Making Electricity since December Melody Collis Facilities Engineering Assistant Manager Toyota Motor Manufacturing Canada
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1 Making Electricity since December 2015 Melody Collis Facilities Engineering Assistant Manager Toyota Motor Manufacturing Canada
2 Cambridge 1 Company Culture Vision Woodstock
3 TMMC's goal is to maintain a balance of satisfaction between each of the 4 stakeholders Community Customers/Suppliers Shareholders Team Members Business (Hoshin) Planning at TMMC is based upon this model 08/06/2016 3
4 Established January 24, 1986 Locations Cambridge, Ontario Woodstock, Ontario Land Area 1,618,730 m 2 (400 acres) 4,046,856 m 2 (1000 acres) Plant Area 280,000 m 2 (70 acres) 165,921 m 2 (41 acres) Investment Team Members $6 billion (CAD) > 8,000 08/06/2016 4
5 Lexus RX 350 Lexus RX 450h Toyota RAV4 Toyota Corolla 08/06/2016 5
6 Production Models & Units Toyota Corolla 195, , ,362 Toyota Matrix 11,670 4,913 - Toyota RAV4 210, , ,311 Toyota RAV4 EV Lexus RX ,236 95,455 87,974 Lexus RX 450h - 8,793 8,076 Total 505, , ,723 Takt Time Corolla: 55 seconds RAV4: 57 seconds RX 350 / RX 450h: 120 seconds 08/06/2016 6
7 TMS Toyota Motor Sales U.S.A. Sales to: USA Mexico Guam Puerto Rico NATO Germany Sales to: Canada TCI Toyota Canada Inc. TMMC TCI TMS 7 08/06/2016
8 Quality Awards Assembly Plant Awards 14 total (most of any mfg. plant in the Americas) Platinum: 2011, 2014 Gold: 1991, 1995, 1996, 2001, 2010, 2012, 2015 Silver: 1992, 2015 Bronze: 1993, 2000, 2012 Segment Awards Corolla: 2001, 2002, 2004, 2006, 2012 RX 350: 2005, 2007, 2008, 2012 Quality Awards 08/06/2016 8
9 The Business Case for TMMC in Cambridge
10 The Business Case for TMMC 1) TMMC s Environmental Management Plan 5-year North American Reduction Plans Yearly Energy Reduction Targets Conservation Kaizen through Team Member Engagement More-Efficient Equipment Breakthrough Initiatives
11 The Business Case for TMMC 2) Ontario s Long-term Energy Plan Building a clean, modern and reliable electricity system Coal Elimination Demand Reduction CHP supports efficiency & regional capacity Supports local utilities to reach assigned conservation targets Relieves electricity demand in a constrained area Cambridge Supports TMMC s Community Stakeholder
12 The Business Case for TMMC 3) Spark Gap Price gap between electricity & natural gas Electricity costs projected to continue to increase Natural gas cost projected to remain stable Electricity Natural Gas Gap Potential $$$ savings Self-Reliance
13 The Business Case for TMMC 4) Consistent Electricity Base Load 5) Significant Steam Load For Heating (winter) For Production Process Summer Winter Why it makes sense at our Cambridge Plant
14 The Business Case for TMMC 6) Aging Steam Boilers Opportunity to increase efficiency of steam production Reduce boiler air emissions Redirect capital funds to new equipment
15 Project Scope
16 Current System Project Scope
17 $27M (2) 4.6 MW Turbines (2) Heat Recovery Steam Boilers (HRSG) Replaces current 3 steam boilers (2) 2000 ton Steam Driven Chillers Replaces two electric chillers (1) Heat Exchanger Replaces one hot water boiler 8760 sq ft building expansion
18 Heat Recovery Steam Generator
19 Design Considerations for Increasing The Energy Efficiency & Production Contingency
20 VE Activity - Example Install (2) 2000 ton Steam Driven Chillers Balance winter & summer steam loads Replace aging electric chillers Reduce ~2 MW electrical load For Heating (winter) Turbine For Chilled water (summer) For Production Process Summer Winter Balance Steam Loads
21 VE Activity - Example Gas Turbine Generator (GTG) Inlet Air Cooler UB1A Temp (F) Generation (MW) 0 10 MW MW MW Temperature of the inlet air impacts the efficiency of the GTG Inlet air cooler will Turbine reduce temperature from 90 to 50F Improves GTG Efficiency Steam Chiller Steam driven chiller provides chilled water for inlet air cooling Substation Gas Booster Pumps Air Inlet Cooling Coils
22 VE Activity - Example Install lb Steam Heat Exchanger Provide heating in winter Equivalent to one hot water boiler Improved efficiency over existing boilers Turbine Leverage Efficiency of New HRSGs
23 VE Activity - Example Install Fuel Gas Booster Compressors Turbines require gas pressure at min. 225 psi Evaluated guaranteed gas pressure from utility versus installing Fuel Gas Booster Compressors (FGBC) More cost effective to install FGBCs for Turbine our site Evaluate Gas Pressure Supply
24 VE Activity - Example Fresh Air Fan & Guillotine Damper Each Turbine / HRSG with duct burners can supply TMMC steam load Contingency added if both turbines are not available Fresh air fan & guillotine damper were added to one HRSG to allow steam production Turbine without a turbine Fresh Air Fan Guillotine Damper Contingency for Steam Production
25 Bringing the Project from Concept to Completion
26 Task / Milestone Design & Permitting Procurement - Major Equipment Tender - Building Tender - Process Building Construction Process Installation Commissioning and Training Plant Operation Planning & Approvals Turbine Design Building Construction Process Install Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Project Approval Schedule Ground Breaking Heat Recovery Steam Generato r (HRSG) Building Handover Steam Chiller Turbines on-site Test Substation Generation Synchronization Gas Booster Pumps SOP In-service Dec 31 November 10, 2014 February 9, 2015 October 2015
27 Milestone - Highlights UB1A Steam Chiller Substation Turbine Gas Booster Pumps Groundbreaking September 9, 2014
28 Milestone - Highlights UB1A Steam Chiller Turbine Equipment Foundation Pour October 23, 2014
29 Milestone - Highlights UB1A Steam Chiller Substation Turbine Gas Booster Pumps Steel Erection - December 3, 2014
30 Milestone - Highlights UB1A Building Substantially Complete Steam Chiller Substation Turbine Gas Booster Pumps February 5, 2015
31 First piece of equipment on site Turbine Delivery February 21, 2015
32 Milestone - Highlights Heat Recovery Steam Generator (HRSG) Offloading - May 9, 2015
33 UB1A Gas Turbine 1 First Light October 17, 2015 Steam Chiller Substation Turbine Gas Booster Pumps Completed CHP Process
34 Breaker & Grounding Transformer Installed the November 28 & 29, 2015 Installation of Last Critical Equipment
35 December 6 First synchronization of GTG1 & GTG2 December 13 Live trip test December Online for training December 31, 2015 Official in-service date
36 Challenges Behind the Scenes
37 OEM Equipment Purchase Agreements Long lead equipment was purchased directly by Toyota Environmental Approvals ECA for Air, Noise & Storm Building Permits ESA TSSA Fuels Branch Pressure Vessels Branch Plant Registration Debt Retirement Registration Insurance Project Review
38 Union Gas Gas projection Contracts New gas station Cambridge North Dumfries Hydro & Hydro One Agreements Connection Impact Assessment (CIA) Cost Recovery Agreement Connection Agreement Operating Agreement Tele-protection Verification Requirements (TVR) Long-term Service Agreements
39 24 Hour, 7 Day coverage Hiring Shift Schedules Equipment Training On-the-job Training Checksheets PMs Contingency Plans Note: Staff already licensed stationary engineers Hands on TM Training
40 Coordination of new equipment with existing plant Confirming controls philosophy & implementation Multiple pieces of equipment with multiple vendors Equipment working together was challenging Greater resources required than anticipated
41 Designing a protection & control (P&C) philosophy that does not erode current reliability No impacts on production from construction Off hour tie-ins Contingency planning Electrical Steam Communication & coordination with manufacturing organization
42 Benefits are realized!
43
44 Monthly Actual Stretch Target Minimum Cumulative Actual Stretch Target Minimum MWh MWh Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
45 Natural Gas Electricity CY15 CY16 Jan - May
46 Official in-service date: December 31, 2015 Total electricity generated: 28,272,694 kwh Enough for 2945 homes 2945 Total steam produced: 85,796,543 kg
47
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Year 0 1 2 3 4 5 6 7 8 9 10 11 12 13 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 2,038 2,922 4,089 4,349 6,256 7,124 8,885 8,885 8,885 8,885 8,885 8,885 9,107
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