. In 1998/99, the utility agreed to upgrade the boiler/turbine and balance-of-plant controls. 1. Field devices. With Honeywells support, LG&E identified critical final drives which had significant impact on the process. These critical components included damper drives for the boiler air-draft fan controls and hydraulic controls on the forced-draft and boiler-feed pump steam turbine drives. In addition, more than 147 Smart and Multivariable transmitters were use to replaced existing analog signals; troublesome digital input pressure switches were replaced with Honeywell Smart transmitter analog logic.
2.

Algorithms. Two modes for boiler control were implemented; both incorporated advance control schemes for the critical process parameters of megawatt output, throttle pressure, excess O2, and steam temperature control. The first mode used a standard Honeywell Coordinated Boiler Frontend control; the second mode was the Robust Multi-Variable Predictive Control (RMPCT) package as the highest advance control. The new advanced controls consist of model-based algorithms that allow tight coupling of critical process parameters to the Boiler control. Operations can select, at will, between the advanced control strategy or standard Coordinated Boiler Frontend Control. Control-room upgrade. The existing control room was removed, along with its gage board, and upgraded to a CRT 5 pack. The center console drove a large overhead 32inch CRT for alarming; this structure helped create quick acceptance and success of the project. A common CRT touch-screen interaction theme for operator interfaces was designed by LG&E and Honeywell. Pinpointed lighting was set behind the consoles to keep direct glare off the

3.

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display screens. A raised floor was installed to assist in cabling and special wiring needs for LAN and LCN connections. Remote secure LAN maintenance access was provided. 4. EHC upgrade. The existing GE Mark I turbine control was removed and replaced with Compressor Controls Corporations (CCC) Total Train control equipment. Redundant LVDTs were used on all turbine valves. This allowed the removal of the valve limit switches.

Turbine components include rotor stress calculations for startup and shutdown, valve testing and valve characterization, critical avoidance, and over-speed protection control. Steam soot-blowing was also included.

Resulting Benefits
Louisville Gas & Electric estimates that the improved controllability has allowed the unit to run at its maximum capability giving production an additional 10MW. The BCS control of Excess O 2 is more effective than the old system. An immediate performance improvement is lower NOx emissions. The overall improvement in Unit EFOR availability was 99.9% at the writing of this report. Flexibility to have turbine follow mode has helped the stability of the unit, and drumlevel is more solid than it ever has been. The utility can place equipment in automatic operation almost immediately, resulting in quicker startup times. Successful run backs, including loss of boiler feed pumps, induced-draft fans, and other critical equipment were guaranteed at full-load conditions.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Power Generation - Electric Utilities Industrial Automation and Control Otter Tail Power Plant Automation Otter Tail Power Company Big Stone, South Dakota 1993-96 Overall unit startup times have been lowered by at least 20%

Introduction
The strategic automation project (SAP) at Big Stone, South Dakota, a 450-MW, Cyclone-fired unit is a controls modernization and retrofit project aimed at achieving the benefits of better heat rate and higher availability, within a state-of-the-art, highly professional, strategic operation. The plant operator and owner, Otter Tail Power Co., Fergus Falls, Minn., is working with Honeywell in a cooperative arrangement that avoids the use of third-party engineering firms. Honeywell Solution The project unofficially began with replacing the data-acquisition system in 1986. In 1993, the utility upgraded the main turbine/generator controls, and in 1996, Honeywell upgraded the company's boiler and balance-of-plant controls. 1. Field devices. Honeywell and Otter Tail staff identified which control devices worked and which were ineffective. Only critical, final drives with a significant impact on the process were replaced. The critical components included damper drives for the boiler air-draft fan controls and hydraulic controls on the forced-draft and boiler-feed pump steam turbine drives. In addition, more than 70 transmitters and 20 current/pneumatic transducers were replaced. 2. Algorithms. Advanced control schemes were implemented for the critical process parameters of megawatt output, throttle pressure, excess O 2, and steam temperature control. The new controls consist of model-based predictive algorithms that allow superior coupling of critical process parameters and are better equipped to handle varying conditionsincluding fuel changes, load swings, and plant subsystems out of service. 3. Control-room upgrade. This upgrade was critical to the full success of the project. New operator interfaces consist entirely of CRT touch-screen interaction. Indirect lighting is used because the old fluorescent lamps presented problems in reading CRT screens. Temperature and humidity are now controlled with a new heating, ventilating and air conditioning system, improved wall insulation has cut down noise levels, and the furniture is arranged for better maintenance staff interaction.

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Resulting Benefits
Otter Tail estimates that its control over excess O 2 is five times more effective than it was with the old system; one immediate performance improvement is lower NOx emissions. Also of importance, the control strategy is expected to be fully compatible with future equipment additions and changes to reduce NOx emissions even further. The overall improvement in heat rate, though hard to quantify, is probably in the order of 0.5%. Deviations in turbine throttle pressure are estimated to be 10 times smaller than they were with the original controls. Drum-level and steam temperature and pressure control cannot even be compared to what was achieved with the original system. Perhaps the most significant gain is in the unit startup. The utility can now place equipment in automatic operation almost immediately after a component is started up. Overall startup times have been lowered by at least 20%, which has reduced stress on operators. Guarantees Successful run backs, including loss of boiler feed pumps, induced-draft fans, and other critical equipment; were guaranteed at full-load conditions. All of the guarantee points have been met since the new controls were started up. Facets of the upgrade that interface with other plant IT components include: rotor stress calculations, valve testing and characterization, on-line valve sequence changes, over-speed protection control, steam soot-blowing, and a fiber optic link from the plant Local Area Network to the utilitys headquarters in Fergus Falls. On-site comments from engineering supervisor Stu Schreurs, engineering supervisor at Otter Tail Power's Big Stone Plant, said plant personnel have witnessed the superb control characteristics, as he put it, of Rate Optimal Control and Concurrent Front End, especially during unit runback situations. A runback is caused by an unexpected, immediate trip of a critical motor or auxiliary steam turbine at high unit loads. In the middle of a blizzard with wind chills of -60 degrees, one of the unit's three operating induced draft fans tripped because of a motor fault. The control system responded immediately by running back the boiler fuel and air in a quick, but smooth, manner. The unit load dropped from 410 MW to 250 MW in about three minutes without tripping off the line. In the past, with the old boiler control system, the unit would have tripped on furnace pressure seconds after the loss of the induced draft fan. After one of the load changes, one of our operators said he would have never believed that we could hold throttle pressure and not overshoot on MW while going at this rate of change, Schreurs said. Again at high load at about 415 MW, one of the two forced-draft fan-auxiliary steam turbines tripped. The boiler controls again responded and ran back the unit to 200 MW, avoiding a certain unit trip because of furnace pressure. This was very near to the most severe test we could have placed on the control system, Schreurs said.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Power Generation - Electric Utilities Industrial Automation and Control Akzo Delesto Ii Delfzijl Delesto BV The Netherlands 1999 Decreases CO2 emissions by about 225 million kg per year

Introduction
Akzo Nobel NV and EDON NV (Dutch Energy Distribution Company) in the Netherlands formed a joint venture, Delesto BV, on December 22, 1983 to build and operate a powerhouse with a capacity of 480 tons per hour of high-pressure process steam and 170 megawatts of electrical power. The utility started production in 1987 and is controlled by a 'one window' Honeywell TPS system.

Honeywell Solution
360 megawatts of combined cycle power and 200 tons per hour of process steam is to be added to the Delesto I site thus increasing its total capacity to 680 tons per hour and 530 megawatts. The new unit will start production in January 1999 and is an important step for Akzo Nobel to assure long-term steam supply and to reduce energy consumption.

Resulting Benefits
This project illustrates Akzo Nobel and EDON's voluntary commitment to the environment, which exceeds the agreement reached at the world climate summit at Kyoto, Japan in December 1997. The new unit will decrease CO 2 emissions by approximately 225 million kg per year. It will also maintain unprecedented low acoustic levels making it one of the quietest plants ever designed. According to Mr. Ir. G.N. Van Ingen (President Akzo Nobel Energy): ''The Delesto site exceeds the most stringent environmental and business demands and provides Akzo Nobel and EDON with a powerful asset to compete for the 21 st century. The engineering, production, automation and management of such a superb unit demands top quality suppliers: internally as well as externally.''

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Power Generation - Electric Utilities Industrial Automation and Control Bobov Dol Thermal Power Station National Electric Company (NEK) Bobov Dol, Bulgaria 9/99 - 12/00 Expected to reduce power station energy consumption by 5%

Introduction
In 1999, Honeywell was awarded the Contract for the modernization of two 210 MWe electric utility power stations in Bobov Dol, Bulgaria, financed by the World Bank. Bobov Dol is a town approximately 90 km south of Sofia. The project is to upgrade the existing coal-fired power stations to a modern technological level, thus meeting environmental standards and improving reliability. The National Electric Company contracted Honeywell Bulgaria for the main engineering, installation and commissioning on the project. The total contract amount is Euro 1,520,000. The project scope covers boiler control, burner management, turbine control, some circuit breakers, and motor control completely eliminating the control room panels and boards. Honeywell provided all application engineering, procurement and installation on a firm price contract.

Honeywell Solution
Honeywell's TotalPlant Solution system (TPS) will provide integrated control and monitoring for two identical 210 MW coal-fired (oil fuel backup) power plants with Rafaco boilers and Russian turbine generators. The system utilizes the NT-based Global User Station as the human-machine interface, High Performance Manager for analog control, and Fail-Safe controllers for safety interlocks and BMS. Implementing a new safety system, based on products with extremely high reliability will reduce unplanned downtime and shutdowns. Removing outdated relay-based safety and Burner Management Systems (BMS) decreases maintenance and allows the implementation of new algorithms for controlling backup burners during process disruptions. Providing Windows NT environment for process interface, user-friendly operation is achieved based on:

Fully integrated CRT-based, operator interface Ability to export data to MX Excel for later analysis

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Open interface for third party packages Improved alarm management (including First Out alarming) One common interface for burner management and SCHENK vibration monitoring

The main advantages resulting from the implementation of the TPS will come from replacing old single loop controllers with DCS, in which main loops are interconnected with advanced algorithms and cascades which significantly improves control and reduces the need for operator oversight. Moreover, bumpless switching is provided for all loops. Compensation for process upsets caused by coal caloricity variation are made with additional computation in CL programs in the High Performance Process Managers (HPM). Corrections by the main controller based on CO2 in effluent gases improve combustion and increases efficiency. Replacing old single loop controllers with DCS will lead to improved reliability, reduced maintenance and less unscheduled downtime because of redundancy. The central processor is "redundant", so in case of failure, a secondary processor takes over thereby reducing unscheduled disruptions and allowing greater reliability. This system can provide redundancy on any level. The new DCS and embedded algorithms make it possible to build a control strategy which cannot be built with conventional single loop controllers. This new control strategy helps not only increase efficiency, but also reduces emissions. These new algorithms and improvements in control will lead to 5% increasing in efficiency. Startup: Unit 2: 01 July 2000 Unit 1: 15 Sept 2000

Startup includes total I/O checks, control loops tuning, coordination with third party equipment, reading data from TPS via TPS DDE. UNIT control from the Central Dispatch Center is also included along with different types of main controller modes: turbine follows, boiler follows and coordinated mode.

Resulting Benefits
The Honeywell TPS System, field instrumentation, and environmental controls are expected to reduce the power station energy consumption by approximately 5%. This project is the first internationally financed project in the power generation sector. With the new control system and strategy, Units 1 and 2 in Bobov Dol Thermal Power Station will meet UCPTE requirements for frequency and load control. These two units will be two of the six units in Bulgaria on Central Dispatch Center control. This results in additional benefits for the TPP Bobov Dol due to an additional premium paid by the National Electric Company (the only buyer) to TPP Bobov Dol. Improving unit control reduces process upsets, which are the main source of higher than normal COx content in effluent gases. With these upsets minimized, environmental performance will be improved. Furthermore, implementation of the FSC (fail-safe controller for safety interlocks) allows meeting latest European and worldwide safety standards

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Power Generation - Electric Utilities Industrial Automation and Control The Komoany Heating Plant Komoany Heating Plant North Bohemia, Czech Republic 1995-1997 Heating plant in compliance with stringent Czech legislation on environmental protection

Introduction
The Komoany Heating Plant was built during the years 1951-1959 as a condensing power station. To insure regional thermal and electric energy supply for surrounding localities and industry, it was gradually rebuilt as a heating plant during the 1970s. The original 10 grid boilers each provide 125 tons of steam per hour at 7.3 MPa pressure and 485 C temperature. In 1992, part of the former national enterprise was separated to form a new company - "Prvni severozapadni teplarenska a.s.," Komoany u Mostu (North Bohemia). The main activity of this company is to combine thermal and electric energy production (including distribution and sale). Prvni severozapadni teplarenska a.s. supplies heat, and operates a distribution network for Most, Litvinov and Chomutov. The overall hot-water pipeline measures more than 175 km. The majority of the heat production is supplied to 65,000 apartments on the network. The overall value of Honeywell's contract is approximately US$4 million.

Honeywell Solution
At the present time, the customer's main priority is focused on the environmental impact of the Komoany Heating Plant's source renewal, pipelines reconstruction and development. The company's goal is to ensure an economical and reliable heat supply while minimizing the negative impact on the environment in this North Bohemian coal-mining region. For this reason, it has been decided to reconstruct the existing boilers using the retrofit system. The heating plant's electricity output is c/a 200 MW. The power is provided by three backpressure turbines, one extraction and three steam condensed turbines. An additional condensed turbine, controlled by a Honeywell system working in conjunction with Compressor Controls Corporation (CCC) equipment, has also been installed. The decision to reconstruct the existing grate boilers using the retrofit system entails using atmospheric fluid combustion while recycling the combustion and desulphurization solid waste. At the same time, the plant management has decided to construct supporting systems.
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Project Implementation Phase 1 Phase 2 1995-96 1996-97 K2, K3 K4, K5

Boiler reconstruction and machine room reconstruction will run concurrently. The turbine hall is equipped with a TG 22 turbine (34 MWel. output capacity). This project includes a Honeywell TDC 3000 control system delivery. The Honeywell TDC 3000 control system is not only used to control four fluid boilers, but also turbine control, as well as control of reduction and feed water pump stations. Supporting systems are controlled using Logic Controllers. Two LC 620s are used for lime and flue ash control and one LC 620 is used for conveyor transport control.

Resulting Benefits
The Honeywell TDC 3000 control system has enabled the Heating Plant to comply with recently adopted Czech legislation on environmental protection (Law No. 212/94: Environmental Protection), which sets stringent pollution limits for coal and gas fired boilers.

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Selected Energy Efficiency and Environmental Capabilities for

POWER TRANSMISSION

Honeywell helps electric utilities reduce their operating costs and improve energy savings through its new generation METGLAS amorphous metal distribution transformers (AMDTs). These transformers can achieve up to 80% lower core loss than conventional transformers. When you consider that 10% of all electricity generated by utilities today is lost in the transmission and distribution process, the potential savings through reductions in core loss can be significant. Amorphous metal transformers were recently awarded the Chairman's Prize by Japan's Energy Conservation Center. In addition, the transformers have received a citation under the 1999 Japanese Energy Saving Law and in April 2000 the Ministry of International Trade and Industry added the transformers to a list of equipment qualifying for a tax credit or special depreciation under the 'Energy Reform Tax System'. The transformers are also listed under the EPA Energy Star program in the US. This section contains an overview of Honeywell products and solutions, as well as specific project examples. The activities represented in this section are as follows: Asia

Andra Pradesh Rural Electrification (India) Electrical System Distribution Efficiency Improvement (Japan)

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Power Transmission Electronic Materials Andra Pradesh State Electricity Board - Rural Electrification Andra Pradesh SEB India 1996 - Ongoing US$2.1M in energy savings program to date; assured Emission reductions of 375,000 MT in CO2, 6,700 MT in SO2

Introduction
The Andra Pradesh State Electricity Board (APSEB) is in the midst of a program designed to supply the rural areas of the nation with electricity for the first time. Reaching so many across the country means a substantial increase in the number of electrical distribution transformers, used to convert high transmission voltage into lower voltages used by customers. As each transformer represents energy losses, careful consideration was given to transformer efficiency and conditions of use since tens of thousands of units were projected to be installed over the life of the program. With power demand in India forecast to be ahead of supply for years to come, every opportunity for energy savings is considered. Existing System The utility had traditionally used silicon steel core distribution transformers that inherently suffered energy losses caused by magnetic friction in their cores. Before starting the project, it was estimated that APSEB lost 19 million kWh of energy each year in the cores of distribution transformers across the state. At typical capacity factors, this also represents over 2.7 MW of generating capacity. Through the use of Honeywells ultra low loss METGLAS Amorphous Metal as a core material, these losses would be reduced by 75%, saving over 14 million kWh each year on a system wide basis. These losses are valued at US$1 million each year, using an average of $0.07/kWh, underscoring the opportunity for lowering core loss.

Honeywell Solution
Honeywell worked with APSEB officials and the local transformer manufacturer, Vijai Electrical, to help design, manufacture and test amorphous metal transformers suitable for Indias electricity grid. Fully approved units were available in time to meet the project schedule. To date, over 26,000 units have been supplied.

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Resulting Benefits
In the case of India, the additional benefit is that more electricity would be available for use rather than lost in transformers. Based on the energy saving of the amorphous metal transformers, the resulting benefits are shown in the table below: Energy Saving1 30 Million kWh Avoided Cost ($) $2.1M
($0.07 /kWh)

Avoided CO2 Emissions2 375,000 MT


(1.065kgCO2/ kWh)

Avoided SO2 Emissions 36,700 MT


(0.019kgSO2/ kWh)

Energy Savings Based on cumulative kWh savings to date for transformers with METGLAS Amorphous Metal installed. 2 Avoided Emissions Based on lifetime (30 Year) emission savings of transformers installed though 1999 (26,359 units).
1

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Power Transmission Electronic Materials Electrical Distribution System Efficiency Improvement Japanese Electrical Utilities Japan 1991 - Ongoing Estimated cumulative energy savings to date exceed US$99M, 340,000 MT in CO2 Emissions

Introduction
Japanese electric power suppliers are succeeding in their efforts to reduce electrical distribution loss to be less than 1/3 of the losses experienced in 1955. One success factor is the use of Honeywells METGLAS Amorphous Metal technology. Transformers, a key part of an electrical utility distribution system, are needed to convert high transmission voltages down to voltages that are suitable for customer usage. In this "stepping down" process, each transformer represents an energy loss to the overall system. With over 9,000,000 such units on the Japanese electrical grid (1997), the cumulative losses are dramatic. Transformer energy losses come from the core and the winding. Core losses are constant while winding losses vary with the load. Core losses represented a large opportunity for energy savings. Using METGLAS Amorphous Metal as the transformers core material, energy losses can be reduced by 70%. This approach to system efficiency is favored because it does not depend upon or impact customers. The resulting benefits are lower electricity costs and reduced emissions of pollutants (CO2/SO2) associated with electricity generation, which contribute to the problems of global warming and acid rain.

Existing System
Before the introduction of amorphous metal transformer cores, Japanese electric power suppliers only used silicon steel core transformers. With an estimated 7,500,000 distribution transformers (1990) on their system, the annual core loss was estimated at 4-billion kWh.

Honeywell Solution
In early 1991, Honeywell and Nippon Amorphous Metals Co. (NAMCO), our joint venture in Japan, supported Japanese electric power suppliers in their efforts to begin large-scale field testing of amorphous metal distribution transformers (AMDT). After an extensive three-year study, Japanese electric power suppliers concluded that AMDT technology was capable of delivering the anticipated long-term energy savings. Each transformer purchasing decision
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translates into long-term efficiency improvements due to large cumulative energy savings which accrue over the approximate thirty-year service life of a transformer. At the end of 1999, approximately 275,000 AMDTs had been installed on Japans electrical distribution system. Amorphous metal transformers recently received the recommendation of Energy Saving Equipment under Japans Energy Saving Law issued April 1999. In April, 2000 the Ministry of International Trade and Industry (MITI) added high efficiency transformers to the list of equipment qualified for a 7% tax credit or 30% special depreciation under Japans Energy Reform Tax System.

Resulting Benefits NAMCO recently conducted a study of the cumulative benefits made possible over the last nine years of amorphous metal transformer purchases. (1991- 1999) The results are summarized in the table below: Energy Saving 585-Million kWh Avoided Cost ($) US$99 M ($0.17/kWh) Avoided CO2 Emissions 340,000 MT-CO2 (0.58KgCO2)

In addition, the energy savings represent an opportunity to delay the cost of adding new generation capacity in the future.

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Selected Energy Efficiency and Environmental Capabilities for

DISTRICT ENERGY
Honeywell is the only company that can provide a complete solution for every part of a District Heating System achieving energy savings at each level of operation up to a total of approximately 45%, and thereby reducing CO2, NOx and SO2 emission. Honeywells approach offers integrated automation of the generation plant, integrated control of the heat distribution systems, and local user comfort control. This section contains an overview of Honeywell products and solutions, as well as specific project examples. The activities represented in this section are as follows: Central & Eastern Europe

Varna District Heating (Bulgaria) st Nad Labem District Heating Plant (Czech Republic) Otrokovice District Heating Plant (Moravia, Czech Republic) Bonyhd ESCO District Heating Project (Hungary) Sikls District Heating Project (Hungary) Katowice District Heating Plant (Poland) District Heating Improvements in Krakow (Poland) Martin District Heating Network (Slovakia) District Heating Boiler House Revamp (Romania) District Heating Substations Control (Romania) Murmansk District Heating (Russia) Tver District Heating (Russia) Moscow: Tushino-3 (Russia) Pozniaky Heating Plant (Ukraine) Kiev Institutional Buildings Assessment Project (Ukraine) Beijing District Heating (China) Yantai TRV Demonstration Project (China) Sangmu District Heating (Korea)

Asia

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control PSO 98/BG/4/3/ - Tebodin, The Netherlands Varna District Heating Company Varna, Bulgaria 8/00 - 12/00 CO2 pollution reduction according to the Kyoto agreement.

Introduction
Varna is the third largest city in Bulgaria with a population of 300,000. It is located in the eastern region of the country and is often referred to as the sea capital of Bulgaria. It is internationally known for its seaside resorts of Zlatni Pyassatsi (Golden Sends) and St. Constantine. Varna is a university city as well, with the Higher Institute of Economics and the Varna Polytechnic. This is a pilot project based on the cooperation of the Dutch and Bulgarian governments to trade CO2 pollution reduction according to the Kyoto agreement. The bid was open from Tebodin The Netherlands under the coordination of the Dutch Government Agency SENTER The Netherlands. The total volume of the project is EUR 150,000. The scope of the project was a modernization of 329 substations of different types and capacities, all of them connected indirectly to the distribution network. For each of the 329 substations the project includes: digital controller (with RS 232 interface for two-way communication via telephone or GSM modems with Centralized Dispatch System (CDS); motorized two-way control valve with actuator; three temperature sensors for outdoor temperature, inlet water temperature and the temperature at the outlet of the substation; and a Centralized Dispatch System for remote monitoring and control of technological parameters in 5 substations situated at the end of the distribution network. Existing System The construction of a centralized district heating system started in 1977. In 1985, two stand-by boilers, type PKM-12 were installed and put into operation. In 1986, the public service company Toplofikatzia was officially established. The Vladislav Varnenchik Power Station, which has two VK-116 MW heating boilers was constructed and commissioned at the end of 1990. The current principal of Toplofikatzia Varna EAD is the State Agency for Energy and Energy Resources. During the last few years the annual heat supply of DH Varna was approximately 150,000 MWh. The District Heating Company of Varna produces heat energy for space heating and domestic hot water for household and public and economic entities. 94% of the District Heating Company's output supplies households, with the remaining 6% of output going to public and economic entities. The main heat carrier is hot water with design parameters for the rated mode (Outdoor temperature Tout = -11oC), T supply = 150oC and T return = 70oC).
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The heat energy is supplied to end-users by means of three distribution networks and 355 substations (SS). Each of the 355 substations supplies heat to one building. All substations are indirectly connected to the distribution networks, with four of them supplying heat to a number of individual consumers (blocks of flats). These are so-called group substations (GSS). The majority of the control equipment installed in the SS was Bulgarian made, and was not working properly. A number of substations are equipped with complete intelligence controllers which meet the required for optimum control of a modern district heating system.

Honeywell Solution
The Honeywell products supplied include digital controllers, motorized two-way control valves and temperature sensors for 329 substations, communication hardware for five selected nodes of the distribution network, a Centralized Dispatch System (CDS) for remote monitoring and control of technological parameters in substations, and software for remote monitoring and control of the substations operational modes. The communication hardware includes: - Local interface (Application Module) for communication between the Heat Meter and integrated translator. - Two analogue inputs for measurement of the inlet and outlet pressure integrated in the Application Module. - Local controller translator integrated in the Application Module. - Multiplexor with the following functions: duplex communication with operator station via GSM modem or a telephone modem; Communication with 12 addressable translators at distance up to 500 m via RS 485 or M-bus at 9600 boud; Embedded realtime clock calendar which ca be corrected by commands from the operator station; Energy independent RAM, string records for 12 channels, 128 records for channel, 156 bytes for a record; LCD indicator - GSM modem The software for remote monitoring and control of substations operational modes is able to provide the following functions: - Data collection of the main technological parameters from the substations, connected to the CDS; - Control of the operational modes of substations, including on-line change of the set points; - Visualization of the current status of the substations; - Visualization of the operational data from the heat meter for selected time interval; - Visualization of the substation position on the city map; - Connected to the existing LAN in the Heating plant for data exchange via standard TCP/IP. - Open system architecture, which allows a new consumer to be connected to the system. - Data archiving; - The software is designed to process up to 1000 nodes (substations).

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Resulting Benefits
The solution and equipment provided by Honeywell enabled the end user to save more than 25% on its energy costs. The project resulted in major environmental benefits such as reduced pollution and greenhouse gas emissions. In addition, the Honeywell solution improved information flow for district heating facility workers.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control st Nad Labem District Heating Plant st Nad Labem District Heating Plant st Nad Labem, Czech Republic 1994-2000 Complete automation for the city heating plant.

Introduction
Centralized heat distribution in st Nad Labem dates back to 1921, when the first four customers were connected to the recently installed steam network. Together with Brno and Dresden, the city of st nad Labem thus became a pioneer in district heating. The heat industry in the region of st nad Labem flourished in the 1960s. During this period the Trmice Power Station, which serves st nad Labem, switched to full heat production, and thus replaced the existing city heat source supplying the city's 22.5-km steam network. The first steam pipeline from Trmice was put into operation in 1959. The present overall steam network length is 106 km. The plant feeds a primary network which has 1239 heat exchangers. The main customers are KB Liker (food industry), Ustecke Pivovary (brewery), Severoceska Armaturka (valves manufacturer), Chemopharma (pharmaceutical industry) and more than 22,000 apartments. The current heating plant output is 643 tons per hour. 1995 was a milestone in the heating plant's history. It was decided that a sizable investment would be made with the aim of changing the heating plant's technological and production base significantly; including construction of a new steam-gas cycle. As a part of this construction, the control system would be modernized. In 1994, st nad Labem Heating Plant signed a frame contract with Honeywell. The overall cost of the project is approximately $9.2 million. Existing System The heat source is composed of four high-pressure, coal grid boilers (K101, K102, K103, K104) of 50 tons per hour output, (12 MPa, 500 C); two low-pressure pulverized coal boilers (K107, K108) of 115 tons per hour output, (1,8 MPa, 300 C); two high-pressure pulverized-fuel-fired boilers (K105, K106) of 160 tons per hour output, (14 MPa, 540 C). A backpressure, 16 MW turbine is currently in operation to utilize the produced steam. Until the control system reconstruction, production was controlled manually using an old Czechmade analog system. An old Czech PC-based system was used for data acquisition for the two boilers (Historical Reporting). All other reports were produced through old analog recorders. All alarms were indicated on a classic mosaic panel.

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The current technological base of the heating plant consists of two separate coal grid 50t/hour boilers and a 16 MW turbine TG6, two separate low-pressure pulverized coal 115 t/hour boilers, and two high-pressure, pulverized coal 160t/hour boilers connected with turbines 2x 20 MW. The main goals of this reconstruction at the plant are to improve environmental protection; make production more effective, and introduce a state-of-art control system.

Honeywell Solution
This is a turnkey project like most projects in the Czech Republic. The project includes: supply of the Honeywell TDC 3000 control system; field instrumentation; sub-deliveries; project engineering; software engineering; overall assembly; installation, production start-up; customer operator training, maintenance and system engineer training. A Honeywell TDC 3000 control system replaced the original Czech-made analog system. This new system allows for complete monitoring and overall control, including large volume process data storage. Using this state-of-the-art, Honeywell control system and its optimization products will help the st nad Labem Heating Plant to increase the effectiveness of its heat and electricity production while minimizing its impact on the regional environment. Project Goals and Phases 1995 1996 1997 1998 1999 2000 Chemical Water Treatment CHUV 5 K101 boiler - control system overhaul, combustion improvement, feed water pumps EN 11-13 for K105 and K106 boilers K104 boiler / K105 boiler / 110kV switch gear K106 boiler K107 boiler / TG6, TG7 turbines K108 boiler

Resulting Benefits
Using UxS Operator Stations, the plant operators have access to the full complement of typical functions such as: monitoring and controlling the process using standard displays (Plant Process Displays, TDC System Displays, System Function Displays) ; Warning and handling process, sequence and system alarms and operator messages; Printing reports, logs and journals; Displaying and printing process histories, trends and averages; Monitoring and changing status of system equipment in the control room and near the process. The TDC system also provides the highest level of reliability, automatic switchover between redundant facilities and comprehensive system diagnostic functions to minimize downtime. Other functions include a large data storage capacity; monitoring of various trends for subsequent production quality control analysis; and the possibility of future advanced control implementation.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Otrokovice District Heating Plant Otrokovice District Heating Plant Moravia, Czech Republic 1996 - 1999 Annual cost savings of US$700K during the first project phase

Introduction
Otrokovice, a small town in central Moravia, was already a strong industrial region in the 1930s. It had its own power station, supplying the entire region with electricity, as well as with heat. This power facility was one of the first stations to combine the production of electricity with production of heat. It lay the foundation for future electrification and heat distribution to the region and surrounding industrial plants. It thus became a worthy precursor of today's heating plant. The subsequent development phase occurred in the 1960s, together with the construction of the new tire manufacturing plant, Barum. The new heating plant complex was put into operation between 1970 - 1976. An additional steam transmission network was built between 1981 - 1985. Among the largest current customers are TOMA, a.s., (leather industry) - 36.3%, Barum Continental, s.r.o., (rubber industry) - 30.5%, FATRA, a.s., (plastics industry) - 10%, and Moravan, a.s., (manufacturer of automobile and aeronautical components) - 5.4%. Apartment heating constitutes about 9.5%. Due to the changes in Czech society following 1989, a heavier emphasis was placed on protecting the environment and improving the effectiveness of manufacturing. Thus it was decided, in 1993, to upgrade the heating plant control system. The main goal of reconstruction was to make production more effective, to reduce the production cost, and to improve the level of control utilizing advantages offered by a distributed control system. In 1996, a contract to optimize the combustion process was signed. The main agents in this project were: Honeywell Technology Center, Prague in cooperation with Honeywell Technology Center (HTC) Minneapolis, and Honeywell Industrial Automation and Control (IAC) Phoenix, US. The overall cost of the project was approximately US$2.2 million. Existing System The existing system consists of two CKD DUKLA pulverized coal boilers (K1,2) of 50 t/hour steam output (3,72 MPa, 445 C), three pulverized coal boilers of 125 t/hour steam output (9,32 MPa, 540 C), one 25 MW turbine, and one 12 MW turbine. Until the control system replacement, the plant had been controlled manually using an old Czech analog control system. Honeywell was awarded the overall contract to reconstruct boilers K3,
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K4, K5, and the control system in 1994, and the following year, a contract to procure a desulphurization control system.

Honeywell Solution
This project, as awarded to Honeywell Czech Republic, was a turnkey project. In addition to a Honeywell TDC 3000 Control System delivery, this project also includes field instrumentation, sub-supplier deliveries, project engineering, software engineering, installation, start-up, and customer training. The first K5 boiler phase following contract signing lasted 5 months. K4 and K3 phases lasted 9 and 10 months, respectively. As stated above, the old Czech-made, analog, control system was replaced with TDC. The original system was 15 years old, and allowed manual load control only where data acquisition was performed by operators through hand written reports. In addition, reliability of the system was extremely low. The TDC 3000 control system provides for complete boiler monitoring and process control, including automatic start-up and shut-down, control and monitoring of the desulphurization unit, and chemical water treatment and heat exchanger monitoring and control. The TDC 3000 system also provides the highest level of reliability: automatic switchover between redundant facilities and comprehensive system diagnostic functions to minimize downtime. In addition to large capacity data storage and monitoring of various trends for subsequent production quality control analysis, this system allows for future, advanced control implementation. Advanced Combustion Control could be one component of such a package. Reconstruction Phases 1994 1995 1995 - 96 1994 - 95 1996 1996 - 98 1999 - K5 boiler - K4 boiler - Water Treatment - Mix filters - Heat Exchanger Station - K3 boiler - K3, K4, and K5 boiler desulphurization - Water Treatment reconstruction (under negotiation)

Resulting Benefits
Only due to the first reconstruction phase, system efficiency improvements have resulted in reduced coal consumption from 380,000 tons in 1990 to 240,000 tons in 1996, thus representing a saving of approximately US$4.2 million in coal costs (at world prices). There has also been a reduction in SO2 emissions from 8,000 tons in 1990 to 4,800 tons in 1996, fly ash from 0.5 ton in 1990 to 0.1 tons in 1996, and NOx from 1.5 tons in 1990 to 0.8 tons in 1996.
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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Bonyhd ESCO Project District Heating Company owned by the local municipality Bonyhd, Hungary 6/2000 - 10/2000 Annual cost savings of over US$175K; reduced greenhouse gas emissions and pollution.

Introduction
Bonyhd is located in the middle of Hungary. It is a small city (about 40 km from Pcs) with a population of 25,000. The scope of the project can be divided in two sections. 1) Modernization of the district heating system owned and operated by the FTM Kft., a non-profit company belonging to the municipality. 2) Modernization of individually gas-heated public buildings. Honeywell ESCO Mo. Rt. is responsible for design, construction, commissioning, maintenance, and follow-up services. The contracting partners are Honeywell ESCO Mo. Rt. and the municipality of Bonyhd. The overall cost of the project is US$990,000 and is financed by the Honeywell Hungary ESCO. This project will install a comprehensive supervisory system covering all heat distribution stations and all significant gas-heated public buildings in order to introduce improved demand-side management which will develop a service with more flexibility, lower costs, and higher comfort. This centralized monitoring and control system, which monitors both the district heating system as well as independently gas heated public buildings, is unprecedented in Hungary. Existing System The district heating company provides heat for 127,658 cubic meters (m 3) in residential buildings (about 850 flats) and 37,192 m3 in public buildings. The length of the primary network is approximately 3,500 m. The secondary side is indirectly connected (with heat exchangers) to the primary side through 12 distribution stations. In the residential and public buildings the secondary heating network consists of 2 pipe systems. The district heating system of Bonyhd consists of two boiler houses. The capacities of the installed boilers are as follows: Fy Street = 7 MW; Vroskzpont Square = 1 MW. The total heat consumption of both boiler houses is 57,800 GJ/annum. There is a centrally circulated domestic hot water supply in one of the boiler houses, while in the larger district heating system the domestic hot water is made in the substations. The fuel source is gas, of which 1.700.000 m3 was consumed in 1998.

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The project includes 12 gas-heated public buildings (including schools, kindergartens, a community center, and physicians' offices), each of which has its own boiler house. The total heat consumption of these buildings is 15,400 GJ/annum. The fuel source is gas of which 453,000 m3 was consumed in 1998.

Honeywell Solution
The objective of the project was the provision of energy and operational savings for the Bonyhd district heating system and the gas-heated public buildings. This involves:

The installation of state-of-art controls in the boiler houses, heat distribution stations, individual flats and public buildings in order to provide heat with more comfort and efficiency. The installation of a supervisory system that will more accurately predict volume and temperature requirements. This improvement will increase the total network efficiency. Also, the district heating company implements a system integration facility that ensures demand cycles are both measurable and predictable. Smaller consumer units will be available with heat metering and control to meet end-users' individual requirements for fairer invoicing and cost distribution. In order to achieve these savings, the supplier provides complete energy auditing for the existing system and over the term of the contract to evaluate and eventually adjust energy conservation measures on a regular basis. Implementation and maintenance Energy management Long term system analysis, tuning and upgrade support Pollution control A training program for the customer's staff Promotional campaign to increase residential end-user awareness.

The project was comprised of five discrete modernization tasks: 1. Modernization of the boiler houses Action: the boiler house modernization included the replacement of four boilers and the installation of up-to-date control systems, reducing the need for human supervision, and the connection of the boilers to the computerized surveillance system. Result: overall efficiency is increased while noise and air pollution is reduced; the lifetime of the equipment is extended, and boiler house control is automated. 2. Modernization of the heat distributing substations Action: modernization of the heat distributing substations included the installation of a Digital Data Control (DDC) system (Excel 50 ) in each substation and their connection to the supervisory system. This enables remote operation and surveillance as well as monitoring and consumption analysis. The substations were fitted with the required control equipment, such as valves, metering devices, and sensors. A total of 12 substations were modernized. Result: Energy losses are decreased via full automation.

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3. Modernization of the consumer side system - residential consumers Action: This subproject included the redesign of the hydraulic system of each subsystem, and the replacement of traditional radiator valves with thermostatic valves. Circulating pumps or riser controllers were installed, depending on the technical conditions. In order to promote energy-saving behavior, each radiator is fitted with evaporating cost allocating equipment. Result: Energy consumption decreases while comfort is increased. 4. Modernization of the consumer side system DH public buildings Action: Assessment and redesign of the hydraulic system, installation of thermostatic valves and riser controllers where needed. Pre-set valves were installed and additional PR activity was provided to encourage user level energy savings. Approximately 780 were modernized. Result: Energy consumption decreases while comfort is increased. 5. Modernization of the gas heated public buildings The boilers (about 24 pieces) in each public building will be replaced and the new boilers (above 100 kW) will be connected to the computerized surveillance system. A DDC control system (Excel 50) will be installed in each building and connected to the supervisory system. This will enable remote operation and surveillance as well as monitoring and consumption analysis. The substations will be fitted with the required control equipment (valves, metering devices, sensors, etc.). Action: Assessment and redesign of the hydraulic system, installation of thermostatic valves and riser controllers where necessary. Pre-set valves will be applied and additional PR activity will be sponsored to encourage energy savings. A total of 12 buildings will be modernized. Result: Overall efficiency is increased while noise and air pollution is decreased. Energy losses are decreased via full automation and the lifecycle of equipment is extended. Energy consumption is decreased while comfort is increased.

Resulting Benefits
Honeywell equipment will enable the municipality of Bonyhd to save more than US$175,000 annually, reduce its greenhouse gas emissions, and improve the working conditions of district heating facility workers through decreased pollution levels and improved information flow. Energy use is significantly more efficient in heat production, distribution and demand side management. In addition, the operational manpower needs for both the DH Company and the municipal buildings are reduced. The DH Company staff will take over the operation of the heating system in those buildings.

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The supervisory system provided for this project is flexible and can be expanded or upgraded in the future according to need. It offers more efficient ways of running the system and reduces the time and cost of fault corrections. Metered energy consumption can be scanned online using Mbus heat meters. The focus of the energy conservation measures is to offer maximum network reliability and increased comfort in heated units, with minimal investment costs. Energy efficiency measures must be evaluated according to their effect on the entire system. The heat demand reduction on the consumer side influences the network and boiler house side. That is why the unconsidered measures increase the payback period. Energy conservation measures increase the cost competitiveness of district heating compared to other energy sources. This encourages more consumers to connect to the system, which further increases the efficiency of the network.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Sikls District Heating Project District Heating Company owned by the local municipality Sikls, Hungary 8/98 - 5/99 Annual cost savings of over US$100K

Introduction
Sikls is located in the southern area of Hungary. It is a small city (about 20 km far from Pcs) and has a population of 20,000. The scope of the project was the modernization of the district heating system owned and operated by the TVH Kht., a non-profit company belonging to the municipality. Honeywell ESCO Mo. Rt. bore the responsibility of design, construction, commissioning, maintenance work and followup services. The contracting partners are Honeywell ESCO Mo. Rt. and the municipality of the city of Sikls. Existing System The district heating company heats 1061 apartments in residential buildings and 456 apartment equivalent units in public buildings. The length of the primary network is around 4000 m. The secondary side is directly connected (without heat exchangers) to the primary side through 61 distribution stations. In the residential and public buildings the secondary heating system is 2 pipe systems. The district heating system of Sikls consists of two boiler houses. The capacity of installed boilers are the following: Hajd Street: 8.1 MW; Kztrsasg Square: 5.5 MW. The total heat consumption of both boiler houses is 43,499 GJ/annum. There is a centrally circulated domestic hot water supply (about 533 m3/annum) in only one of the boiler houses. The fuel source is LP gas of which they consumed 496,036 m3 in 1997.

Honeywell Solution
The task was provision of energy-saving service over the life of the contract, evidenced by achieved energy and operational savings for the Sikls district heating system. This involved: Significantly more efficient energy use including heat production, distribution and demand side. The reduction of environmental pollution caused by old boilers. State-of-art controls were implemented in the boiler houses, heat distribution stations, individual flats and public buildings in order to provide a DH heat supply with more comfort and efficiency.
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A comprehensive supervisory system was carried out covering all heat distribution stations in order to introduce a complete demand side management to develop a DH service with more flexibility, low cost, and higher comfort. The supervisory system was also intended to predict of the accurate volume and temperature requirements to increase the total network efficiency. The supplier implemented a system integration facility that ensured demand cycles to be both measurable and predictable. Operational manpower needed both for the DH Company and municipal buildings with DH were reduced. The staff of the DH Company fully took over the operation of the heating system in those buildings. Smaller consumer units were available with heat metering and control to meet end-users' individual requirements for fairer invoicing and cost distribution among the end-users In order to achieve these savings, the supplier provided complete energy auditing for the existing system and over the term of the contract to evaluate and eventually adjust energy conservation measures on a regular basis. Design of products and systems was implemented during the project. Implementation and maintenance. Energy management. Long term system analysis, tuning and upgrade support. Pollution control. Training program for the customer's staff. Promotional support for awareness campaign for residential end-users.

The work consisted of five subprojects: 1. Modernization of the boiler houses Result: Overall efficiency was increased while decreasing the noise and air pollution, also life extension and automation. Tasks carried out: Replacement of two boilers, installation of up-to-date control systems, (making human supervision unnecessary), and connection of the boilers to the computerized surveillance system 2. Modernization of the heat distributing substations Result: Energy losses were decreased via full automation. Tasks carried out: Installation of DDC control system (EXCEL 50 ) in each building and their connection to the supervisory system, enabling remote operation and surveillance as well as monitoring and consumption analysis. The substations were fitted with the required control equipment (valves, metering devices, sensors, etc.). A total of 61 substations were modernized in this way.

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3. Modernization of the consumer side system - residential consumers Result: Energy consumption was decreased while increasing comfort. Tasks carried out: Hydraulic redesign of each subsystem, replacement of traditional radiator valves with thermostatic ones. Circulating pumps or riser controllers were installed, depending on the technical conditions. In order to motivate energy-saving behavior, each radiator was fitted with cost allocating equipment. 4. Modernization of the consumer side system public buildings Result: Energy consumption was decreased while increasing comfort. Tasks carried out: Assessment and hydraulic redesign of the system, installation of thermostatic valves and riser controllers where needed. Pre-set valves were applied and additional PR activity done to increase energy savings. Seven buildings were modernized. 5. Partial replacement of the distributing pipelines Result: Energy and water losses were decreased, extending the lifetime of the pipelines. Tasks carried out: Design and installation of the new pipelines, site restoration. Two sections were replaced with preinsulated tubes. The total length of replaced tubes was 300 m.

Resulting Benefits
Honeywell equipment enabled the municipality of Sikls to save more than US$100K annually, reduce its greenhouse gas emissions, and improve the working conditions of district heating facility workers through decreased pollution levels and improved information flow. This project was sponsored by the Honeywell Hungary ESCO. The overall cost of the project was US$724K. Energy efficiency measures must be evaluated according to their influence on the whole system. That is why the sequence of measures had to be prioritized. The heat demand reduction on the consumer side influences the network and boiler house side. That is why the unconsidered measures increase the payback period. Energy conservation measures increase the competitiveness of district heating compared to other energy sources. This creates additional possibilities to connect new consumers to the system, which increases the efficiency of the network. The provided supervisory system is flexible and can be extended in the future, according to the demand. It offers new ways of running the system and reduces the time and cost of fault corrections. Metered energy consumption can be scanned online using M-bus heat meters. The focus of the energy conservation measures is to offer maximal reliability of the network and comfort in heated units, with minimal investment costs.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Combined Heat and Power, 120 MWe and 180 MWt unit Katowice District Heating Plant Silesia, Poland 1998 - 2000 Emissions reductions of SO2 11,5000 tons/yr., NOx 1,300 tons/yr., CO2 163,000 tons/yr.

Introduction
Katowice is a large town in southern Poland in the coal mining and heavy industrial region of Silesia. This region contains some of the most serious environmental concerns in Poland. Due to the changes in environmental policy, more emphasis has been placed on protecting the environment and improving the effectiveness of heat production. The biggest local heat supplier, Katowice District Heating Plant made the decision in 1996 to build a new combined heat and power unit with 120 MWe and 180 MWt capacity based on circulated fluidized bed boiler technology. The benefit from this type of boiler is the reduction of emissions and the utilization of coal slurry as an additional fuel, accounting for up to 30% of boiler fuel consumption. The new unit was placed into commercial operation in January 2000. Existing System The existing plant consisted of two 100 t/h and one 200 t/h heat only boilers with analog control systems.

Honeywell Solution
Honeywell Poland was awarded a turnkey contract to deliver complete instrumentation and control systems for a new unit with auxiliary installations, and for monitoring the old plant from the unit control room. The scope of supply and services included:

DCS delivery Field instrumentation Project engineering Software engineering Installation Commissioning Customer training

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The hardware and software platforms were based on:


TotalPlant Solution (TPS) distributed control system for unit control Fail Safe Controller (FSC) for unit interlock and protection system Uniformance for plant database TotalPlant Bottomline Results (TPBR) for plant performance monitoring

The original Honeywell software package for plant performance monitoring (TPBR) enables online supervision of unit operation. The package consists of several modules such as:

TotalPlant Performance Monitoring Module for continuos monitoring of unit efficiency Thermal stress monitoring of critical boiler components Unit start up and shut down heat loss calculation Emission monitoring

Resulting Benefits
Optimal utilization of primary energy was achieved by providing operational staff with plant management tools for on-line supervision and optimization of electricity and heat production and emissions control. The solution provides stress monitoring for critical boiler and turbine components during start up and load changes, which extends the capital equipment lifetime of each unit. Honeywell promotes and provides improvements in energy efficiency both by supplying control technologies and expertise and supervisory system for plant operation. The Honeywell Solutions significantly improved unit efficiency and led to emissions reductions amounting to: SO2, 11,500 tons/year, NOx, 1,300 tons/year and CO2, 163,000 tons/year.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control District Heating Improvements in Krakow MPEC Krakow, Poland 8/94 12/96 Overall fuel reduction of 33%

Introduction
The Krakow Clean Fossil Fuels and Energy Efficiency Program was initiated by the United States Department of Energy at the beginning of the 1990s. The United States Department of Energy selected Honeywells proposal to improve energy efficiency in part of Krakows district heating system as a demonstration project. The proposed project was aimed at reducing emissions from the local Balicka boiler house by improving emissions control and by reducing the load of the boiler plant. In order to reduce the load from the boiler house it was proposed to install plate heat exchangers with automatic controls and Thermostatic Radiator Valves (TRVs) on the radiators in the individual apartments. After discussions and agreements reached between Honeywell, the United States Department of Energy, MPEC - Krakows District Heating Authority - and WIDOK Housing awarded the contract to execute the project on the 1st of August 1994. The total approved budget was over US$4 million including a federal cost sharing of 50%. The remaining 50% was financed by the customer. During autumn 1994 an additional potential partner showed its interest in participating in the program: the Krakow Combined Heat and Power Plant, LEG. Honeywell proposed an extension of the program to the United States Department of Energy. The purpose of the extension was to further reduce low emissions by shutting down local boiler houses and replacing them with heat exchanger stations connected to the LEG Heat and Power Plant through the main district heating network. This extension was officially awarded to Honeywell on the 2nd of March 1995. The total approved budget for the extension was over US$1 million including a federal cost sharing of 36.33%. The remaining financing was provided by the customer and the Polish ECO fund.

Honeywell Solution
Project Implementation The project was initially split into two budget periods: Budget Period 1 and Budget Period 2 (BP1 and BP2), each for one-year duration. Since the Budget Period 2 scope of work was expanded
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and the winters were very severe a further time extension of BP2 until the 31st of December was necessary. Within each budget period, four parallel phases with dedicated budgets were defined; each phase consisted of a number of tasks: Phase 1: Phase 2: Phase 3: Phase 4: Upgrade of the Balicka Boiler House, MPEC Replacement of existing hydroelevators with modern heat exchanger stations, MPEC Upgrade of the internal heating system and installation of Thermostatic Radiator Valves (TRVs), WIDOK and Bienczyce Replacement of local boilers and installation of heat exchanger stations with automatic controls, LEG

The phases described above were performed over a period of 2.5 years. This time frame was broken down into two budget periods. The details for the expenditures of each phase are presented in the table below:

Phase 1 Budget Period 1 Budget Period 2 Total Project 570,273 139,329 709,602

Phase 2 412,863 2,486,160 2,899,023

Phase 3 155,726 449,566 605,292

Phase 4 405,447 707,501 1,112,948

Total 1,544,309 3,782,556 5,326,865

(All figures in US $ include federal cost sharing)

Scope of Work 1. Balicka District Heating Network Balicka Boiler House: Upgrade of the hydraulic section, water treatment and pumping station of the Balicka Boiler House. The implemented Control System (S9000) by Honeywell perform mainly the following functions: 1. Measurement of physical parameters affecting the functioning of the boilers. 2. Control of the water purification installation 3. Control of the mixing node 4. Variable speed control of the motors at the pumping station 5. Flue gas measurement 6. Supervision of the Balicka Boiler House

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Installation of a Supervisory Control and Data Acquisition System (SCADA) The system performs central monitoring of the Balicka boiler house and supervision of the Building Heat Exchanger connected to the network supplied with heat by the boiler house. The SCADA is a Honeywell SCAN 3000. Data gathering, monitoring and commanding of the boilers and the building heat exchangers is provided. Network:

Installation of 64 plate heat exchangers connected to the Balicka district heating network, supplied with heat by the Balicka Boiler House (installed capacity 16.5 MW). The new installed plate heat exchangers are equipped with Honeywell EXCEL controllers allowing outside temperature compensation and night set back. In addition to these important functions the controller performs flow limitation, automatic start function, pump control for the circulation pump and an auto filling function. Upgrade of the controls and instrumentation of the WIDOK Zarzecze Group Heat Exchanger and modernization of the internal heating installation in 25 single family houses connected to it. Installation of a Data Acquisition and Monitoring system for Heat Meters Each substation connected to the Balicka network is equipped with a heat meter. Each heat meter has a communication device, which is connected via a separate communication network to a central. The network for the heat meter monitoring system was installed parallel to the communication network for the SCADA. The central, a computer with special software, is located in the Balicka boiler house. The data of each heat meter can be displayed on the computer monitor, processed and stored on the hard disk. Upgrade of the internal heating system in the WIDOK Housing Cooperative by installing 11,200 Thermostatic Radiator Valves (TRVs). The installation works performed included the following tasks: Removal of the radiators and cleaning them Installation of the Thermostatic Radiator Valve - Bodies Installation of the Lockshield Valves Mounting to the radiators Installation of the Thermostatic Radiator Valve - Heads Installation of the Differential Pressure Overflow Valves on the vertical pipes Pressure test of the installation Start up and setting of the TRVs Training of the residents (cooperation between installer and Honeywell)

2. Main District Heating Network: Removal of 4 large local coal fired boiler houses and replacing them by 4 Group Heat Exchangers (installed capacity 11.8 MW), connected to Krakows Main District Heating network.

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Delivery of instrumentation and controls and related project services for 85 newly implemented heat exchanger stations with a joint financing from the ECO Fund (installed capacity 41 MW). Complete upgrade of 4 heat exchanger substations at the Hospitals Narutowicza and Jana Pawla II (installed capacity 20.7 MW). Upgrade of the internal heating system in the Bienczyce Housing Cooperative by installing 2,145 Thermostatic Radiator Valves.

Resulting Benefits
Since the project was a demonstration project, an assessment of the achieved reductions of energy consumption and low emissions was carried out. In order to obtain a baseline, an assessment of the present energy consumption and existing installation was performed. This was done by means of a feasibility study which was performed during the beginning of the project. An American consultant, RMA, has completed this study in cooperation with Krakows Office for Development (BRK) and Polinvest Ltd., a Krakow engineering consulting firm. At the end of the project a post audit was performed. The objective of this audit was to determine the effects of the modernization at the Balicka District Heating Network and also to analyze the impact of the overall implemented Honeywell program on the city of Krakow in terms of environmental benefits. Achieved Performance Improvements at the Balicka District Heating Network The Balicka District Heating Network is an independent part of the overall District Heating System in Krakow. Honeywell provided controls for the Production, Distribution and Consumer Side of the Balicka network. The data are based on the studies performed and the historical data available from the customers. The result for the reduction of the energy consumption on the distribution and end-user side is calculated as an average of data obtained in selected residential buildings. The specific energy savings and environmental benefits for this as an implemented demonstration project are presented below: 1. 2. 3. 4. 5. Reduction of Energy Consumption on the Distribution and Consumer Side [ 15% ], Reduction of Fuel Consumption in the Balicka Boiler House [ 17% ], Reduction of Energy Consumption due to the SCADA system [ 5% ], Reduction of the Electricity Consumption in the Balicka Boiler House [ 29% ] and Annual Emission Reductions of : Particulate by 86%, Sulfur dioxide by 23%, Carbon oxides by 23%, Equivalent Emissions [Er] by 55%.

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Based on the savings presented above, the overall fuel reduction for the Balicka Boiler House is 33%, representing savings of 5,500 tons coal per year. Environmental Impact Taking into consideration the projects implemented by Honeywell: the elimination of local boiler houses the modernization of the Balicka District Heating Network As presented above, the impact of the Honeywell program on the environment in the entire city of Krakow has been calculated. The following emission reductions were achieved: No Specifications Annual emissions
Particulate [Mg/year] SO2 [Mg/year] CO [Mg/year] NOx [Mg/year] Er [Mg/year]

I II 1.

2.

III

Low emissions in Krakow baseline in 1992 Effects of the program Honeywell contribution: Reduction in low emissions due to elimination of boiler houses by connecting them to the main DH network Reduction in emissions due to modernization of the Balicka DH System Total Reduction: Low emissions in Krakow after implementation of the program

8126

6048

17780

1995

44289

690

590

950

129

3440

101 791 7335

36 626 5422

-9 941 16839

9 138 1857

352 3792 40497

The results expressed in percentage: Emission Type Particulate SO2 CO NOx Equivalent Emissions [Er] Emission Reduction for Krakow 9.7% 10.4% 5.3% 6.9% 8.6%

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Martin District Heating Network Municipality of Martin Martin, Slovakia 12/96 - 3/99 Annual customer savings of over US$350K

Introduction
Martin is a heavily industrialized town in central-northern Slovakia. Its heating power station dates from the 1950s, and was one of the first to combine the production of electricity and heat in Slovakia. An additional steam transmission network was built between 1990 and 1996. Among the largest current energy customers are ZTS (heavy machinery factory), Martin brewery, Martin paper and furniture factory, the City hospital and about 70% of the town's apartments. With an overall cost of US$3.3 million, the payback period is less than 10 years. The EBRD and PHARE, the EU's financial instrument to assist transitioning Central and Eastern European countries, financed the heat exchanger stations reconstruction. Existing System Boilers K4 and K5 were new SES Tlmace pulverized coal boilers of 75 t/hour steam output which used to be controlled manually, partly using an old analogue control system. Additionally, there was an inadequately high demand for heat from the blocks of apartments due to an unbalanced hydraulic system and lack of a modern control system in the heat-exchanger stations. After the fall of communism, there was an emphasis on environmental protection and on increasing the effectiveness of the manufacturing process. In 1994, it was decided that a revamp of part of the old heating plant, including a new control system, was necessary. The main goal was to lower energy costs by reducing the overall steam consumption in the area. Honeywell was awarded the contract to supply the control system.

Honeywell Solution
In addition to a Honeywell Micro TDC 3000 Control System (boiler K5) and TPS Control System (boiler K4), including the interconnection of operator level (LCN) deliveries, this project also includes field instrumentation, sub-suppliers deliveries, project engineering, software engineering, installation, start-up, and customer training. The Honeywell DCS control system provides monitoring and process control, including automatic start-up and shutdown, and the highest level of reliability through automatic switchover between redundant facilities and comprehensive system diagnostic functions to minimize downtime.

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More than 15,000 apartments will save on heat consumption thanks to the 15 Excel 100 and Excel 500 controller units installed in heat-exchanger stations, and the 60 units of Excel 20 and Excel 50 controllers in house stations, installed by the end of 1998. Before the end of 1997, TRVs were installed in most of the apartments, along with hydraulic balancing of the secondary heating pipeline networks. Communication with Graphic Central (XBS) will be developed via Cable TV (fiber-optic). Allocation meters will be prospectively linked with the Excel controllers via M-Bus.

Resulting Benefits
The solution and equipment provided by Honeywell enabled the customer to save more than 15% on its energy costs. Assuming a seven-month heating season added to the hot water savings for the whole year, the savings are US$355,000 per year. The project resulted in major environmental benefits such as reduced pollution and greenhouse gas emissions. In addition, the Honeywell solution improved information flows for the district heating facility workers.

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Capability: Business Unit:


Project Title:

District Energy Industrial Automation and Control District Heating Boiler Houses Revamp Project RAT District Heating - Fagaras Fagaras, Romania 6/1999 10/2000 20% reduction in gas consumption, payback period of approximately 2.5 years

Customer: Location: Duration: Significance:

Introduction
In first half of 1999 Honeywell, with its Romanian partner Romenergo, won a European Bank for Reconstruction and Development (EBRD) financed bid for the renovation of four district heating boiler houses in Fagaras, an industrial town located in central Romania. Energy use for heating and domestic hot water systems in Romanian buildings is 1.5-2 times higher than in Western countries with similar climate conditions. The main goal of the project was to modernize the measurement and control equipment of small boiler houses, which are typical of Romanian centralized district heating systems. Existing System Each boiler house consisted of 2 or 4 small (up to 5 Gcal/hour) Romanian gas fired hot water boilers. These boilers used to be controlled manually, partly using an old analogue control system. Additionally, there was an extraordinarily high demand for heat from apartment blocks due to an unbalanced hydraulic system and the lack of a modern control system in the heatexchanger stations. The main task was to create a modern boiler control strategy where the boilers provided hot water according to the needs of the heating and domestic hot water circuits. The number of boilers in operation and the value of the modulating burner valve have to be determined by the heat demand, which is calculated as a sum of the heating and hot water circuits. Boiler operational sequencing was also requested.

Honeywell Solution
The Honeywell solution optimizes the number of boilers in operation according to the heat output of each boiler and the heat demand of the distribution system.

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In each Boiler house a Honeywell Excel 5000 system was installed to perform the following functions:

control water temperature at the input and output of the boilers; optimize the fuel burning process (fuel/air ration control); water and heat consumption measurement and control; pump sequencing control; reporting of alarms and key physical parameters.

All four boiler houses were connected to a central dispatcher based on the Honeywell Graphic Station (XBS). The software was developed on three levels of monitoring and control:

Level 1 basic control functions of each boiler; Level 2 plant strategy level calculating the heat demand and number of boilers in operation; Level 3 - dedicated to emergency shut down and other protection functions.

The installation was completed in two steps: 1) In October 1999, the first two boiler houses were put into operation with automatic control and supervisory functions of the dispatcher. 2) The last two boiler houses will be retrofitted and started up before the 2000-2001 heating season. Customer engineers and operators were trained for implementation and maintenance of the installed equipment.

Resulting Benefits
The first stage of the project resulted in a 20% drop in gas consumption, yielding savings of US$180,000 with a payback period of 2.6 years. This system represents a huge increase in the level of technology used for heat generation and distribution via district heating systems in Romania.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control District Heating Substations Control RAT (District Heating Company) of Ploiesti Ploiesti, Romania 9/98 - 2001 First step of a large-scale district heating program to reduce energy consumption in Ploiesti (over 400 buildings)

Introduction
Ploiesti is a heavily industrialized city of 350 thousand inhabitants in central-southern Romania. There are four large Romanian refineries and a large combined heating plant located around Ploiesti. Around 70% of the city receives its heat and hot water from the city district heating system. In August 1998 Honeywell, with its local partner Romenergo, won an international tender financed by the European Bank for Reconstruction and Development (EBRD) for the renovation of the control systems for 20 Heat Transfer substations in the city of Ploiesti. The project scope includes a full renovation of the heating substations with new compact heat exchangers (from Alfa Laval), new pumps (from Grundfos), new heat meters (from Sontex) and new measurement and control systems with a central dispatching unit (from Honeywell). The timetable plans for the realization of the project over 4 consecutive years 1998 to 2001. The total investment for the project was US$1.25 million, from which about US$500,000 was for Honeywell controls and a central supervisory system (dispatcher), including equipment, engineering, transportation, installation, commissioning, start-up assistance, and training of local staff. Existing System The District Heating system in Ploiesti receives heat from the Combined Heating Plant (CHP), located in the industrial area next to the city. The hot water is then distributed throughout the city by a network of heat pipes which serve more then 40 heat transfer (exchanging) stations: 20 of these were modernized as part of this project. The heat exchangers were then connected to the residential and non-residential (hospitals, university buildings, schools) buildings. The existing heat distribution system had some major dysfunctions that resulted in excessive fuel consumption and air pollution:

no heat metering to measure the heat consumption at the various levels in the energy chain; no on-line heat capacity adjustment mechanism; no control system in the heat exchange stations to take weather conditions into consideration; high heat losses in the piping network due to excessive water temperature in the pipes.
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Honeywell Solution
The renovation consisted of a full revamp of 20 heat transfer stations focusing on the installation of state-of-the-art control systems, integrated into a central dispatcher. Each substation was equipped with a Honeywell controller (Excel 500 ), outside temperature sensors and control valves to perform the following functions:

communicate with the central supervisory system to transmit major functioning parameters to the operator in order to optimize heat output as a function of demand; control water temperature in the heat exchangers; control pressure on the secondary side. control water temperature at the input and output of the local hot water vessels (boilers); report alarms and key physical parameters.

The central dispatcher was based on the Honeywell Graphic Central (XBS), located inside one of the refurbished heat exchanging stations. The installation will be completed in three steps. Step 1: in November 1998, the first heat transfer station was put into operation with automatic controls. Step 2, including 10 heat transfer substations, was realized before October November 1999 with the required central supervisory control from the dispatcher. Step 3: the last 10 heat exchange stations should be fully equipped before the beginning of the 2000-2001 heating season. Finally, customers, engineers, technicians and operators were trained for implementation and maintenance on site, using installed equipment.

Resulting Benefits
In the second season, with modern equipment in operation in 10 heat transfer stations, the Honeywell solution enabled the customer to save more than 10 % of its energy costs. Consumer comfort was increased as a result of fewer interruptions in the heat and hot water supply and better temperature regulation. Finally, the Honeywell solution facilitated information flows for district heating facility operators.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Centralized Heating Project of Murmansk City TEKOS Murmansk, Russia 1996 Annual customer savings of over US$250K

Introduction
In the fall of 1996 Honeywell installed a TDC 3000 system and field instruments for automation control of four steam boilers which are part of the Centralized Heating Project of Murmansk City, Russia. It is the northernmost operating TDC 3000 system in the world. Murmansk is located on the Kola Peninsula on the North Sea. It is the largest city in the world located north of the Arctic Circle, and is Russias largest port for fishing and military use. The city has a population of 400,000, and the region is home to more than one million inhabitants. The major sources of economic activity are natural resources, manufacturing, fishing and port facilities for the shipping industry. The customer, TEKOS, is a municipal company owned by the State of Murmansk and serves the Murmansk city and region. TEKOS owns and operates a total of ten boiler houses plus network and heat distribution systems. With an investment of US$1.2 million, the payback period is less than five years. The Existing System The scope of the project is the modernization of a boiler house consisting in total of six large steam boilers with a capacity of 50 tons of steam per hour, and equivalent thermal capacity of about 30 Gcal/hour; five steam boilers of capacity 25 t/h; and four water heating boilers with thermal capacity of 30 Gcal/h. Black oil (mazut) is delivered by railroad or sea as the source of fuel. The existing system instrumentation was insufficient for complete monitoring and automatic control. Multiple single loop controllers were replaced by a complete integrated system.

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Honeywell Solution
Honeywell automation control solution for TEKOS consists of the following:

TDC 3000 system with two Operator Universal Stations, redundant controller Advanced Process Manager with I/O cards, History Module for archiving, Network Interface Module for Local and Universal Control Networks. Field Instruments, including temperature sensors, pressure and differential pressure transmitters, mass flow meters, control valves, 4 oxygen analyzers. Adjustable frequency converters for large motors. Water Analysis panels for on-line monitoring of boiler water quality.

The system controls four boilers out of fifteen in the boiler house, and system software provides operator interface for the process alarms, loop control and shut down functions. Honeywell succeeded in implementing this project within a period of six months.

Resulting Benefits
The solution provided by Honeywell enabled the customer to reduce consumed fuel (mazut) by 5%. Assuming a seven-month heating season and an average fuel consumption of 1,800 tons per boiler per month, total fuel savings will be 2.52 tons. At US$100 per ton of fuel, the savings are US$252,000 per year. Compared with the existing system the TDC 3000 system is highly reliable and has little down time. It is easier to operate and improves working conditions for the operators.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Tver District Heating Project Municipality of Tver Tver, Russia mid-1996 - 12/96 15% reductions in greenhouse gas emissions and energy costs

Introduction
In the fall of 1996, Honeywell increased the efficiency of a 51-substation district heating distribution network in Tver. The project was implemented within a six-month period and was completed in December 1996. Tver is one of the oldest cities in Russia, dating back from the 13 th century. It is located between Moscow and St. Petersburg and has a population of 1.5 million. The project was sponsored by the USAID and the overall cost of the project was USD 1.1 million. The payback period is calculated at 3.15 years. Existing System The integral heating system of Tver consisted of three combined heat plants and four boiler houses, connected in ring circuit. Heat consumption was regulated directly from heat suppliers according to the heating schedule. The heating system was a combination of closed and opened systems. In the districts with closed systems, heat was transferred through a two-pipe network to central heating stations. This supplied heat through two-stage heat exchangers to a four-pipe secondary network with separate circuits for domestic hot water supply and space heating. Domestic hot water was supplied to residences through heating elevator units.

Honeywell Solution
The following Honeywell automatic solution supervises and measures heat demand from both consumers and suppliers in Tver, allowing substantial heat savings for the city: Heat meters and sensors at the top level of the system measure pressure differential between supplying and feedback lines at Heating plant-1, Central boiler house, Water boiler house-1, and Water boiler-2. Data is transferred through telephone communication lines to XBS management system with Central Graphic System. Heat meters at the middle level measure the hot domestic water supply system heat and the heat level at three central heating stations of "A" sector of "Jushnij" District.

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Heat meters and regulators of heat expenditure are installed at the lowest level for space heating in elevator units of 37 residential buildings connected to central heating stations. In order to compare data and measure the effectiveness of regulating device implementation, two heating units were installed with meters only (without a regulation option).

Resulting Benefits
Honeywell equipment enabled the municipality of Tver to save 15% of its energy costs or 2,740 tons of natural gas annually, reduce its greenhouse gas emissions by 15%, and improve the working conditions of district heating facility workers through decreases pollution levels and improved information flow.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Tushino - 3 Moscow City Government Moscow, Russia 12/91 - 2/98 Gas consumption reduction

Introduction
One of the largest energy conservation projects Honeywell implemented is in the city of Moscow, in a district called Tushino-3, where 100,000 people live and receive their heat and domestic hot water from the city district heating system. In December 1991, a contract was signed between Honeywell and the Moscow City Government to modernize the district heating system in Tushino-3 in order to show evidence of the potential for energy savings in this sector. The total investment for the project was US$3 million, which breaks down into US$2.2 million for the boiler house (including field instrumentation and pump controls) and US$800,000 for the heat transfer stations. This figure includes all activities (equipment, engineering, installation, commissioning transportation, duties and taxes). Existing System The gas fired boiler house of Tushino-3 has four gas fired boilers (PTVM 100 generation) of 100 Gcal/h, i.e. 400 Gcal. total. The hot water is then distributed throughout the city by a network of heat pipes which serve 33 heat transfer stations: 19 of these were modernized. The heat exchangers are then connected to the apartment buildings. The existing system had some major dysfunctions:

low boiler efficiency due to the absence of a burner optimization system; no gas and heat metering to measure gas and heat consumption at the various levels in the energy chain; no on-line heat capacity adjustment mechanism; no control system in the heat exchange stations to take weather conditions into consideration; high heat losses in the piping network due to excessive water temperature in the pipes.

This resulted in excessive gas consumption and air pollution.

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Honeywell Solution
The renovation consisted mainly of the installation of state-of-the-art control systems in the power plant as well as 19 heat transfer stations. Due to budget constraints, no equipment could be installed in the actual buildings. In the power plant a Honeywell Micro TDC 3000 system was installed to perform the following functions:

water temperature control at the input and output of the boilers; optimization of the fuel burning process (fuel/air ratio control); gas, water and heat consumption measurement; safety management of the boilers; reporting of alarms and key physical parameters.

Each substation was equipped with a Honeywell EMC controller and valves to perform the following functions:

communication with the central supervisory system to transmit major functioning parameters to the operator in order to optimize heat output as a function of demand; water temperature control in the heat exchangers, pressure control on the secondary side.

The installation was completed in two steps: in October 1993, the first two boilers were put into operation with automatic controls. The other two continued to be manually operated. The last two boilers were retrofitted and started up in June 1994. The heat exchange stations were also fully equipped; thus, the system has been fully modernized since the beginning of the 1994-95 heating season. To continuously analyze oxygen and carbon monoxide, Honeywell provided a flue gas analyzing system. Its data allows an optimal fuel/air ratio control to improve plant efficiency and minimize air pollution. Customers, engineers, technicians and operators were trained for implementation and maintenance in Austria, Moscow and Brussels, as well as on site, using installed equipment.

Resulting Benefits
In the second season, with all modern equipment in operation, gas consumption dropped by 17 million cubic meters, yielding savings of US$1.3 million with a simple payback period of 2.3 years. Consumer comfort was increased as a result of fewer interruptions in the hot water supply and better adjustment of temperature. Finally, this system represents a quantum jump in the level of technology for heat and power networks in the Russian Federation.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Pozniaky Heating Plant Kievenergo Kiev, Ukraine 2000 Increased energy efficiency, reliability

Introduction
Honeywell Industrial Automation & Control in Ukraine recently signed a US$2.6 million World Bank contract with Kievenergo for automation hardware and software and engineering services for the Pozniaky Heating Plant in Kiev, Ukraine. This is the first internationally financed competitive tender in a US$200 million government program for energy efficiency and district heating in Ukraine. The Pozniaky Heating Plant serves an estimated 15% of the population in Kiev and is one of the largest heat-only plants in Ukraine for District Heating customers. Nine international companies took part in the bid for this contract. The Honeywell solution was selected for its ability to exceed the specifications, provide a competitive price and the strong presence of Honeywell in Ukraine.

Honeywell Solution
Honeywell will supply its PlantScape Hybrid control system, Fail-Safe Control (FSC) system and field instrumentation to provide automation & control of four district heating hot water and steam boilers. Honeywell will also provide engineering, installation supervision and project management services. PlantScape, FSC Automation & Control System:

Two hot water boilers KVGM 100 Gcal / hour Two steam boilers - 25 tons/hour steam Pumping station control Make up water, de-aeration plant Natural gas supply station Heavy fuel (mazut)supply station 3 x Operator Stations 1 x Operator Station (remote make up water) 1 x engineering station 1 x server (redundant) 2 x FSC (fail safe controllers) 4 x Controller

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Home and Building Control Kiev Institutional Buildings Assessment (KIBA) Project Kiev Municipality Kiev, Ukraine Fall 1997 - 1998 First step in a large-scale district heating program to reduce energy consumption in over 1,600 Ukrainian buildings

Introduction
Energy use for heating and domestic hot water systems in Ukrainian buildings is 1.5-2 times higher than in Western countries with approximately the same climate conditions. Factors such as former building codes influenced by the availability of cheap energy, inefficiency of building heating systems, and inadequate operation and maintenance have resulted in substantial opportunities for energy efficiency improvements in heating Ukrainian buildings. The KIBA demonstration project was implemented in Kiev in the fall of 1997. Four school buildings were selected to demonstrate the effectiveness of weatherization and control measures to reduce the heat energy consumption provided by the district system. The demonstration project was financed by the US Department of Energy and Honeywell was awarded general contractor. The demonstration project cost was approximately US$100,000. This demonstration project is part of the KIBA program, which was designed to reduce energy consumption in 1,678 institutional buildings in Kiev. The continuation of the project is scheduled to begin in 1999 and last for five years. The total cost of the KIBA program is estimated at about US$40 million, with a large portion financed by the World Bank. The simple payback was calculated at 3.3 years. Existing System Currently, the vast majority of buildings connected to Kievs District Heating system are equipped with a hydroelevator type of substation. In this kind of substation hot water from the DH primary loop is introduced directly to the building heating system and circulates in pipes and radiators. The heat balancing within the building is accomplished by loop balancing valves. In order to maintain the temperature of the radiators within a predetermined level, the hot supply water is mixed with cold water returning from the building. A hydroelevator is used to mix the two water streams. The mixing ratio is fixed and is only a function of the physical dimensions of the hydroelevator and the pressure in the primary circuit. The supply water flow is controlled by the fixed flow restrictor (orifice) sized and installed by the DH company. This system is very simple and inexpensive, and requires little maintenance. However, it is very energy inefficient and since the DH water circulates directly through the radiators, pipe corrosion and debris deposits carried by the water cause the system to clog, thus reducing the heating
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system performance and causing frequent problems. Except for the presence of a simple solid particle separator, no other filter is used in the system. Also the building heating pipes and radiators are exposed to higher pressure (0.5 to 0.8 Mpa) which can cause leaks.

Honeywell Solution
The Honeywell solution enables the control of the indoor temperature in response to outdoor conditions, occupancy, and changes to the thermal characteristics of the building. The installed system is based on a heat exchanger where the DH water enters the cross-flow, plate heat exchanger on the primary side and the heat is transferred through the heat exchanging surface to the secondary water which distributes the heat throughout the building. Thus, the heat exchanger effectively separates the primary, district heating side, water flow from the closed loop building system. Both water flows are passed through strainers, which remove debris and protect the surface of the heat exchanger. The pressure-equalizing valve maintains constant pressure difference in supply and return lines and prevents damage to the heat exchanger from pressure pikes. The heat consumption is measured by the heat meter (consisting of the water flow meter), two temperature sensors and an integrator. Provisions for connecting the building domestic water heating system and the ventilation system heating equipment are made on the primary pipes after the heat meter. The building side piping is connected to the secondary side of the heat exchanger. Water returning from the building passes through the strainer. Two circulating pumps with check valves are installed and the pumps are alternated every 12 hours so that one always serves as backup. The secondary side is equipped with a feed valve and a bypass valve, pressure relief valve, and expansion tanks to allow the secondary side to be filled with water from the primary side and then function as an independent close loop. The control system utilizes inputs from the indoor temperature sensor, outdoor temperature sensor, supply water sensor, and the programmed occupancy schedule to maintain the indoor temperature by modulating the valve which controls the primary water flow input to the heat exchanger.

Resulting Benefits
The project resulted in both an energy savings rate and an internal rate of return of 29%. These technical and financial improvements represent annual savings of US$30,000. Since the project investment was US$100,000, these savings result in a payback period of 3.3 years. The Honeywell solution enables control of the indoor temperature in response to outdoor conditions, occupancy, and changes to the thermal characteristics of the buildings. The system provides for a stable indoor temperature, which enhances the comfort of the building inhabitants, including schoolchildren.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Beijing District Heating Beijing District Heating Company Beijing, China 12/95 - end of 1997 First DH project in China open for international tender

Introduction
The first district-heating contract for Honeywell in the China Area was signed in Beijing in December 1995 after three years of discussions. The contract itself is valued $2.4 million and is the first such project open for international tender in China. The customer is the Beijing District Heating Company, a state-owned supplier of heat that serves about 20% of all residences and commercial buildings in the city of Beijing. The project is funded by the World Bank.

Honeywell Solution
As this was the first project of its kind for Honeywell in the China Area, the region relied on Europes significant experience, which proved to be instrumental in the contract win. Furthermore, the technical solutions for this particular project, some of them new, require close cooperation between Honeywell China and the Honeywell development/support centers worldwide. During the planning and implementation stages of the contract, Honeywell China Area received extensive support from global resources. Contributions included the Chinese text display for the Excel 5000 System from Schoenaich, Germany; fiber-optic C-bus Ring Network testing from the Technical Assistance Center in Maintal, Germany; application and manpower support from Honeywell IAT in Brandenburg, Germany; the SCAN 3000 system from Sydney, Australia and the S9000 controllers from Fort Washington, USA. As a regional resource, the Center in Hong Kong delivered technical support through implementation and training.

Resulting Benefits
The end of 1997 completed the first phase of the project. Around 25 substations were installed and an extensive communication network was established. The BDHC gathers the data of the entire western part of their network and transfers them to their main control center.

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Capability:

District Energy Industrial Automation and Control Yantai TRV Demonstration Project Yantai Minshen District Heating Company Yantai, China 7/97 - 2/98 Introduced consumption-based billing in China

Business Unit: Project Title: Customer: Location: Duration: Significance:

Introduction
The Yantai TRV (Thermostatic Radiator Valve) demonstration project was signed between Honeywell and Yantai Minshen District Heating Company in July of 1997. This project will support the efforts of China Ministry of Construction (MOC) to establish high environmental standard and energy conservation and promote Honeywell District Heating business in China. The project is under the supervision of the US-Sino Energy Efficiency District Heating sub-team, for which Honeywell was selected as the US team leader and MOC serves as the Chinese counterpart. The main purposes of the project are to bring about the most suitable solutions for:

introduction of the consumption-based billing of heating indoor temperature control hydraulic balancing reduction of return flow temperature reduction of water flow improvement of overall system efficiency

Honeywell Solution
This retrofit project involved the installation of TRVs and heat allocation meters on each existing radiator of selected apartments. Heat meters were installed in each selected apartment building unit as well. Since the single-pipe system is a common practice in Chinese district heating, the experiment includes converting some existing single-pipe systems into double-pipe systems for comparison.

Resulting Benefits
The motivation for introducing the consumption-based billing of heating is that the energy consumption (EC) in space heating for buildings uses 35% of the total energy consumption in China. The EC for heating in the northern cities like Beijing and Harbin is about 40% of the whole city's EC.

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The common practice of the billing system in European countries, such as Denmark, Netherlands, Germany, etc., has shown the high energy-saving potentials varying from 20% to 40%. This kind of saving is even more attractive and crucial to China due to the fast growing economy and the increasing demand for buildings with heat supply. The result of the successful system installation and operation will also serve as an example for retrofitting other heating system in China through setting guidelines and principles for other heating installation. This will help the Chinese society to improve the comfort of the heating system, reduce pollution and energy consumption. It is the common goal to promote energy efficiency and energy conservation through this project.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

District Energy Industrial Automation and Control Sangmu District Heating Korea CES Kwang Ju City, Korea 3/99 - 10/99 First Honeywell contract with Korea District Heating Corp.

Introduction
The Sangmu District Heating project is the first contract with Korea District Heating Corp. (KDHC), the country's leading district-heating company, for Honeywell Korea. It was signed on Mar. 29, 1999 and valued at US$200,000. The site is located at Kwang Ju city, the nations third biggest city. The customer is Korea CES, and the project was carried out by a consortium of Kum-Ho Ind. (46%), Kwang Ju city (34%), and KDHC (20%). Kum-Ho Ind. is responsible for the construction including material supply, Kwang Ju city is to provide the land, and KDHC is in charge of the project supervision.

Honeywell Solution
This district-heating project was designed to provide steam to the public buildings in Sangmu complex area and its capacity of heat production facilities is 20 ton/hour 2-unit heat-only boiler (23Gcal). To meet the requirement, Honeywell Korea is to install PlantScape TM composite of 1 redundant server, 2 operator stations and 1 redundant hybrid controller. The construction is scheduled to be completed by October 1999. In this district heating project, PlantScapeTM is designed to provide following service: Consumption-based billing of heating Reduction of return flow temperature Reduction of water flow Control of the boiler

Resulting Benefits
Cost and energy savings had not yet been determined at the time of publication.

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Selected Energy Efficiency and Capabilities for

PROCESS INDUSTRIES

Substantial amounts of energy and power are utilized in the process of manufacturing many of the materials and products that consumers and businesses consume each day. Honeywell is a world leader in automation solutions for a wide range of process industries, including oil & gas, chemicals and petrochemicals, pulp & paper, mining, metal and minerals, pharmaceuticals and other consumer goods. By providing advanced control and information management software and industrial automation systems and related field instrumentation and control products, Honeywell helps industries optimize their manufacturing processes and in so doing, achieve greater energy efficiency in the plant operations. Honeywells control systems can also be applied within a plants powerhouse, thereby achieving improved energy efficiency in both the process and power generation aspects of the industrial facility.

This section contains an overview of Honeywell products and solutions, as well as specific project examples. The activities represented in this section are as follows: North America

Amoco Chemicals (Decatur, AL) Gulf States Lime Kiln Optimization (Demopolis, AL) South Australia Water Optimization - SCADA (Australia)

Asia

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Process Industries Industrial Automation and Control Amoco Chemicals Amoco Decatur, Alabama 3/95 - 9/96 Annual cost savings of over US$1 million, payback of less than one year

Introduction
The Amoco Decatur site is a chemical plant with a large installed base of Honeywell equipment. Amoco sought to reduce fuel costs in the utility portion of their chemicals facility through automating their boiler control schemes and the optimizing of steam production. Amoco justified the controls replacement project based on projected fuel savings the Honeywell solutions offered. Existing System This system description however is restricted to only the powerhouse applications. The powerhouse consists of four boilers, which fire either oil or gas. Three of the boilers are rated to deliver steam at approximately 90 t/h, and a fourth is rated at 105 t/h. The normal mode of operation is to operate all four boilers firing gas. Oil is usually only fired during times of natural gas curtailment. The typical total steam demand is approximately 205 t/h; however significant variations can occur rapidly to meet process demands.

Honeywell Solution
Honeywells Industrial Boiler Control (IBC) package was applied to all four boilers. This package provides a standardized control solution and a single window interface for all the boilers. The loops controlled on each boiler included; fuel, air, furnace pressure, feedwater, along with an integrated steam header pressure control (plant master) for setting loads to the boilers. Standard features of the IBC package include: bumpless fuel change over, fuel/air cross limiting, O2 trim, drum level density compensation, and both single- and three-element feedwater control. Implementation of the IBC package provided significant improvement in boiler operation, reducing flue gas O2 levels to <2%, an improved response to steam demand fluctuations, and gave the operators the single window to the process they wanted. A testimonial to the IBC package is that Amoco was able to achieve both their targeted performance improvement and fuel savings, before optimization was implemented. Honeywells Turbo Economic Load Allocation (TELA) solution was layered above the Industrial Boiler Control package. TELA, using a patented application of a mathematical optimization technique known as optimization by parts, calculates the optimum loading for all the boilers at all possible steam header loads.

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Two on-line solution sets are presented to achieve minimal steam cost: The first is referred to as the Local Solution, which sets the loading of all active boilers that are maintaining header pressure automatically. This solution of TELA calculates and applies a bias to each boiler to achieve optimum performance (lowest steam cost). The second solution takes into consideration all potential boilers to generate what we refer to as the Global Solution. The Global Solution makes recommendations to advise the operator as to what the optimum loading is for all the boilers, including recommending adding or removing boilers from service, and changing the load on any base-loaded units (boilers in manual mode). Implementation of TELA at this site provided additional fuel savings beyond the sites original expectations. The figure below graphically depicts these results.

Resulting Benefits
The success achieved exceeded Amocos expectations, the implementation of Honeywells solutions resulted in a fuel savings approximately double the amount used to justify the project, resulting in savings of over US$1 Million annually. This return on investment is large enough to yield a payback in well less than one year. Fuel savings versus steam production
Fuel Flow vs Load Comparison

Total Gas Flow, SCFH

Gas Curve fit (TELA Off) Gas Curve fit (TELA On)

400

420

440

460

480

500

Total Steam Flow , KLB/Hr

TELA requires information regarding boiler steam costs as a function of load. One of the best methods for determining this is through boiler efficiency calculations. Honeywells Industrial Boiler Performance Monitoring (IBPM) package was selected and incorporated within the total solution set. The IBPM is based on ASME Power Test Codes and provides on-line boiler efficiency calculations using both input/output calculation and the Heat Loss calculation methods. Following this successful implementation at Decatur, TELA was installed in 1999 at the AMOCO Whiting site, which has five 500,000 lb./hr. boilers.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Process Industries Industrial Automation and Control Gulf States Lime Kiln Optimization Gulf States Paper Demopolis, Alabama 1997 8% reduction in energy use and better emissions control

Introduction
The Gulf States Paper lime kiln operation is unique because it typically runs at 50% capacity, resulting in operational complexity and high operating costs. When Honeywell approached the mill with a solution to reduce energy consumption and improve product quality, many at the mill did not believe it was possible. However, the mill justified the project based on projected fuel savings of 4%, improved control of lime quality and stabilized operation of the kiln. Existing System Control of the lime kiln presented a unique challenge for Gulf States. The large capacity creates long transport delays and control response times. Only two manipulated variables must be used to control three controlled variables. Many of the measurement responses are noisy due to the harsh operating environment, and some are non-linear, changing the way they react as the process changes. To stabilize lime product quality, the operator must maintain the kiln temperature profile and anticipate the effect of operational disturbances on the hot and cold end temperatures. All of this must be accomplished while maintaining complete combustion and controlling total reduced sulfur (TRS) emissions a difficult task even for the most experienced of operators.

Honeywell Solution
Honeywell provided its Advanced Lime Kiln Solution (ALKS), with its Robust Multivariable Predictive Control Technology (RMPCT) implemented as a multi-input, multi-output controller. The RMPCT control system is designed to anticipate the effects of a disturbance on the process based on a model prediction. Using model predictions, the controller manipulates the kiln controls to maintain the process within operating tolerances. The ALKS also uses RMPCT to apply an optimizer to the system, increasing the kiln operational flexibility and allowing the controller to manipulate the temperature profile, within boundaries set by the operator, to operate the kiln as efficiently as possible. Development for Gulf States lime kiln control solution required the modeling of a disturbance and manipulated variables versus the control variables to establish a control model matrix of the process. Typical model development involved three to six step tests for each variable over a wide range of operating conditions. The RMPCT regression analysis tools processed the resulting data
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to produce a mathematical transfer function relationship to approximate the dynamic behavior of the process. A multi-variable controller is then defined by these transfer functions. Excess oxygen was considered the single most important variable to control. Excess oxygen must be controlled in a balance where complete combustion is occurring without wasting energy. This control is also vital to the control of TRS emissions. Too little oxygen will starve the process and raise TRS to unacceptable levels. The ALKS RMPCT controller manipulates the energy flow and induced draft fan speed to control the excess oxygen and maintain the kiln temperature profile, lime quality, and fuel flow. The optimizer will minimize fuel usage while maintaining all other parameters within the target range.

Resulting Benefits
Gulf States has seen a number of operational, quality and cost benefits with the Advanced Lime Kiln Solution project. Energy savings exceeded US$250,000 per year. Other processes have also benefited with improved pulping chemical quality and variability. The package greatly exceeded expectations of the mill resulting in:

Lime kiln energy usage reduction of 8% Excess oxygen variability reduced by 60% Quality improvement of over 35% Operation variability reduction by 65%

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Process Industries Industrial Automation and Control South Australia Water Optimization/SCADA System South Australian Water South Australia, Australia 1998 Energy cost savings of 7-15%

Introduction
This project comprises the design and supply of a PlantScape TM SCADA system incorporating an optimization system for control and optimization of major pumping systems with South Australia (A state in central southern Australia). The contract is for approximately $1.5 million and was completed in 1998. The integrated system is known as the Integrated Demand Management and SCADA (IDMS) System. The state of South Australia is generally arid with little natural rainfall. The natural rainfall and catchment areas are substantially augmented by pumping through four major pipelines to various areas of the state from the River Murray, the major river system in Australia. The pumping is currently manually scheduled and operated using several operating rooms and systems in different locations. The aim of the project is to integrate all of the current control systems into one system that can automatically control all pumping to give optimum reservoir levels at minimal cost. This will reduce operating manpower and electricity costs significantly. Eventually the operations center will be manned only during day shifts on weekdays, with the system operating automatically at all times using data gained from the current telemetry systems and manually entered by operators.

Honeywell Solution
Honeywell PlantScapeTM The SCADA package is the PlantScapeTM NT version, operating as a fully redundant system on DELL Pentium Pro 200 personal computers. The system incorporates many advanced features of PlantScapeTM including composite points and extensive logic networks to a user-friendly front end. Honeywell is providing the complete network and software interfaces to enable seamless operation through the local systems currently installed. SCAN is interfaced to three separate SCADA systems including MITS Megadata and Citect. The MITS interface is a purpose built system, whereas the Citect interface uses a standard DDE interface. This is networked over ISDN lines with PSTN automatic back-up to remote control centers up to 250km from the SCAN Server location in the central control room at Thebarton in Adelaide. Control room fit-out and installation was carried out by Honeywell.

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Honeywell ProfitMax The optimization package for SA Water utilizes the Honeywell ProfitMax package which operates on a DEC Alpha platform. ProfitMax comprises an integrated suite of tools designed for online optimization. This provides a means to collect data from the SCADA system, optimize this and then pass the results back to the control system for action. ProfitMax will utilize the redundancy features of SCAN to ensure that no data is lost in case of failure of the primary Alpha. Honeywell has also employed a G2 Expert System to enable complex constraints to be incorporated into the optimization. This system will determine such factors as contingencies for water quality changes and pump priorities. The use of this system will be expanded as both SA Water and Honeywell gain experience in the operation of this complex system. A user configurable ACCESS Database package is being used to automatically populate significant data tables required for demand, tariff and maintenance conditions on all plants at all pumping locations. This operates seamlessly with SCAN and ProfitMax to provide a userfriendly interface through Visual Basic to an otherwise data intensive process. Listed below (and shown in Figure 2) are the four major components of the ProfitMax System within IDMS. Executive Coordinator Engineering Interface System Database Modeling System Executive Coordinator. The executive coordinator (executive) schedules, handles requests for, and coordinates the execution of the various ProfitMax functions. It also allows multiple users to interact with ProfitMax through the engineer interface. Each interface interacts directly with the executive so that execution of system functions can be coordinated. Engineering Interface. The engineering interface provides the ability to interact directly with the executive and thereby access the various components that comprise the ProfitMax system. System Database. The Proft.Plus system database is the repository for on-line plant data as well as system results such as the daily pump schedule, transfer volumes, and target levels off reservoirs and storage tanks. The database is structured to allow easy configuration, maintenance, and data access. The Modeling System. The modeling component of the on-line system is the MASSBAL process flowsheet simulator. MASSBAL is an open equation-based simulator that uses sparse matrix solution techniques to perform mass, energy, and momentum balances for a specified process. A library of process unit operations is available to construct the representative mathematical models in a modular one-to-one fashion. Engineer-defined performance relationships, inferred analyses, and economic calculations may also be included. MASSBAL is a flexible and robust tool for carrying out simulation and optimization.

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System Operation There will be two operating modes for the optimization system: 1. The On-line System will operate automatically based on a total recalculation of all system parameters every twelve hours. If tank or reservoir levels exceed operational limits at any time, the optimization system will re-optimize that pipeline, automatically starting and shutting down pumps and modifying valve positions. This system operates in a seamless manner, with operating staff required to monitor the performance of the system and provide updated predictive information based on external factors such as changed plant, water or weather conditions. The system enables SA Water to operate on the National Grid System, enabling adaptation of the pumping to align with the availability of low cost energy with minimal advance notice and no risk to the customers for the supply of high quality water. Optimization runs generally require a few to approximately fifteen minutes depending on the number of iterations required. Operators can also manually request an operation of the optimization System if desired. 2. An off-line system - or What If System operates on the same hardware and software platforms. This enables SA Water to try different scenarios, such as different energy providers, energy tariff arrangements, water sources and water storage balances. The On-line System operates as a priority. Customer / HLA team dynamics This project required close cooperation between SA Water and Honeywell due to the system complexities and empirical knowledge formed over many years of operation of the systems. An implementation team was formed comprising personnel from SA Water and Honeywell to provide a system implemented in the shortest possible timeframe. The implementation of a fully automatic system will be carried out on site by team members from SA Water and Honeywell utilizing information gained over the PlantScapeTM network.

Resulting Benefits
SA Water is the largest single consumer of electricity in South Australia; the majority of which is used for bulk pumping. While pumping has always tended to be performed during low energy cost periods, this has in the past been operator controlled. The IDMS system allows the system to run closer to constraints without jeopardizing water supply or water quality. In addition, the IDMS has a global view of the entire pumping network enabling more flexibility in operations. It is predicted that energy cost savings will be in the order of 7-15% based on the ability to modify pumping profiles and trade on the National Grid Energy market. The projected payback period is approximately 24 months. Current projections are for trial implementation in March 1998, with fully automatic operation being implemented in September 1998.

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Selected Energy Efficiency and Environmental Capabilities for

BUILDINGS
Honeywell offers comprehensive energy retrofits for wide variety of facilities, enabling the homeowner, building owner or operator to enjoy greater comfort and easier management while also achieving energy and thereby cost savings. Honeywell offers control systems and products that can improve the operating performance of key systems (heating, cooling, lighting and security) within homes or apartment buildings, factories, schools, hospitals, airports, commercial buildings, and military installations. Performance Contracting or Comprehensive Technical Service (CTS) is a service that Honeywells Home and Building Control division offers to owners of building complexes, particularly to hospitals, industrial plants, schools and universities. Working with the customer, Honeywell identifies a range of infrastructure improvements that will significantly reduce the customers operating costs. Honeywell then formally guarantees that the cost of the improvements will be completely covered by energy and operational savings. This section contains an overview of Honeywell products and solutions, as well as specific project examples. The activities represented in this section are as follows: Western Europe

Performance Contracting for Ford (Belgium) Performance Contracting for Samsonite (Belgium) Performance Contracting for Norton (France) Performance Contracting in the University of Cologne (Germany) Performance Contracting for Schools (Germany) Performance Contracting for Poste Italiane (Italy) Performance Contracting for Willem Alexander Hospital (The Netherlands) Performance Contracting for Groot Ziekengasthuis Hospital (The Netherlands) Energy Site Monitoring - Ford Espaa S.A. (Spain) Performance Contracting for Ford Espaa S.A (Spain) Performance Contracting in Crawley Hospital (West Sussex, England) Performance Contracting for Havering Hospitals NHS Trust (Essex, England) Performance Contracting for Glan Hafren NHS Trust (Newport, Wales) Hanvit Bank Intelligent Building System Project (Korea) Immanuel Methodist Church (Korea) Inland Revenue Authority of Singapore Air Quality Project (Singapore) Honeywell Asia-Pacific Headquarters (Singapore) Positive Pressurization of the Paint Shop at Ford Motor (Mexico) Lighting Retrofit and Control Project at Ford Motor (Mexico)

Asia

Latin America

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Performance Contracting for Ford ESA Contract Ford Motor Company Genk, Belgium 8/99 04/00 Energy Savings of US$300K per year

Introduction
Ford Belgium, which manufactures more than 400,000 vehicles per year and has a long-standing relationship with Honeywell, decided to enter into an Energy Service Agreement (ESA) with Honeywell Belgium in 1999. The goal of this agreement was to promote Energy Savings related projects in all Ford facilities. Ford Belgium was the first in Europe to go ahead under the ESA contract by signing a US$1.4 million contract with Building Control Solutions and Services. The Existing System HVAC System The control system for Air Handling Units (called Penthouses) was obsolete and inefficient. No optimization or integration with process extractors was performed, which resulted in energy losses and problems with air balancing in the plant.

Honeywell Solution
Honeywell's solution included a major control retrofit, which resulted in electrical and thermal savings as well as improving air balance in the plant. The control retrofit includes a new control system with time optimization and duty cycling for most of the Penthouses, with new generation controllers and a Building Management System. The data transmission between plants runs via an existing Customer Local Network. More than 150 Penthouses were equipped with new panels, controllers, etc. Reducing the peak through a customized advanced peak solution was also part of the project.

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Resulting Benefits
The project reduces total annual energy bills by more than US$300,000. In addition to the guaranteed savings, the new control enables the operators to save time by being proactive instead of reactive. As a result of the success of this and other Honeywell/Ford collaborations, Ford is looking to contract Honeywell for additional projects at other Ford sites.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Performance Contracting for Samsonite Samsonite Oudenaerde, Belgium 4/99 12/99 Energy and operational savings of US$125K per year

Introduction
Samsonite is a global case manufacturer in Oudenaerde, Belgium that produces more than 1.8 million cases per year. In 1998, Samsonite met with Honeywell representatives to discuss the Honeywell Performance Contracting System and how it might help Samsonite improve its facility security and utility management. The major drives during the evaluation of the solutions were: to secure and control access to the premises to reduce operating costs to improve the control and metering of various utilities In order to meet these objectives, Samsonite decided to enter into a Performance Contracting contract in April 1999 when a detailed financial analysis proved the project to be attractive. The existing system Compressed Air System The compressed air system consists of 3 compressors located in different locations in the plant, which were proven to be operating inefficiently. This led to pressure fluctuations in the plant and quality issues on the production floor. A leaks survey exposed a significant leak rate in the plant that was causing excess electricity consumption. Water Cooling System Process cooling is performed through various chillers which operate throughout the entire year to produce process cooling water at 15C. The cooling water is then used to cool down plastic injection machines. HVAC System Most of the existing Air Handling Units were operating independently and were not centralized. This resulted in excess consumption and comfort issues.
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Access control and CCTV The existing system for controlling and monitoring access to vehicles and trucks was limited. Vehicles and trucks were to present themselves at the gate and call reception for access into the plant. This procedure required two security officers on duty at all times.

Honeywell Solution
Compressed Air System An old compressor was replaced with a more efficient model, and the operation of the compressed air plant was centralized, thereby optimizing the control and general layout of compressed air production. This enables us to secure compressed air production and reduce consumption. The installation of an Xceed Demand Expander between the supply and the demand-side prevents pressure fluctuations. This allows improved pressure stability in the plant and improved production quality in machines using compressed air. A leaks management program and redesign of specific compressed air users improved the overall performance of the plant. Water Cooling System The installation of an air cooler that operates more than 5 months per year, combined with improvements in the control of the chillers during the summer period, allows the plant to save energy and operational costs. The Honeywell solution also uses "free cooling" to save energy in the cooling process. Free cooling uses outside air to cool down the process water rather than using chillers. After implementation of the Honeywell solution, the operation of the various chillers improved and operational costs were reduced. HVAC System Duty cycling, peak shaving, and start/stop optimization were some of the energy conservation measures implemented on the HVAC system. A centralized Building Management System completes the strategy to better manage plant utilities. Access control and CCTV Installing automatic gates, cameras, and other security equipment are some of the features installed to improve plant security and better track vehicles and trucks on the premises.

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Resulting Benefits
The estimated project cost of US$625,000 proved to be attractive to Samsonite when additional benefits such as improving the management of utilities, reducing risks of intrusion, and improving the protection of assets were demonstrated. The project reduces the total annual maintenance and energy bills by more than US$125,000 per year.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Norton Project Saint-Gobain Conflans Saint Honorine, France 3/00 12/00 Retrofit + Annual cost savings of over US$100K

Introduction
Norton is a manufacturer of abrasive band. The company was created in the 1950s and is now part of the worldwide glass manufacturer Saint-Gobain Group. In 1998, Norton became interested in the concept of Performance Contracting as a means to upgrade their aging compressed air systems and modernize their utility assets. The proposed project had three major objectives: 1. Reduce operating costs 2. Provide a technical upgrade of existing installations. 3. Improve the environmental performance of their facilities. In order to accomplish these goals, the following projects were selected: Post-water treatment recovery of Phenol-contaminated water Optimization of compressed air production and distribution Optimization of electrical power consumption Improved lighting management These projects will optimize energy usage as well as improve environmental impact, both necessary in view of an ISO 14000 certification. The value of the project is US$500,000 with a payback period of less than 5 years. The Existing System Compressed Air System The compressed air system consisted of six 30+ year-old piston compressors which were proven to be inefficient and unreliable. The compressed air system controls were old and obsolete, resulting in pressure fluctuations throughout the plant and quality issues on the production floor. A leaks survey exposed a high leak rate in the plant, which was causing excess electrical consumption.

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Wastewater Treatment Wastewater coming from various containers in the plant is collected and treated in a wastewater treatment plant. The major wastewater concern in the plant is the high phenol content which prevents the plant from discharging the wastewater to a municipal treatment plant. Norton must contract with an outside company to remove the contaminated water, which significantly increases costs. Electrical Installation Obsolete electrical cabinets, as well as distribution circuits, demonstrated risks. Also, uncorrected power factors and obsolete/non-existent controls of particular equipment were in need of modification.

Honeywell Solution
Compressed Air System The outdated compressors were replaced with more efficient models. The compressor control system and the general layout of the compressed air production system were updated, thus enabling us to secure production and reduce consumption. The installation of an Xceed Demand Expander between the supply and the demand-side will prevent pressure fluctuations. This improves pressure stability in the plant and improves the production quality of machines using compressed air. A leak management program and the redesign of specific compressed air users improved the overall behavior of the plant. Waste water Treatment Honeywell reengineered the existing water treatment plant, enabling Norton to optimize the use of specific reactors and eliminate almost all the contaminated water that must be removed by outside specialists. The major modifications include the installation of measuring devices to control the quality of the effluents and, when possible, dilute the major pollutants. Electrical Installation Reengineering particular electrical cabinets and installing power factor correction will reduce risks of power interruption and electrical bills. A major contribution to the program results from the installation of various meters and information points into the system. The existing systems were poorly instrumented and mainly manually recorded. In certain cases, such as compressed air and waste water, daily manual meters reading obliged staff members to spend two hours per day collecting data. Once the data were collected, there was little follow-up analysis since no data treatment was performed. A Honeywell Energy management system was installed not only to record the existing data (such as the electrical consumption of the compressors), but also adding measurements such as

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compressed air flow and data analysis, such as giving the ratio of produced compressed air versus the electrical consumption to get the efficiency of the air production.

Resulting Benefits
The project will reduce total annual maintenance and energy bills by US$100,000. These savings are directly invested in modernizing infrastructure as well as improving environmental performance. Additional benefits include a reduction in the risk of equipment failure and improved management of all utilities through the installation of a detailed instrumentation and data collection system.

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Capability:

Buildings Home and Building Control Performance Contracting at the University of Cologne University of Cologne Cologne, Germany Project dates not available Annual cost savings of US$145K

Business Unit: Project Title: Customer: Location: Duration: Significance:

Introduction
This project involved the replacement and installation of control systems for district heating, electricity and water throughout the University of Cologne, including the library, seminar rooms, and underground parking lot. Existing System Under the existing system, the utility costs and unit expenditures were as follows: Utility District Heating System Electric Water Units (kWh, kW, etc.) 4,122,000 kWh 3,216,200 kWh 32,565 m Amount in US$ $152,000 $347,000 $49,000

Honeywell Solution

CO2 warning system in the underground parking lot; installation of CO2 sensors in the library; replacement of the old space heating valves and installation of thermostatic valves in the seminar rooms; reconstruction of the HVAC system; installation of Honeywell individual room control systems in the seminar rooms.

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Resulting Benefits
The environmental impact of this project was the reduction of CO 2 and SO2 emissions. The annual utility cost savings totaled US$145,000, with cost and energy savings as follows: Utility District Heating System Electric Electric (power charge) Total Units (kWh, kW, etc.) 1,684,061 kWh 1,363,311 kWh 50 kW Amount in US$ $35,000 $104,000 $6,000 $145,000

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Performance Contracting for Schools "Kthe Kollwitz Schule" - Integrated Secondary School Main Kinzig Kreis County, Hessen, Germany 1998 Operational cost savings of 64% and energy pollution reduction by 67%.

Introduction
The four school buildings of Main Kinzig Kreis in Germany serve as a center for excellence in primary education. Providing a good education is important to the administrators, and this includes the physical aspects of a solid education comfortable classrooms. In addition, they are concerned about doing their part to protect the environment surrounding Main Kinzig Kreis. When Honeywell met with school administrators, they discovered several problems with the heating and lighting systems including a backlog of heating system components that needed repair. However, limited staff and a tight school budget made these repairs seem impossible. Honeywell worked together with Main Kinzig Kreis from both technical and financial perspectives to create a performance contract that provides innovative heating and lighting solutions. Pleased with the resourceful contract that solved even more problems than the administrators thought possible without impacting the budget, Main Kinzig Kreis became a pilot program. This school provides a practical example for other schools throughout the area on how to solve backlog maintenance problems within existing budget constraints. Improved infrastructure saves DM 180,000 annually The Main Kinzig Kreis project began with a thorough examination by Honeywell technicians of the 12,675 square meter (m) area in need of repair. Once the buildings were surveyed, and Kreiss needs clarified, a Honeywell crew stepped in and devised a plan for the following long overdue changes. First, two new hot water boilers and classroom heating panels and additional pipes were installed throughout the buildings. Once the new, more efficient heating system was in place, the costly electrical space heating system was dismantled. To simplify heating control and maximize energy efficiency, the control center was rebuilt. The new system provides a much more comfortable classroom learning environment. In addition, state-of-the-art CO2 sensors were installed in the gymnasium and conference room.

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The finishing touch to the Main Kinzig Kreis renovation was the installation of new lighting systems in all of the classrooms. The new lights greatly reduce energy costs and provide more effective reading light for students and teachers.

Honeywell Solution

Two new hot water boilers and classroom heating panels New pipes installed throughout the buildings Electrical space heating system removed Heating control center rebuilt including new wiring New lighting system installed in the classrooms CO2 sensors installed in the gym and conference room Maintenance and energy control throughout the contract

Resulting Benefits

Students and teachers enjoy vastly improved comfort All health standards are surpassed Safety is improved by reliable equipment and consistent maintenance More durable heating and cooling systems reduce system down time and labor costs

Environmental benefits

Reduced CO2 emissions Reduced energy usage throughout Main Kinzig Kreis County

By teaming with Honeywell, the administrators at Main Kinzig Kreis were able to overcome the business challenges inherent in making changes to a large school system. They believed Honeywell understood their requirements and could provide a top-quality solution. They also respected Honeywells role in their community and have enjoyed a long-standing relationship with Honeywell. Now that the refurbishment project is complete, the administrators, teachers and students all enjoy a more comfortable learning environment. Furthermore, the performance contract will continue to protect their environment and surrounding areas well into the future. "The Honeywell package gave us an opportunity to improve the classroom environment while saving energy. This concept became a pilot program. And other schools in the same area can also benefit from this program"
- Mr. Schnabel School Administrator

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Main Kinzig Kreis Utility Projected Savings Per Year with Honeywell Energy Management Program
Improvements 1999 vs. 1995 Electricity peak rate Electricity day rate Electricity night rate Heating Classrooms Heating Gym Repair for Heating and Lighting Total Savings in DMs 24,500 17,500 6,000 89,500 12,500 30,000 180,000 Savings in % = 55% = 46% = 46% = 75% = 31% = 100% = 64%

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Performance Contracting Poste Italiane Rome Poste Italiane S.p.A. Rome, Italy 01/2000 12/2003 Guaranteed annual cost savings of US$125K

Introduction
The Italian mail company, Poste Italiane S.p.A, was recently privatized. This contract is the first performance contract of its kind launched by Poste Italiane. With this performance contract Honeywell is guaranteeing energy savings of US$125K per year. The Performance Contract project was implemented at the Poste Italiane headquarters in Rome, a large office complex (about 250,000 square meters) where more than 5,000 people work. It requires an investment of US$500K and has an estimated payback period of 4 years. Existing System The Poste Italiane headquarters had a 20 year old Honeywell D2KTM monitoring system with pneumatic regulators for temperature control. With the existing system it was not possible to optimize any of the heating and ventilation plants. During our preliminary investigation, we also found very high water consumption due mostly to leaks. We also discovered a potential opportunity to receive rebates and rates reductions for electricity.

Honeywell Solution
The performance contract included the replacement of the old Delta 2K system and pneumatic controllers with a new Honeywell Excel 5000 control system. With the new system, heating and ventilation is more accurately controlled, allowing the different requirements of each area of the building to be fully met. Disruption of service was minimized during installation by assembling most new items offsite. In addition, Honeywell provided solutions to reduce electric and domestic water consumption. To save electricity we reduced the working hours of electric motors (pumps, fans and chillers) by using optimum start and stop programs. To save water, we reduced the cooling towers' blowdown and reduced nighttime consumption by installing electric automatic valves.

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Resulting Benefits
The project was financed directly by Honeywell Italy and guarantees total annual savings of US$125,000, with a payback period of 4 years. Savings exceeding the contractual guaranteed savings will be shared 50%-50% with the Customer. Our estimate of the theoretical savings for the current year is about US$175,000, about 40% more than the contractual guaranteed savings. The savings also include rebates and a rate reduction for electricity, which comprise additional estimated savings of US$85,000.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Willem Alexander Hospital Bosch Medicentrum s-Hertogenbosch, The Netherlands 4/98 10/98 Electricity usage reduced by 20%, gas and hot water usage was reduced by 17%

Introduction
All Dutch Hospitals have signed a long-term energy agreement with the government to reduce their energy consumption. To fulfill this commitment, the hospital was faced with new investments in energy saving equipment. At the same time, the Willem Alexander Hospital needed to invest in an upgrade of their air handling system. By signing the Honeywell Performance Contract the hospital solved both issues. The Bosch Medicentrum signed a Performance Contract with Honeywell for the Willem Alexander Hospital in s-Hertogenbosch, the Netherlands. This Performance Contract helped Bosch Medicentrum achieve compliance with energy agreements and reduced backlog maintenance. Honeywell and the Bosch Medicentrum developed the contract in a close partnership using a clear implementation process. After an introduction phase all requirements (technical, financial and contractual) were defined and a feasibility study was undertaken. Based on mutually defined requirements the hospital signed a letter of intent. Through an in-depth study a program was developed to meet all project requirements. The final phase was putting all this together in a contract. After the contract was signed, Honeywell implemented this turnkey project acting as a main contractor.

Honeywell Solution

The installation of a Heat Recovery System on all major Air Handling Units and of variable frequency drives on the major fans were the major energy conservation measures implemented. All Air Handling Units were retrofitted to face new pressure drops created by the heat recovery system and to solve backlog maintenance. Replacing pneumatic controllers with DDC controllers in particular places improved climate conditions and helped reduce energy consumption. Lighting appliances were retrofitted where necessary and replaced with new, efficient armatures and high frequency ballasts.
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Resulting Benefits
Electricity usage was reduced by 20% and gas/hot water usage was reduced by 17%. These savings are in addition to those generated by the hospital's cogeneration plant. The total savings are sufficient to comply with the savings objectives in their long-term energy agreement with the government, and the energy savings paid for the investment in new energy saving equipment and the upgrade of the existing air handling systems.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Groot Ziekengasthuis Hospital Bosch Medicentrum s-Hertogenbosch, The Netherlands 9/1999 - 5/2000 Energy savings of US$225K per year

Introduction
After the success of the Performance Contract with Bosch Medicentrum for the Willem Alexander Hospital, the Bosch Medicentrum signed a second Performance Contract with Honeywell for the Groot Ziekengasthuis Hospital in s-Hertogenbosch, the Netherlands. The Performance Contract with the Bosch Medicentrum provides compliance with energy agreements and reduces backlog maintenance. All Dutch Hospitals have signed a long-term energy agreement with the government to reduce their energy consumption. To fulfill this commitment, the hospital was faced with new investments in energy saving equipment. At the same time the hospital needed to invest in an upgrade of their air handling units. Having solved this problem for the Willem Alexander Hospital, Honeywell was asked by Bosch Medicentrum to perform this process again. In a close partnership, Honeywell and the Bosch Medicentrum developed the contract using the same implementation process as for the Willem Alexander hospital. However, due to the knowledge of this process, the sales cycle was shortened to less then one half. After the contract was signed Honeywell implemented this turnkey project acting as a main contractor.

Honeywell Solution

The installation of a Cogeneration Unit adjacent to the existing boiler plant to create substantial energy cost savings. The installation of a Heat Recovery System on all major Air Handling Units, and variable frequency drives on the major fans, were the major energy conservation measures implemented. Due to the optimization of the Heating and Cooling demand of the building, the required capacity of the chiller could be downsized, realizing substantial cost savings on the purchase of a new absorption chiller, installed by Honeywell. All Air Handling Units were retrofitted to handle the pressure drops created by the heat recovery system and to reduce backlog maintenance. Replacing pneumatic controllers with DDC controllers, as well as implementing a Building Management System, improved the climate conditions and reduced energy consumption.
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Resulting Benefits
After implementation of the Honeywell solution a yearly saving of US$225,000 was achieved. In addition to energy savings, a substantial reduction in CO 2 emissions was achieved by the continuous use of the Cogeneration Unit generating the baseload electric and heat demands of the hospital. Even during the summer period the installation of a new absorption chiller consumed the heat generated by the Cogeneration Unit. All energy conservation measures resulted in a 40% reduction of CO2 emissions. Based upon the good results and the long-term relationship with Hospital, an additional order was awarded to Honeywell to reduce city water consumption in the water cooling system.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Energy Site Monitoring Ford Espaa S.A. Valencia, Spain 4/99 - 1/00 Utilities cost reduction of US$1.2 million

Introduction
The Valencia Ford plant is approximately 2.5 million m 2. The annual consumption of electricity, gas and water costs a total of US$15.6 million. This amount could be reduced with improved management. The Project objective was to monitor and control overall energy usage by affected factory departments. The cost of the project was US$1.3 million and was implemented over the course of one year. Existing System The existing measuring method was totally manual, with employees walking along the entire factory reading individual meters. This method was not able to provide historic information with real time data. Under the existing system, efficient utility management was not feasible.

Honeywell Solution
Honeywell's proposed solution was based on an expansion of the existing Honeywell control system for HVAC control. It included new metering devices with remote data transmission to XBS stations in the central control room. New computers in the control room were provided to handle this data. For this purpose an electronic meter has been mounted in each bus bar in 47 substations. Each meter provides the following data: Voltage in each phase (R,S and T) Intensity in each phase (R,S and T) Active power Reactive power Power factor Frequency Active power consumption Reactive power consumption

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In addition, these meters have been connected with four alarms in each substation through several Mod-bus. They are then connected to the Honeywell system via Open-Link protocol converters. For natural gas metering, 8 new vortex type meters have been mounted. For water metering, 12 new meters have been mounted. All newly installed meters have pulse transmission capabilities and are connected to the Honeywell Excel 500 controllers. New meters (orifice plate and vortex type) with temperature transmitters have been installed at the absorption chillers to monitor machine efficiency. Finally, a system to monitor capacitor banks for reactive energy control has been provided. In the control room a new XBS station was installed to manage the new points in addition with two existing stations for HVAC control. A fourth computer was connected to prepare consumption reports and summaries to dump into the customer LAN for departments' information needs.

Resulting Benefits
Estimated savings are expected to be approximately 8% of the present consumption of US$1.2 million.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Paint Shop Air Tempering Ford Espaa, S.A. Valencia, Spain 1/96 12/96 Energy Savings of US$1 million per year

Introduction
In 1996, Ford Espaa decided to enter into an Energy Savings Performance Contract with Honeywell Building Control Solutions and Services. Due to the success of previous jobs performed in the Paint Shop, in which 2 complete enclosed cabins with climate control were installed in the preparation areas (drastically reducing the rejection rate of painted body cars), Ford selected Honeywell as the best partner for addressing their challenges concerning negative pressure and climate control in the Paint Shop. A US$5 million contract was awarded to Honeywell to address both issues while at the same time optimizing the energy usage to save US$1 million annually. The Existing System HVAC System The control systems of Air Handling Units (called Penthouses) were obsolete and inefficient. There was no optimization or integration between the supply of air in the Halls and the extraction of air with process extractors resulting in energy loss and problems with air balance in the plant.

Honeywell Solution
The Honeywell solution included two types of retrofit, a mechanical retrofit for plant air tempering and a control retrofit to create savings and improved air balance. The mechanical retrofit included the modification of 15 existing Penthouses, installing in each a cooling coil and new motorized dampers for return air and outside air. A new air duct and diffusion system for the entire shop, new chilled water distribution piping, pumps from two existing absorption chillers, and electrical actuators in high-pressure hot water headers valves were also installed. The control retrofit included a totally new control system for the whole plant, with modern controllers and a building management system in the control room. Data is transmitted between plants via an existing customer local network. In sum, Honeywell equipped 125 Penthouses with
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new control panels, variable speed drive fans, and variable speed drives for chilled water pumps. Upgrading the plant lighting control system by replacing the existing system new controllers, was also part of the project.

Resulting Benefits
The project reduces total annual energy costs by more than US$1 million. The guaranteed savings were achieved and exceeded, and climate conditions have been improved resulting in better working conditions, employee comfort and better product quality. Thanks to the success of this and other projects, Ford and Honeywell have extended their local collaboration to additional projects including a reverse osmosis plant extension, and comprehensive metering, data gathering and management of all utilities.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Performance Contracting for Crawley Hospital Crawley Hospital West Sussex, England 9/97 - 8/98 Annual total cost savings of over US$575K

Introduction
Crawley Hospital decided to invest in this project because it was almost self-funding, it addressed key backlog maintenance issues, and the savings were guaranteed. The project spanned four buildings and 30,769 m2. The project solved two important sets of problems for Crawley Hospital:

Technical: comfort of staff and patients, health & safety issues, plant reliability Business: lack of funding for capital programs

Honeywell Solution

Decommissioning of existing oil fired central steam boiler plant New gas service to the site Provision of new low pressure hot water boilers and direct gas fired water heaters to 2 existing plantrooms replacing existing steam to water calorifiers New low pressure hot water mains to a third plant room and decommissioning of steam to water calorifiers New small gas fired steam generator located in basement to serve kitchen, sterilization plant and a few small services Replacement chiller plant serving operating theaters Refurbishment of the zone control system in the main (stage 2) building Variable speed drives to key air handling units Replacement double glazed windows with low E glass to the south face of the tower block Lighting refurbishment throughout the majority of the building Water conservation project 10 years fully comprehensive maintenance of the equipment installed by Honeywell Provision of a half-time TRM.

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Resulting Benefits
Environmental Impact 1. Reduced NOx, SOx emissions with change from oil to gas 2. Reduced CO2 (approx. 700 tons/year from lighting alone) Cost Savings Environmental Measures Conservation Measure Decentralized boilers Building Management System Window replacement Conversion to gas Lighting Inverters Water conservation measures Total Operational Measures Conservation Measure Decentralized boilers: 2.9 Whole Time Equivalents at US$28,236/WTE Decentralized boilers: materials Lighting labor and materials Windows Chiller Rates and capital charges Total Savings in US$ $81,900 $55,100 $34,800 $8,100 $1,600 $12,900 $194,400 Audit Method Metered Metered Metered Metered Run Time Run Time Run Time Projected Savings in US$ $57,800 $28,500 $3,800 $142,200 $111,200 $9,500 $28,300 $381,300

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Capability:

Buildings Home and Building Control Performance Contracting for Havering Hospitals NHS Trust Havering Hospitals NHS Trust Essex, England 9/97 - 8/98 Guaranteed annual cost savings of US$645K

Business Unit: Project Title: Customer: Location: Duration: Significance:

Introduction
In one of the first performance contracting projects of its kind to be launched under the UK's National Health Service (NHS) Private Finance Initiative, Honeywell is guaranteeing Havering Hospitals NHS Trust savings of US$645,000 per year in operating costs, while providing an improved quality healthcare environment. This Comprehensive Technical Services (CTS) project was implemented at Oldchurch and Harold Wood Hospitals in Essex, with an investment of US$3.5 million and an estimated payback period of seven years. Existing System Oldchurch Hospital had an oil-fired steam boiler house, built in the 1970s, with five packaged gas boilers of differing sizes (up to 2 MW) situated around the site. The old system circulated steam to calorifier stations to heat water, which resulted in high maintenance costs and low energy efficiency. In addition, the lighting used throughout Harold Wood and Oldchurch Hospitals was not energy efficient.

Honeywell Solution
The performance contract included the replacement of the oil fired steam boiler house at Oldchurch Hospital. In the new system, steam for catering and sterilizing operating theatres and equipment is provided by one small steam boiler. The use of gas instead of oil also significantly reduces waste emissions. Heating and ventilation is accurately controlled by an advanced energy management system, allowing the differing requirements of each area of the hospital to be fully met. Disruption to services was minimized during installation by assembling most new items offsite. In addition to the boiler and management system changes make at Oldchurch Hospital, all fluorescent lighting tubes and Tungsten lights at both Harold Wood and Oldchurch Hospitals have been replaced with low energy units.

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Resulting Benefits
The project will produce 25% savings in annual gas, oil, electricity and water costs as well as savings of US$129,000 in maintenance costs. These savings are being directly invested into infrastructure changes that improve patient care. Any savings achieved over the guaranteed annual amount of $645,000 are retained by the NHS Trust, in addition to all savings gained after the seven-year payback period. The new system has considerably lowered the overall risk of breakdown and has significantly reduced waste emissions through the substitution of gas for oil. In addition, not only have new light fittings cut energy usage, but also the new flicker and sound-free lights have created an improved environment for patients, visitors and staff.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Performance Contracting for Glan Hafren NHS Trust Glan Hafren NHS Trust Newport, Wales 10/98 - 2013 Guaranteed annual cost savings of over US$800K

Introduction
For many years, Glan Hafren NHS Trust was known for employing state-of-the-art energy control and conservation measures. But recently Glan Hafren NHS Trust, like many Trusts in Wales, was facing deteriorating estate infrastructure at a time of chronic shortage of capital. The Trust wished to replace worn-out, heavy fuel-oil boilers with cleaner and more efficient technology. The Trust signed a 15-year performance contract with Honeywell in October 1998 for this US$6.5 million hospital project. The project was designed to achieve significant energy savings, reduce toxic emissions, and improve building appearance and comfort.

Honeywell Solution
Honeywell has undertaken to introduce seventeen energy and utility savings initiatives under this contract, including a gas turbine CHP, dual-fuel boilers, high frequency lighting, water conservation and a leading edge BMS.

Resulting Benefits
Honeywell has guaranteed annual savings of US$807,000 over the course of the contract. The contract will reduce the total cost and consumption of utilities, while improving the hospital environment and the comfort of patients, staff and Newport residents.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Hanvit Bank Intelligent Building System Project Hanvit Bank Korea 8/97 - 6/99 Annual cost savings of US$570K

Introduction
This is one of the biggest Intelligent Building System (IBS) projects in Korea. Honeywell Korea signed a contract for the installation and supply of IBS at the headquarters of the Hanvit Bank on August 1997 valued at US$ 17 million (the amount was converted by the exchange rate on the date of contract signed). Hanvit Bank was created from the merger of the Commercial Bank of Korea and Hanil Bank, the nations largest commercial bank in terms of total assets. This project was designed to integrate building management, office automation, and telecommunications for the building with the application of the most up-to-date system integration technologies. The major purpose of this IBS project was to:

provide a pleasant indoor environment increase productivity allow for significant energy and maintenance cost savings assure total security of the building

Honeywell Solution
To achieve this, Honeywell Korea installed Xfi (Excel Facility Integrator ) and XSM (Excel Security Management) in the building. Installation of these systems was completed in June 1999.

Resulting Benefits
After the implementation of the system, Honeywell Korea expects that total annual cost savings will amount to US$570,000. This will achieved through:

Implementation of building management system, by US$480,000. (Enthalpy control, night purge, duty cycle, power demand control, lighting control, labor cost saving, etc.) Facility Management System (FMS), by US$47,000. Installation of ARS/VMS/FMS, by US$36,000. Others, by US$4,000.

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Benefits are not limited to energy savings listed above, but could be extended to increasing the overall value of the assets as well. As the countrys power supply utilization reaches full capacity, the government realized that the cost of building power plant becomes more expensive and even power plants like nuclear power plants are not typically environmentally friendly. So the government now recommends installation of energy efficient facilities and has started to raise more funds to support the retrofit of aging building facilities. The Hanvit bank IBS project shall become a Korean landmark in this respect.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Immanuel Methodist Church Korea Energy Management Corp. Korea 3/99 - 5/99 Energy consumption cut by one-quarter

Introduction
Immanuel Methodist Church project is a retrofit project upgrading hot/cold water supply system and building management system. Honeywell Korea signed the contract in May 1999 for a total of US$350,000. The project was funded by the government, under the Korea Energy Management Corp. The government lends 92% of the total contract amount to Honeywell Korea for the system upgrade and then Honeywell Korea shall redeem the loan in 5 years with a five-year grace period (conditions of loan are subject to change in each case). Honeywell Korea shall redeem the loan and secure profit from the energy cost savings after the system upgrade, based on the careful evaluation of a specific payback period including profit and initial investment. The owner only needs to sign the contract and enjoy the benefits after the contracted payback period. This project was mainly focused on replacing the existing common hot/cold water supply system driven by electric power with a gas-driven system and installing a building management system: the Smart Central (Honeywell Korea's small building management system.) Due to the exchange fuel of the water supply system, Honeywell Korea expects a slight increase in gas consumption and a significant decrease in electric power consumption. Such energy saving effects become greater after installing BMS, which allows greater energy efficiency through enthalpy control and optimum start/stop. The total energy savings are estimated as follows:

Energy Consumption
Gas volume Power volume Total volume Gas cost Power cost Total cost

Before
281.5 toe/year 667.6 MWh/year 448.4 toe/year US$ 74,174 US$ 56,870 US$131,044

After
305.9 toe/year 142 MWh/year 341.5 toe/year US$60,783 US$12,087 US$72,870

Savings Achieved
(24.4 toe/year) 525.6 MWh/year 106.9 toe/year US$13,391 US$44,783 US$58,174

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Therefore, the total cost savings of the project is estimated at US$58,174, which represents a 23.8% reduction in total energy consumed. Honeywell Korea expects a 6.4 year payback period. After Korea was hit by the "IMF gale," the government recommended that building owners make their facilities more energy efficient and increased Energy Management funds to boost its nationwide campaign. Honeywell became one of the well-known ESCOs (Energy Service Companies) in Korea.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Inland Revenue Authority of Singapore Air Quality Project Inland Revenue Authority of Singapore Singapore 7/98 - 9/98 Estimated annual energy savings exceed US$100K

Introduction
Inland Revenue Authority of Singapore (IRAS) is a prestigious building in Singapore. It is currently installed with Honeywell's state-of-the-art building management system and office automation systems. In 1998, the Indonesian fires spread its smoke haze to Singapore, which affected the quality of indoor and outdoor air. As a result, the Ministry of Environment sent letters to 800 building owners in Singapore to caution them on the adverse effects of the haze on building occupants. The investment cost for this project was US$290,000. It is estimated that the payback period for the investment for IRAS is about 2 to 2.5 years. Existing System IRAS was using low efficiency disposal-type media filters that could not eliminate the high level of outdoor pollution contaminants brought into the building. In addition, the air conditioning system was costly to operate due to frequent cooling coil cleaning and filter replacement.

Honeywell Solution
In mid-1998, IRAS made the decision to upgrade to Honeywell's F58F, a high efficiency electronic air filtration system. Replacing disposal-type media filters with Honeywells electronic air filtration system was IRASs environmental gesture towards reducing the amount of garbage on the island state. The retrofit process was completed within eight weeks with no disruption to employees working schedules or downtime to facility equipment. The air cleaners were also fully integrated with the existing Honeywell building management system for easy monitoring and maintenance.

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Resulting Benefits
Honeywell Singapore recently conducted a building audit and presented its findings to IRAS. These were the findings:

A 15% saving on the monthly electrical bill, which works out to US$8,700 a month. Estimated annual energy savings exceed US$100,000. This savings is the result of: (1) the lower energy consumption due to the lower pressure losses across the filtration system and (2) the improved efficiency of the cooling coil, which is now kept clean at all times by the air filtration system A laser particle count test was conducted by an independent party and the result was a promising 85% reduction in particulate contamination Cleaner environment and a higher standard of indoor air quality, regardless of the outdoor air quality Lower operating cost because there is no need for regular filter replacement and coil cleaning Indeco Engineering, the maintenance company of IRAS, has commented that there are fewer complaints from the tenants on variances in the temperatures after the installation of the Honeywell air cleaners

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Capability: Business Unit: Project Title: Location: Duration: Significance:

Buildings Home and Building Control Honeywell Asia Pacific Headquarters Singapore 2000 Energy efficient, environmentally friendly facility

Introduction
Honeywell's Asia Pacific regional headquarters is now located in a new building that utilizes Honeywell's state-of-the-art comfort control, fire and security systems, making it as energy efficient as possible. The building was officially opened on September 19, 2000 by Mr. Lim Swee Say, Minister of State for Communications & Information Technology Trade & Industry and Mike Bonsignore, CEO and Chairman of Honeywell.

Resulting Benefits
Using cutting edge technology and a good measure of common sense, Honeywell's team of technical experts have designed a building that is super energy efficient, environmentally friendly, convenient and safe. Lui Wing Sin, Director of Professional Services for Honeywell said, "We wanted to create the best indoor environment for our staff since most of us spend at least on third of our day - eight hours or more - in the office. Besides, studies have shown that clean air not only improves work productivity, it can reduce the air-conditioning energy cost by up to 15%." The new Honeywell facility includes: Occupancy sensors Radiant heat sensors Double electronic air filtration system Carpark ventilation controllers Outdoor lighting controller Digital CCTV System Integrated Building Management and Office Automation System Fire & Security Systems Proximity & Biometric (Finger) Access Control System Asset Tracking System

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Positive Pressurization of the Paint Shop at Ford Motor Co. Hermosillo Stamping and Assembly Plant Hermosillo, Mexico 12/97 - 2/98 Annual cost savings of over $416K

Introduction
The Hermosillo Stamping and Assembly Plant (HSAP) needed to retrofit the paint departments air handling systems, central plant piping and cooling tower system and install a central control system. The retrofit will provide positive pressurization of the paint shop, improve the operation of the air house, and enhance the instrumentation and control of the paint booths in order to reduce energy, maintenance, material, and labor costs directly related to the operation of these systems. The project was completed in a year and two months, from December 1997 to February 1998. The cost of the project was US$1.8M and the payback is calculated at three years and five months. Existing System The HSAP paint shop clean room currently operates under a lower pressure than adjacent in-plant spaces such as the administrative offices, body shop, and final assembly areas. The impact of this negative pressure condition is excessive infiltration of unfiltered air, either from outside of the plant or from the body shop or final assembly areas. This condition perpetuates the infiltration of airborne contaminants that ultimately result in paint defects. Paint defects from dirt, as well as repairs and re-paints, are well documented by paint shop staff. Paint quality and consistency have suffered and conditions have resulted in shorter equipment life and reduced system reliability. Paint efficiency is diminished, resulting in higher paint costs. Operating, maintenance, and energy costs are also higher than anticipated. The negative pressure condition also impacts booth balance and control. Due to the high negative pressure of the clean room, constant balance of static conditions around the primer and enamel booths cannot be presently maintained. The existing condition causes uncontrolled, inconsistent booth balance (airflow between zones) and air velocity control resulting in zone-to-zone infiltration and paint over-sprays results. Paint quality suffers and substantial paint and energy is wasted.

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Although the systems were designed properly and provided adequate supply-air, the Durr and Buffalo Forge air handling units have been shut off because they do not have cooling capability (i.e. no chilled water coils). Without cooling capability, the supply-air from the Durr units can exceed 90oF and 85% rh during the summer months. Under these conditions the units are actually heating the space and must be shut off. When these units are turned off, the clean room supply air is less than design, balance is gone and pressure turns negative. In addition, these units have shown to be a direct cause of repaints because of condensation drips in the booth. The existing ABB/Flakt air supply houses serving the paint shop area are ineffective in providing reliable humidity control and are also a source of airborne particles resulting from the degradation of the humidifier and filter media into the air stream. The instrumentation and controls required to monitor and control these systems remotely or centrally do not currently exist. Therefore, monitoring and control is performed locally at each spray booth and system adjustments for air and water flow; temperature and humidity are performed manually. There is currently no instrumentation in place to monitor booth balance or the air velocity profile inside the booths. The current process is costly, labor intensive, and has limited effectiveness. There is also no capability to centrally monitor booth conditions over time. Current paint costs are US$8.5M. Rejects account for 7.13% of total paint costs, or US$606,000. Of that amount, 25%, or US$152,222 is rejected because of airborne dirt. In addition, paint overspray accounts for 29% of total paint usage or $2.5M USD. Current energy costs to operate the paint departments mechanical and air systems are US$861,690.

Honeywell Solution
The systems within the Hermosillo Paint Department function under a high level of interdependency which makes it critical to take a comprehensive approach to solve the problems that are present in the existing condition. This project is intended to take a comprehensive approach in order to reduce paint shop operating costs by US$515,000 by providing positive pressurization of the paint shop area, enhanced operation of air handling units, and improved monitoring and control of the paint booth conditions by implementing the following six actions. 1. Rehabilitate three (3) disabled Durr units. The rehabilitation of the Durr units will increase supply air and assist in the re-balancing of the paint shop pressure. To accomplish this goal, the three remaining disabled Durr units need to be rehabilitated and re-started. Through this project HSAP will install new chilled-water coils, rehabilitate humidifiers (including replacement of pumps and evaporation media), and install new temperature and humidity controls. 2. Install three (3) new make-up air units. Replacing these units is critical to providing positive pressurization to the paint area. The existing Buffalo Forge make-up air units are in poor condition, lack heating and cooling capability, and are currently not being operated. Based on our evaluation, it is not cost effective to repair, modify, or add additional chilled-water capacity to serve the existing units. Therefore, HSAP propose to install three new custombuilt two-stage evaporative cooling units. The units will be outfitted with filtration, direct fired gas heat, and variable volume capabilities. Indirect evaporative cooling is necessary to avoid over-taxing of the central chilled water plant.

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3. Connect central plant chillers into common system . With the new chilled-water coils in the Durr units, chilled water requirements in the paint shop will increase. The most costeffective way to increase system capacity is to tie all ten existing chillers into a common system. This project involves connecting chillers (seven Flakt, one paint, & two make-up air chillers) in parallel with common suction and discharge headers, and converting the system to primary/secondary operation. 4. Install new cooling tower. This element of the project is necessary to provide the chiller plant with adequate condenser water to serve the rehabilitated Durr units. The existing tower is about 25% undersized, based on an independent evaluation and plant operator experience. This part of the project will expand the condensing capability of the existing chilled water plant by installing a 33% extension of the existing tower with a new cell. The new unit will be field-erected and identical to the existing two cells. 5. Rehabilitate nine (9) Flakt Air-Handling Units . This section of the project will entail repositioning the coils/humidifiers and the installation of new coils, bypass dampers, and controls to provide the proper operation to generate appropriate air conditions and volume. This area of the project addresses the scaling and humidity control problems in the Flakt units. 6. Provide new paint booth instrumentation and controls. This section of the project will include the installation of a Honeywell Scan 3000 central computer and the installation of new instrumentation for improved central measurement and control of paint booth key operating parameters. Key operating parameters (KOPs) include temperature, humidity, air velocity, and between zone airflow in primer and enamel booths. This is critical to properly monitor the pressurization of the booths and overall paint area.

Resulting Benefits
Calculated savings in paint costs because of an anticipated 50% reduction of dirt rejections is US$76,111 annually. Savings attributed to improved overall spray efficiency are US$246,734 per year based upon a conservative efficiency improvement of 10%. Overall energy savings for the operation of the paint shops mechanical and air systems will be US$93,619annually. In addition, there will be more than US$98,000 of savings attributed to equipment replacement and O&M reductions.

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Capability: Business Unit: Project Title: Customer: Location: Duration: Significance:

Buildings Home and Building Control Lighting Retrofit and Control Project at Ford Motor Co. Hermosillo Stamping and Assembly Plant Hermosillo, Mexico 6/97 - 7/98 Annual energy, operation and maintenance savings of $276K

Introduction
The Hermosillo Stamping and Assembly Plant needed to retrofit the plants existing fluorescent lighting systems with new high efficiency electronic ballasts and energy efficient lamps along with the installation of a lighting control system to operate and monitor the ambient and fluorescent lighting systems. The retrofit will reduce energy, maintenance, component, and labor costs directly related to the operation of these systems. The one-year project was executed from June 1997 to July 1998. The cost of the project was US$750,000, and the payback is two years and 11 months. Existing System The Hermosillo Stamping and Assembly Plant currently operates several different lighting systems throughout the plant to provide adequate lighting levels. The general plant area is illuminated with 250-watt high pressure sodium and 400 watt metal halide HID fixtures that are arranged throughout each department. The plant currently makes use of more than 15 different types of fluorescent lighting fixtures within the different areas of the plant. The fluorescent systems that are most prevalent in the manufacturing areas are 4 lamps 8 Very High Output Industrial, 2 lamp 8 High Output Industrial and 2 lamp 8 Slimline fixtures. The components that are being utilized in these 8 fluorescent fixtures are core-coil magnetic ballasts along with standard efficiency T12 lamps that consume 220 watts, 110 watts and 75 watts, respectively. These fixtures represent nearly half of the fixtures that are utilized in the entire plant. In the offices, administration area and cafeteria, there are a wide variety of 2x 4 recessed troffers. The recessed troffers are made up of 2, 3 and 4 lamp fixtures with 85% of those fixtures being the two-lamp type. The 2x 4 fixtures are currently utilizing a standard core-coil magnetic ballast and 40 watt T12 lamps. These fixtures are the original fixtures that were selected and installed during the construction of the plant in the mid-1980s. The plant also currently does not have a system to control the operation of the high intensity discharge and fluorescent lighting systems. The problem at the plant is that the lamps and ballasts that operate the fixtures are extremely inefficient compared to the newer technologies that are available today. The use of these inefficient components and the long operating hours of the fixtures creates an excessive use of
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energy. An additional problem is that the plant lacks a central control system to disable the ambient and task lighting systems throughout the plant. Although energy costs are relatively low in the Hermosillo area, projections regarding the future trend for utility costs indicate that annual escalations could be as high as 15-20 percent per year. In order to take a proactive approach to address this problem, HSAP is aggressively searching for ways to minimize the cost of utilities in their operating budget. The current lighting system is costly to operate, labor intensive, and lighting levels are marginal. The existing fluorescent lighting system currently consumes 7,548,695 kWh per year at a total cost of US$339,691 per year. The current HID system consumes an additional 7,555,794 kWh, at an annual cost of US$340,010. The current cost to provide labor and materials to maintain the lighting systems in the plant is in excess of US$82,000 per year.

Honeywell Solution
This project is intended to take a comprehensive approach to reducing energy consumption and maintenance costs attributed to the operation of the plants lighting systems while simultaneously improving light levels, equipment life and control of the lighting systems. The proposed solution is to retrofit the existing fluorescent fixtures throughout the plant with new high efficiency electronic ballasts and T8 lamps. By retrofitting the fixtures, the fixtures will consume fewer kilowatt-hours (kWh) per year, which will result in substantial energy savings. Another source of savings that is attributed to this retrofit is the reduction in cooling costs that are a result of the lighting system producing less kW and, in turn, less heat. It is also proposed to install a Honeywell XBS computer and a LiteCom System that will control and disable the high intensity discharge and fluorescent lighting systems. This will reduce energy costs further and extend the life of the HID and fluorescent lighting components.

Resulting Benefits
The savings of this project were obtained by: energy savings through more a efficient fluorescent lighting system energy savings by controlling the runtime of the fluorescent and HID lighting systems energy savings through less use of air conditioning operation and maintenance savings by using longer life lighting equipment Total project savings were calculated at US$276,218 per year.

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Selected Environmental and Energy Efficient Capabilities for

THE AEROSPACE INDUSTRY


Honeywell offers a variety of systems and solutions designed to improve aircraft environmental performance and reliability. These products include flight management systems that assist the flight crew in selecting the most efficient flight path and aircraft operating settings to maximize fuel efficiency and noise reduction, and more fuel-efficient engines and power systems. Flight Management Systems (FMS) Many of Honeywell's FMS products are designed to control for lowest fuel burn and to allow the crew to fly the airplane in the most cost efficient way, thus reducing the energy consumed and the emissions created by the aircraft. Honeywell has developed patented algorithms for several performance and economy functions that offer the flight crew choices impacting environmental issues. Engines and Systems - A900 Series Turbofan Engines The AS900 Series Turbofan Engine was designed to provide main power for new technology regional airliners and corporate aircraft being manufactured and delivered over the next twenty years. The AS900 has been designed to increase fuel savings and reduce direct maintenance costs (DMC). The AS900 utilizes 15% less fuel than current engines in the same thrust class and has DMC guaranteed to be 20% less than comparable engines. This section contains an overview of Honeywell products and solutions in this sector. The activities represented in this section are as follows:

Honeywell Flight Management Systems AS900 Series Turbofan Engines

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Capability: Business Unit: Product: Customer Example:

The Aerospace Industry Aerospace Electronic Systems Flight Management Systems American Airlines Boeing B777: 14 of the last 15 modern Air Transport aircraft are standard equipped with Honeywell Flight Management Systems Reduced fuel consumption; Reduced noise output

Significance:

Introduction
Honeywell has become the world leader in Flight Management Systems (FMS). Honeywell has developed patented algorithms for several performance and economy functions that offer the flight crew choices impacting environmental issues. Along with the efficiency index algorithms and greater navigation accuracy, Honeywell has developed self-tuning performance capability for optimum efficiency and Noise Abatement Departures features. Customers: Customers include manufacturers and operators of commercial air transport, business, regional and general aviation market aircraft, as well as airlines.

Resulting Benefits
Navigation Accuracy: The incorporation of external sensor position references, such as Inertial Reference Systems (IRS) and Global Positioning Systems (GPS) have increased the efficiency of FMS equipped aircraft. FMS equipped aircraft are not bound by flight tracks over the earth defined by ground based navigation equipment as are non-FMS equipped aircraft. In many cases the FMS equipped aircraft can now take direct paths that were previously unusable due to nearby obstacles or deteriorated weather. The inclusion of more accurate position references has led to less drift, less fuel used, and more predictable performance. Fly by turns are standard, in lieu of the conventional mode of over-flying a ground based navigation device, resulting in less distance flown and less fuel burned. Sophisticated features in some Honeywell flight management systems, such as four level wind models, also help accuracy and efficiency by better modeling the real world. Real time uploadable wind and weather data allows aircraft operators to evaluate and choose best case flight parameters, avoid storms, and reduce delays and corresponding fuel use. By negotiating a Required Time of Arrival (RTA) with the Air Traffic Controllers, an FMS equipped aircraft can avoid costly holding pattern time. Performance: Honeywell is the world's leader in aircraft performance optimization through a variety of unique solutions. This optimization is achieved either via tabular aero/engine parameters supplied by the manufacturer, known as Efficiency Indexing, or SmartPerf, an active learning algorithm.

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Honeywell performance computations will display predictive data for the flight to the destination and alternate. The predictions include estimated time enroute, fuel required, optimum altitude and airspeed, step climb increments, distance, estimated time of arrival, fuel remaining and gross weight. During the flight, updated plan information is calculated and the difference between plan and updated plan is displayed with crew annunciations when appropriate. SmartPerf is a patented algorithm that obviates the need for a separate performance computer in the aircraft. Honeywell Flight Management Systems that employ the patented SmartPerf method of performance computation using real-time fuel flow measurement, distances, air speed, winds (both entered and actual), in conjunction with a model of the aircraft flight characteristics. The Honeywell FMS equipped with SmartPerf is thereby able to accurately predict fuel remaining at each navigation fix in the flight. The aircraft model is based on a set of Kalman filters, which adapt to current airframe/engine performance for each aircraft in a fleet. This means that the system will actually learn the performance of each aircraft. Reduced Noise Output: Noise Abatement Departure (NADP). Terminal area departure procedures are being developed jointly by the FAA, the aircraft operators, and Honeywell to reduce noise pollution. These procedures no longer rely on flying directly over ground based navigation aids. Instead, DME-DME (multiple radio Distance Measuring Equipment) or GPS (Global Positioning System) is used to navigate optimal paths over the earth. Introduction of optimal aircraft takeoff/climb profiles through automatic thrust management features enable noise reduction at restricted airports while minimizing the need for other engine or aircraft modifications. This is a very cost-effective benefit for environmental noise problems. Engine warrantee costs are actually reduced for aircraft that have automatic thrust management modes too. Honeywell FMS at Work A Customer Example Boeing Commercial Airplane Group: All long range Boeing aircraft today are delivered with Honeywell Flight Management Systems Boeing, the first commercial aircraft manufacturer to introduce standardized next generation efficiencies known as Future Air Navigation System (FANS), turned to Honeywells industry leadership to make the B747-400 capable of flying specialized routes to bring substantially lower fuel requirements and direct routing. Since this introduction, Honeywell has provided these latest features to the B717, B757, B767, B777, MD10 and MD90 aircraft as well. Airlines worldwide enjoy substantial benefit from the Honeywell technology in these Boeing aircraft.

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Capability: Business Unit: Product: Customer Example: Significance:

The Aerospace Industry Engines and Systems The AS900 Series Turbofan Engines Selected as main power for the British Aerospace AVRO RJX Regional Airliner and the Bombardier Continental Jet Aviation Turbofan Engines with world class reliability, lower operating costs and reduced noise and emissions

Introduction
The AS900 Series Turbofan Engine was designed to provide main power in the 4,000 to 9,000 pounds thrust class applications for new technology regional airliners and corporate aircraft being manufactured and delivered over the next twenty years. The first two engine models under development and scheduled for FAA certification in March 2001 are the AS977 optimized for regional airline applications with demanding high cycle operation and the AS907 optimized for business aviation applications with its requirement for high altitude operation and high speed cruise flight. Both engines deliver 7,000 pounds thrust. The AS900 design concept was derived from a "Voice of the Customer" survey of 22 regional and business aircraft Original Equipment Manufacturers (OEM) and operators that expect a reliable, cost-effective engine from a supplier that can be counted on. The AS900 concept utilizes lessons learned in 20 million hours of previous regional airline experience with remedies for service revealed difficulties incorporated in the initial design and proven through technology validation. Customers: The AS977 Turbofan engine has been selected to power the British Aerospace AVRO RJX - four engine regional airliner in 70 to 115 seats, scheduled to enter regional airline service in third quarter, 2001. The AS907 has been selected to power the Bombardier twin engine Continental Jet in corporate use, with deliveries scheduled early in 2002. In addition, Honeywell is working with numerous major aircraft manufacturers in both the regional and business segments to secure additional applications for the AS900 Engine Series.

Resulting Benefits
Increased reliability: The airline industry expects a reliable product in selecting its main power engines and the AS900 has been designed to deliver transport class reliability - guaranteed, as well as 12,000 hour minimum on-wing life.

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Lower energy costs: The AS900 has been designed with fuel savings and reduced direct maintenance costs (DMC) as a prerequisite. The AS900 utilizes 15% less fuel than current engines in the same thrust class and has DMC guaranteed to be 20% less than comparable engines. Environmental benefits: The AS977 has been designed with effusion cooling and airblast atomizers in the primary fuel system. The AS977 will meet IATA Class 5 requirements for emissions at entry into service and is below the ICAO 2003 emission standards and is 40% below the maximum limits for CO; 42% below the maximum limits for NO X; and 45% below the maximum limits for UHC. In addition, NASA advanced fan and mixer technology was applied to the AS977 and community noise is cumulative 18dB below Stage 3 requirements for any aircraft variant.

AS900 Series Turbofan Engines at Work - A Customer Example AS977-1A selected as main power for the British Aerospace Avro RJX Regional Airliner
The AS977 turbofan engine has been selected as the main power source for the British Aerospace Avro RJX aircraft. This engine offers a reduction in noise output and is environmentally friendly, with very low gas emissions. Furthermore, the new Avro RJX family of aircraft will offer operators significant improvements over the existing Avro RJ including:

an increased range of about 17% 5% additional thrust in climb a 15% reduction in fuel burn a reduction of approximately 20% in overall direct engine maintenance costs

The reduction in maintenance costs reflects the fact that the AS977-1A will have 40% fewer engine parts.

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Selected Environmental and Energy Efficient Capabilities for

THE AUTOMOTIVE INDUSTRY

Honeywell brings higher fuel economy and helps reduce automotive-related emissions through our Garrett Turbocharger engines and on-board automotive sensors. Engines outfitted with Turbochargers give a small engine the same horsepower as a much bigger engine and make bigger engines more powerful, up to 40% more powerful than it would have without the turbocharger. Because a turbocharger delivers more air to the engine, combustion of fuel is more complete and cleaner, which helps reduce emissions. Fuel economy is increased as small, turbocharged engines turn more of the fuel energy they consume into power and waste less of it through heat loss and friction. Honeywell Sensing and Control is a leading supplier of active cam, crank, transmission, body systems, and wheel speed sensors for applications that require high accuracy, extreme temperatures, or specialized packaging to survive rugged environments. Our cam and crank position sensors are most often used to help customers enhance their system's pollution control, fuel efficiency, and ignition timing. Transmission speed sensors help automatic transmissions shift smoothly. This section contains an overview of Honeywell products and solutions in this sector. The activities represented in this section are as follows:

Garrett Turbochargers Automotive On-Board Sensors

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Capability: Business Unit: Product: Customer Example: Significance:

The Automotive Industry Transportation & Power Systems Garrett Turbochargers Saab Automotive: As of 1999 Model Year, every Saab passenger car is Garrett turbocharged Lower emissions; Increased fuel economy

Introduction
A turbocharger is a centrifugal air pump that improves engine power, performance and combustion efficiency with corresponding reduction in exhaust emissions. Normally wasted engine exhaust gases leaving the combustion chamber drive the turbine wheel on the turbine side of the turbocharger. The turbine wheel is connected on a common shaft to the compressor wheel. As the turbine wheel spins faster and faster, so does the compressor wheel. The rotation of the compressor wheel pulls in ambient air and compresses the air as it enters the engine's combustion chamber. Turbocharged or boosted air in the combustion chamber permits the introduction of more fuel increasing power, torque and combustion efficiency. Customers: Manufacturers of diesel and gasoline passenger vehicles, on and off highway commercial vehicles, stationary and marine applications.

Resulting Benefits
Fuel Economy Improvements: A Garrett Turbocharger provides gasoline engines with a 15% increase in fuel economy along with improvements in horsepower and torque. Turbocharging increases fuel economy by 20% in diesel engines with even more dramatic improvements in power output and emissions reductions. Improved emissions: A Garrett Turbocharger reduces harmful exhaust emissions by delivering more air to the engine, providing cleaner more efficient combustion. It accomplishes this task by compressing or condensing the intake air so the oxygen molecules entering the engine combustion chamber is denser or more tightly packed. This results in an impressive 85% reduction in NOx and a 90% reduction in particulate emissions. Increased power, performance and efficiency: The Garrett Turbocharger improves the power and performance of all diesel and gasoline engines because of the increases in combustion efficiency. A turbocharged diesel engine may have power output that's is 100% higher than that of a comparable naturally aspirated engine. Gasoline engines see a 15% improvement in horsepower and a 22% increase in torque. These improvements enhance driveability, which is the sum of the improvements in power, performance and efficiency, making the vehicle fun to drive

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Garrett Turbochargers at Work A Customer Example Saab Automotive: As of 1999 Model Year, every Saab passenger car is Garrett turbocharged
Beginning with their 1999 models, Saab recognized the advantages of turbocharging with the inherent improvements in power, performance, and emissions reduction. Turbocharging with Garrett complements their entire product line, positioning them as one of the leaders in automotive technology. By opting for boosting technologies, car buyers around the world can now drive vehicles that are cleaner, economical and fun to drive.

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Capability: Business Unit: Product: Significance: Customer Example:

The Automotive Industry Sensing and Control Automotive On-Board Sensors Increased fuel economy; helps vehicles meet governmental emission regulations On over 20 million of the 50 million vehicles produced globally each year

Introduction
The U.S. Government has mandated that vehicle original equipment manufacturers (OEMs) improve fuel economy (through Corporate Average Fuel Economy/CAFE legislation) and drastically reduce vehicular emissions (through the second generation of On-Board Diagnostics, a.k.a. OBD-II). At the heart of a vehicles engine management and emissions control strategies are sensors that measure attributes in the fuel delivery, air handling, ignition, and exhaust systems. Honeywell Sensing and Control designs and manufactures a broad variety of these sensors for automotive on-board applications. For example, magnetic position sensors for engine management are comprised of crankshaft position sensors, camshaft position sensors, and distributor vane sensors. Their purpose is to improve fuel economy and fulfill emissions standards for OBD-II. Over 90% of a vehicles emissions occur within the first two minutes after the car or truck has been started. This is because a vehicles catalytic converter takes approximately two minutes to get up to the temperature where it can efficiently reduce the pollutants generated by an internal combustion engine. During this start-up period, the on-board computer that controls the engine must determine which pistons are in compression and which are in the exhaust stroke before it will start the fueling process. Crankshaft and camshaft position sensors determine precise engine position and pass that information on to the computer to control the engines fueling, ignition timing, and misfire detection. Consequently, the fuel is delivered to the proper cylinders and unburned gasoline is not exhausted to the atmosphere. Another portion of OBD-II legislation is to ensure vehicles flag emissions-related issues to the driver so that they can be fixed. One such issue would be a leak in the fuel tank or fuel lines. Honeywell Sensing and Control manufactures evaporative purge pressure sensors that help determine if there is a leak in the fuel delivery system.

Resulting Benefits
Cars and trucks are more fuel efficient and environmentally friendly today than they have ever been, thanks in part to Honeywell Sensing and Controls automotive on-board sensors. Our commitment is to help make tomorrows vehicles even more green.

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Selected Energy Efficient and Environmental Capabilities for

THE CARPET INDUSTRY

Evergreen Nylon Recycling, our joint venture with DSM Chemicals, is the first of its kind in the world. Opened in November 1999, the facility will process 200 million pounds of normally landfilled carpet and nylon waste into high-quality caprolactam, the basic building block chemical used to make nylon. Honeywell's Type-6 nylon has inherent properties that allow it to be broken down into its base components with the company's proprietary recycling process. Competitive types of nylon are more difficult to work with and involve more cost and complexity. With the new facility fully operational, it is now possible to turn your old carpet into the door handle on your next new car with no loss of performance or vibrancy of color. In addition to eliminating significant carpet and nylon waste, the renewal of nylon 6 will save 4.4 trillion BTUs of energy annually -- enough power to heat over 100,000 homes each year. It will also create 100 million pounds of virgin-quality nylon 6 per year, thereby reducing dependence on oil as a raw material. This section contains an overview of Honeywell products and solutions in this sector. The activities represented in this section are as follows:

Infinity Nylon (Evergreen Recycling Plant: Augusta, Georgia)

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Capability: Business Unit: Product: Customer Example: Significance:

The Carpet Industry Performance Polymers and Chemicals Infinity Forever Renewable Nylon Program Mohawk Commercial Carpet, Atlanta, Georgia Keeps over 200 million pounds of carpet and nylon waste out of landfills; produces virgin quality nylon product from a "closed-loop" recycling process

Introduction
Infinity Forever Renewable Nylon is the product of a true closed-loop recycling process. This process enables the renewed nylon product to retain all of its original quality and performance characteristics, creating a virgin-quality product. The Infinity program will accept over 200 million pounds of used carpet and nylon waste every year and will accept carpet from any manufacturer or source. The size of this program exceeds, more than 20 times, the capacity of any other recycling effort. To ensure that a continuous supply of post-consumer carpet is maintained, Honeywell is working with solid waste management and recycling companies to establish an extensive collection network across the country. This collection effort will become increasingly important as our landfill space diminishes. Once collected, these used nylon 6 products will never become waste in a landfill again because they can be renewed indefinitely. Closed-loop recycling: The Infinity nylon closed-loop recycling process is the most sophisticated and complete form of nylon 6 recycling available. At the heart of this renewal effort is a patented chemical process that depolymerizes, or "unzips", nylon 6 back into its original building block, caprolactam. This new caprolactam can then be polymerized back into new nylon 6. The Infinity nylon process is not only efficient, it actually creates virgin-quality caprolactam. The nylon is purified in a process similar to water distillation. The lighter caprolactam molecules separate from all the dyes and impurities and only pure caprolactam is captured. Tests prove this new caprolactam produces nylon fibers that are indistinguishable in every way from nylon made from original caprolactam. Significantly, this renewal process can be repeated forever without any degradation in quality. This unlimited reusability of nylon means that carpet and other products made from nylon 6 will never end up in a landfill. Customers: Infinity nylon can be manufactured into ANY nylon 6 product, including the highest performance fibers for residential and commercial carpets, plastics for electronics and automotive parts, performance fibers for car airbags and tires, and specialty films for pharmaceutical packaging. Target customers for Infinity nylon include carpet mills, manufacturers of automotive products, and anyone who manufactures or sells any nylon 6 product.

Resulting Benefits
Reduced landfill waste: As result of the Infinity renewal process, more than 200 million pounds of old nylon 6 carpet and nylon waste avoids the landfill. That equals 20% of the nylon 6

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carpet that is disposed every year. Since this renewal process can be repeated forever without the loss of any quality, carpet and other products made with Infinity nylon will stay out of landfills. Reduced energy consumption: The closed-loop process itself will save energy annually as compared to conventional caprolactam production. Reduced oil consumption: The Infinity renewal process will produce 100 million pounds of virgin-quality caprolactam per year. And since the raw material for this process is old nylon 6 carpet and waste, there is a saving of 700,000 barrels of oil (a non-renewable resource) annually enough energy to heat 100,000 homes for one year. This not only results in conservation of a scarce resource and reduced dependence on oil, but in greater nylon supply and stability.

The Evergreen Nylon Recycling Plant


Honeywell's commitment to the long-term recycling of nylon 6 and the production of Infinity recycled content nylon is evidenced by our investment in Evergreen Nylon Recycling LLC (ENR) in Augusta, GA, built in cooperation with our joint venture partner. ENR is an $80 million dollar state-of-the-art facility that is dedicated solely to the renewal of nylon 6 products. This facility will keep more than 200 million pounds of post-consumer nylon 6 carpet and nylon waste out of U.S. landfills each year. The Evergreen plant uses patented technology that converts nylon carpet into caprolactam. The facility will produce more than 100 million pounds of caprolactam each year. The recycling system instituted at the Evergreen plant is called "post-consumer, closed-loop". The most complete form of recycling, this process allows nylon fibers to be renewed over and over again. The ENR facility itself is also a model of energy efficiency, saving 700,000 barrels of oil (equivalent to 4.4 trillion British Thermal Units) each year compared to conventional caprolactam production facilities. Already ENR has collected 100 million pounds of carpet to begin production of Infinity nylon, but large quantities are still needed for its continued production. To ensure that a continuous supply of post-consumer carpet is maintained, Honeywell is working with solid waste management and recycling companies to establish an extensive collection network across the country.

Infinity at Work - A Customer Example Mohawk Commercial Carpet


Mohawk Commercial Carpet has introduced a line of commercial carpet line made with Infinity nylon, leading the way in manufacturing high quality, recyclable carpeting. Headquartered in Atlanta, Georgia, Mohawk Commercial Carpet develops, styles and manufactures carpet for the business, educational, health care, hospitality, retail, and aircraft industries. Mohawk Commercial carpet can be found in office buildings, airports, hotels, shopping centers, stores, hospitals, schools, and universities throughout the country, as well as in every major airline carrier.

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Since 1878, Mohawk has built a reputation for value, design, and innovation in the manufacture of fine quality carpet. Mohawk Commercial Carpet is a division of Mohawk Industries, Inc., the 2nd largest carpet manufacturer in the United States. Mohawk Commercial has always expressed interest in developing environmentally friendly solutions through their carpet reclamation and recycling programs. With the introduction of their commercial carpet line made with Infinity nylon, they are recognized as a leader in manufacturing high quality, environmentally preferable carpeting.

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Selected Energy Efficiency and Environmental Capabilities for

THE CHEMICAL INDUSTRY


Honeywell is a leading developer and producer of environmentally safer fluorocarbons used to replace ozone-depleting CFCs (chlorofluorocarbons) and HCFCs (hydrochlorofluorocarbons). These products, sold in many regions of the world under the Genetron trade name, are used in commercial refrigeration (supermarkets, warehouses, grocery stores), stationary (residential and commercial) and automotive air conditioning and foam insulation for building construction and appliances. Genetron products offer an environmentally friendlier alternative for air conditioning in automobiles and homes. Genetron products have a variety of other commercial applications. This section contains an overview of Honeywell products and solutions, as well as specific project examples. The activities represented in this section are as follows:

Genetron Environmentally Safer Refrigerants and Foam Blowing Agents

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Capability: Product: Business Unit: Significance:

The Chemical Industry Genetron Refrigerants and Foam Blowing Agents Performance Polymers and Specialty Chemicals Efficient and safe alternatives to ozone-depleting chemistries

Customer Examples: Genetron 134aUV A Service Technicians Point of View Genetron AZ-20 The A/C Refrigerant Choice of the Future Honeywells 245fa The Next Generation Blowing Agent

Introduction
Honeywells line of hydrofluorocarbon products offers a broad selection of non-ozone-depleting refrigerants and blowing agents for a wide range of applications including mobile airconditioning, residential and commercial air-conditioning, refrigeration and foam blowing. These products are marketed in Europe under the Honeywell name, and in the rest of the world under the trade name Genetron. Listed below are the four primary applications for Genetron products with some selected customer highlights.

Applications and Resulting Benefits


Mobile A/C: Genetron134a is an environmentally safer choice in refrigerant technology that has helped to lead the auto industry away from CFC dependency. Our new 134aUV product comes pre-mixed with a bright green fluorescent dye that is detectable using a handheld untraviolet lamp. This revolution in automotive refrigerants allows service technicians to pinpoint system leaks quickly and accurately, without having to wait the hours or days until the leak could be detected using more traditional dye methods. This results in a direct benefit to the environment by reducing refrigerant system leaks. Commercial and Residential A/C: GenetronAZ-20 (R-410A) is a non-flammable, non-ozonedepleting substitute for HCFC-22 that has been adopted by several original equipment manufacturers for use in their air conditioning systems. Since HCFC-22 is scheduled for phaseout as an ozone-depleting substance, customers can now select air conditioners with non-ozonedepleting Genetron AZ-20 refrigerant systems that are potentially quieter and more reliable than the HCFC-22 systems they replace. Refrigeration: Honeywell is also a world leader in providing environmentally safer refrigerants for commercial refrigeration applications. Genetron AZ-50 (R-507) replaces CFC-502 but offers similar servicing and performance characteristics, allowing for a smooth transition to chlorine-free systems. Like AZ-20, AZ-50 is a cost-effective non-ozone depleting HFC solution. Honeywell offers other HFC solutions such as R-404A, which has proven to be a reliable refrigeration choice for many manufacturers and users.

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Blowing Agents: Honeywell has been a key supplier of fluorocarbon blowing agents for more than 40 years. Today, Honeywell offers a complete line of HCFC and HFC blowing agents ideally suited for a variety of foam blowing applications. Honeywell has continued its tradition of introducing environmentally safer products through the commercialization of 245fa. This new product is a non-ozone depleting, non-flammable, non-VOC, liquid blowing agent ideally suited to replace HCFC-141b, which will no longer be manufactured or imported for use in the United States after January 1, 2003. HFC-245fa performs particularly well in insulation-critical applications such as refrigerator/freezer insulation, and building insulation such as board-stock and spray foams. Honeywell will construct a world scale manufacturing facility in Geismar, Louisiana to produce 245fa. Start-up for the plant is targeted for the first half of 2002.

Genetron at Work Customer Examples:


Genetron 134aUV: A Service Technician's point of view Honeywell launched Genetron 134aUV in February of 1999. Genetron 134aUV combines an environmentally safer, non-ozone-depleting refrigerant with the convenience of a pre-mixed, refrigerant soluble fluorescent dye that rapidly disperses throughout the system.. This dye is easily seen with the aid of an inexpensive handheld ultraviolet lamp. This product also eliminates potential spills associated with manually injecting dyes. Genetron 134aUV helps service technicians quickly pinpoint and repair leaks, including leaks too small to be detected by most other methods. After a six-month plus test period, Ron Knuth, owner of R.K. Auto Air Conditioning Sales & Services Inc. of East Aurora, New York, said there are many advantages of using a refrigerant pre-mixed with UV Dye. Repair shops benefit because everything can be done more quickly, Knuth said. There are so many advantages: you save on labor; you save on stocking costs; theres no mess to clean-up; the process is reduced to one simple step; and you reduce down-time because youll never run out of dye. By simplifying the process, Genetron 134aUV has made it easier and less expensive for technicians to find and fix refrigerant leaks, while at the same time satisfying their customers. Genetron AZ-20 The A/C Refrigerant Choice of the Future With the scheduled phase-out of R-22, the workhorse refrigerant for most air conditioning systems, getting closer, we see more and more air conditioners and heat pumps entering the market with Genetron AZ-20 or R-410A inside. R410A is an azeotrope-like blend of 50% HFC-32 and 50% HFC-125 invented and patented by Honeywell, and now marketed by Honeywell under the name AZ-20. Honeywell has worked closely with major system, compressor, and component manufacturers over the last decade to make a refrigerant transition as smooth as possible. By 2001, seven of the top system manufacturers will have introduced air conditioning systems utilizing R-410A refrigerant. Genetron AZ-20 has a higher pressure than the HCFC R-22, and therefore, cannot be retrofitted into existing R-22 systems. North American OEMs have chosen R-410A as the preferred substitute in residential and light commercial air conditioning equipment. Copeland Corporation, a leading manufacturer of
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compressors for air conditioning and refrigeration, reports that R-410A refrigerant has the potential to deliver superior system performance to R-22 in a variety of unitary air-conditioning applications. Copelands field studies to date have shown that R-410A Copeland Scroll Compressors are more reliable and quieter than similar R-22 compressors. Honeywells 245fa The Next Generation Blowing Agent For Spray Foam With the phase-out of HCFC-141b approaching rapidly, Honeywell has invented a HFC solution that has been adopted by several key customers for foam blowing applications. Insulating foams are an important part of many commercial and consumer products, and a cost-effective and energy-efficient product was necessary to replace the ozone-depleting HCFC 141b. As an example, Resin Technology Company, headquartered in Ontario, California, has developed an economical and practical, third generation, polyurethane foam system that meets the 1987 Montreal Protocol for reduction and elimination of ozone depleting chemicals. According to Will Lorenz, vice president and marketing manager for RTC, the firms new HFC-245fa formulation combines the high yield coverage and high insulating value. He said that RTC plans to make HFC-245fa-based rigid polyurethane foam systems available in 2003, in line with the phase-out of 141b. Some people in the industry have concerns that formulations of HFC-245fa are too expensive and would require special drums and special equipment. Our trials proved otherwise, says Will. In our tests, the roofing formulation came in standard drums and was sprayed with standard foam equipment. In short, we see HFC-245fa as a viable replacement for HCFC-141b in terms of application technique, says Will. Plus weve found that the new formulations have superior properties and yields. Honeywell is making a significant investment in HFC-245fa in Geismar, Louisiana, to ensure they can meet the expected demand as the next generation blowing agent HFC-245fa displaces 141b.

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For Further Information


For any questions about this document, please contact: Susan Rochford Director, International Affairs Honeywell 1001 Pennsylvania Avenue, NW Suite 700 South Washington, D.C. 20004 USA Tel: (1-202) 662-2618 or 2650 Fax: (1-202) 662-2674
susan.rochford@honeywell.com

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Acknowledgements
The 2000 Energy Efficiency & Environmental Capabilities booklet was compiled and edited by Jill Pollack, Trade Finance Associate for the International Affairs Trade Finance & Business Development Program in the Washington, D.C. office. The 2000 revision of this booklet was made possible thanks to the contributions of: Robert Babiak, Bill Brooksbank, Truc Brown, Albert Chung, Don Cieri, Costel Coravu, Neil Freeman, Annette Guarisco, Ted Hansen, Kevin Harris, John Hillier, Daniel Lopez, Steve May, Bill Mitchell, Jerg Merau, Jack Nehlig, Luc Onockx, Krisztian Oze, Pam Pemp, Dave Powell, Randy Price, Jana Rabenowitz, Stephanie Reuer, Jeff Ritter, Susan Rochford, Pamela Schechter, Steve Schultz, Simeon Belorechki, Art Simonetti, David Snyder, Don Todd, and Jiri Ulbrich.

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