Making Electricity since December 2015
Melody Collis
Facilities Engineering Assistant Manager
Toyota Motor Manufacturing Canada
1
Cambridge
Company
Culture
Vision
Woodstock

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
Established
January 24, 1986
Locations
Cambridge, Ontario
Woodstock, Ontario
Land Area
1,618,730 m2 (400
acres)
4,046,856 m2 (1000
acres)
Plant Area
280,000 m2 (70 acres)
165,921 m2 (41 acres)
Investment
Team
Members
$6 billion (CAD)
> 8,000
08/06/2016
4
Lexus
RX 350
Lexus
RX 450h
Toyota
RAV4
Toyota
Corolla
08/06/2016
5
2013
2014
2015
Toyota Corolla
195,900
242,465
252,362
Toyota Matrix
11,670
4,913
-
Toyota RAV4
210,576
226,783
242,311
953
1002
-
86,236
95,455
87,974
-
8,793
8,076
505,335
579,411
590,723
Production Models & Units
Toyota RAV4 EV
Lexus RX 350
Lexus RX 450h
Total
Takt Time
 Corolla:
55 seconds
 RAV4:
57 seconds
 RX 350 / RX 450h: 120 seconds
08/06/2016
6
TMS
TCI
Toyota Motor Sales U.S.A.
Toyota Canada Inc.
Sales to:
 USA
 Mexico
 Guam
 Puerto Rico
 NATO Germany
Sales to:
Canada
TMMC
TCI
TMS
7
08/06/2016
Quality Awards
Assembly Plant Awards
Segment Awards
14 total
 Corolla:
(most of any mfg. plant in the
Americas)
 Platinum: 2011, 2014
 Gold:
 Silver:
 Bronze:
1991,
1996,
2010,
2015
1992,
1993,
1995,
2001,
2012,
2001,
2004,
 RX 350: 2005,
2008,
2002,
2006, 2012
2007,
2012
2015
2000, 2012
Quality Awards
08/06/2016
8
The Business Case for TMMC
in Cambridge

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

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

The Business Case for TMMC
3) Spark Gap
Gap
2023
2025
2020
2015
Natural Gas
2010
• Price gap between
electricity & natural gas
• Electricity costs
projected to continue
to increase
• Natural gas cost
projected to remain
stable
Electricity
Potential $$$ savings
Self-Reliance

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

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
Project Scope
Current System
Project Scope



$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
Heat Recovery
Steam Generator
Design Considerations for
Increasing The Energy Efficiency
& Production Contingency
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)
For Chilled
Turbine
water (summer)
For Production
Process
Summer
Winter
Balance Steam Loads
VE Activity - Example
Gas Turbine Generator (GTG) Inlet Air Cooler
UB1A
Temp
(F)
Generation
(MW)
0
10 MW
38
9.1 MW
50
8.8 MW
90
7.4
• Temperature of the inlet
air impacts the
efficiency of the GTG
• Inlet air cooler willTurbine
reduce temperature
from 90 to 50F
Improves GTG Efficiency
Air
Inlet
Steam
Chiller
Substation
Cooling
Coils
Gas Booster
Pumps
Steam driven
chiller provides
chilled water for
inlet air cooling
VE Activity - Example
Install 26000 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
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
Turbine
install FGBCs for
our
site
Evaluate Gas Pressure Supply
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
Bringing the Project from
Concept to Completion
Planning &
Approvals
Task / Milestone
Design & Permitting
Procurement - Major Equipment
Tender - Building
Tender - Process
Building Construction
Process Installation
Commissioning and Training
Plant Operation
Schedule
Process Install
2014
Test
SOP
2015
Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Steam
Chiller
Substation
Project
Approval
Turbine
November 10, 2014
Building
Construction
Design
Heat
Ground Recovery
Building
Breaking
SteamHandover
Generato
r (HRSG)
Turbines
on-site
February 9, 2015
Generation
Synchronization
Gas Booster
Pumps
In-service
Dec 31
October 2015
Milestone - Highlights
UB1A
Steam
Chiller
Substation
Turbine
Gas Booster
Pumps
Groundbreaking – September 9, 2014
Milestone - Highlights
UB1A
Steam
Chiller
Turbine
Equipment Foundation Pour
October 23, 2014
Milestone - Highlights
UB1A
Steam
Chiller
Substation
Turbine
Gas Booster
Pumps
Steel Erection - December 3, 2014
Milestone - Highlights
Building
Substantially
Complete
UB1A
Steam
Chiller
Substation
Turbine
February 5, 2015
Gas Booster
Pumps
First piece of
equipment
on site
Turbine
Delivery
February 21,
2015
Milestone - Highlights
Heat Recovery Steam Generator
(HRSG) Offloading - May 9, 2015
Gas Turbine 1
First Light
UB1A
Steam
October 17, 2015
Chiller
Substation
Turbine
Completed CHP
Process
Gas Booster
Pumps
Installation of
Last Critical
Equipment
Breaker & Grounding
Transformer
Installed the
November
28 & 29, 2015

December 6
◦ First synchronization
of GTG1 & GTG2

December 13
◦ Live trip test

December 13 – 30
◦ Online for training

December 31, 2015
◦ Official in-service date
Challenges Behind the Scenes

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

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


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
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
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

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





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




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
Benefits are realized!
Cumulative
Monthly
Stretch Target
Minimum
Actual
Stretch Target
Minimum
MWh
MWh
Actual
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
Natural Gas
CY15
Electricity
CY16
Jan - May


Official in-service date: December 31, 2015
Total electricity generated:
28,272,694 kWh
Enough for 2945 homes

Total steam produced:
85,796,543 kg
2945