Upgrade Electrical power

Measurements Project
Energy Management Information Systems
(EMIS).
Suez Cement Plant
MBA PROJECT MIS _ Midterm

Under Supervision Dr: Sayed Kamal

By: Samir Sabry Aldeeb

Contents
1. Company Description
2. Managerial Problem
3. SIVA Model
• Solution
• Information
• Value
• Access
 Suez Cement Group of
Companies (SCGC)
 Established in 1977, Suez Cement is the largest grey cement producer in Egypt with a
production capacity of four million tons of cement per year. The company started its
activities by building its first plant in Suez followed by its Kattamia plant with total
investments of about L.E. 1.7 billion. Both plants operate using the dry method with
whitewash and primary heating. The company serves the domestic market and
exports its products to Arab, African and European markets.
 In 2000, Suez Cement Company Acquired approximately more than 70% of Tourah
Portland Cement Company (TPCC).
 In 2001 Italcementi Cement Acquired more than 50% of Suez cement Group.(Suez
cement and Tourah plant.
 In August 2005, Suez Cement Company acquired approximately 99% of ASEC Cement
Company (currently Helwan Cement Company).
 In July 2016, Heidelberg Cement acquired 45% of Italcementi, a subsidiary of
Italmobiliare. Suez Cement, in which Italcementi owned a 55% stake, therefore joined
the Heidelberg Cement Group as one of the world’s leading building materials
producers
-3
Suez plant
 Built in 1979, the Suez plant currently has two production lines that use the dry
method production process. The cement plant and two quarries are in an area
spanning 3,095,000 m².
 Suez Cement plant has an annual production Capacity of a bout 3,000,000 ton of
cement

Types of Cement Produced at the Suez Plant:

• Ordinary Portland Cement(OPC) CEM I 42,5 N
• Sulphate Resistance Cement(SRC)
• Pozzolanic CEMII / A-P 42,5 N.
• Blast Furnace Cement - CEM III 42.5 N
• SUEZ OASIS Cement 22.5 N

-4
Managerial Problem
 Suez Cement Plant Electrical energy is supplied from the EEHC (Egyptian
Electricity Holding Company) public Electrical network :
1. The Max. Elect Power Consumption is 33.00 MVA.
2. The Average power Consumption is 31.125 MVA.
3. The Total annual Electrical energy consumed is about 220,000,000 KWH
4. Average Cost /KWH is about 1.2 EGP
5. The Total annual cost for the consumed Electrical Energy is more than 250
MEGP.

-5
Managerial Problem
 Always There are high difference and error in Electrical power readings between EEHC power meters and plant
power meters.

2020 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Error -1.06% -4.99% -3.07% -8.37% -2.64% -2.63% -5.14% -1.56% -3.54% -4.00% -3.66% -4.59%
KWH (189,100) (662,162) (462,642) (1,451,720) 416,014 (481,859) (859,082) 253,773 (641,170) (658,115) (655,203) (790,949)

 Existing two types of Electrotechnical analog power meters.

 One type installed with first production line since 1978.

 The second type installed with line 2 since 1998.

 In addition to meters obsoleteness, All this power meters not calibrated since installation.
 The Data is manually collected and documented.

-6
Managerial Problem
 The existing energy metering system not cover all different consumption processes,
areas or department , So most electrical energy consumptions are estimated.
 The very old electrical energy meters affect negatively on the power consumption
calculations and cause high difference and errors in power reading between EEHC
(Egyptian Electricity Holding Company)Electric power meters and plant power
meters.
 The most important to have an accurate energy readings(digitalized and
documented)) at the different section of the production line to calculate the
production cost for each section and make good control for the electrical energy
consumption for the main equipment in the production line.

-7
 Solution:
 Supply and install Energy measuring system consists of :
1. Energy Management Information System (EMIS) (SCHNEIDER EcoStruxure™ Power Monitoring Expert
Software) .
2. The existing medium voltage cells will be equipped with energy multi-function digital meters(microprocessor
based) .110 measuring device. These new power meters are mainly used for comprehensive monitoring of
the power supply network.
3. A communication network will be installed to link all these power meters to a power metering monitoring
Software(SCHNEIDER EcoStruxure™ Power Monitoring Expert Software) which will be installed on
workstation located at the plant Control Center Room(CCR)
. This will allow real time monitoring of the plant power supply network. This monitoring facility will allow further
analysis and decisions that will lead to improvements of the energy consumption system performance.

-8
Solution:

14. Deze - 9
mber
Samir20
Sabry Aldeeb
24
Solution:

- 10
Information
1. Real time energy consumptions readings for all large consumers at the plant;
2. Daily energy consumption reports for most large consumers and collective areas in the production line.
3. Monthly energy consumption reports for most large consumers and collective areas in the production line.
4. Monthly collective Energy consumption report(bill) for the whole plant, indicating different energy
parameters(power factor , reactive power , rush hours consumption, ….)

- 11
Information

- 12
Value:
 By using the Energy Management Information System (EMIS), the below values will be accomplished :
1. Verify that Entity utility bill is accurate, both from a metering and bill calculation perspective.
2. Measure and allocate energy costs by business unit, department, area, floor or building in order to analyzing
and understand which load type, business unit, area, floor or building provides the biggest savings
opportunities.
3. Benchmark energy usage with respect to other buildings / plants / process lines.
4. Analyze how much energy is consumed by the various load types and/or areas in the plant to determine
where to focus my energy conservation initiatives.

- 13
Access:
 The Access for Energy Management Information System (EMIS), is only for the concerned parties below:
1. Process and follow up manager and related staff
2. Maintenance control manager and related staff
3. Electrical Maintenance team
4. Automation maintenance team
5. Access by SW provider technical support team

- 14
Project Time schedule

Planned Time Schedule

Description 2022 2023 2024
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
AFE uploading and Approvals
Tendering phase & PRs creation
Issuing orders
Delivery Time
Installation works
Commissioning & start up

- 15