Industrial Energy Management Vc

This document was specifically prepared to aid Tech Resources clients that wish to inform their customers about availableenergy management solution options that these customers may wish to consider. Any other use of this material (in whole or inpart) is not allowed without the expressed written consent of Tech Resources, Inc., 2025 Riverside Drive, Columbus, OH 43221.

2009 Tech Resources, Inc.

Energy ManagementOpportunities

Reduce Energy Intensity andCarbon Emissions by Changing the

Way You Use Energy

2009 Tech Resources, Inc. 2

Energy Management

Mike Carter

Mark Farrell


Energy Management Benefits

Bottom line cost savings today! Energy Maintenance

Reduced noise levels Better indoor air quality Reduced air emissions


Energy Management Opportunities

Basics Energy Management Insulation HVAC Lighting Heating Systems Motors Transformers Compressed Air


Power versus Energy Kilowatt (kW) is a measure of power, like the

speedometer of your car that records therate at which miles are traveled. A bigger engine is required to travel at a faster rate. Peak power demand is usually measured as an average

over a 15-minute period. Spikes and surges from motor startup and other short-term

anomalies have little influence on peak demand.

Kilowatt-hour (kWh) is a measure of energy/loadconsumptionsimilar to the odometer on your carwhich measures miles traveled.

Energy Efficiency Basics


Energy Efficiency Basics

Power versus Energy (contd) Energy Cost = Energy Consumption x Unit Cost =

kWh x $/kWh A 113-Watt four-lamp light fixture costs about $66 annually

when operating 16 hr/day (113 W x 5,840 hr x $0.10/kWh 1,000 W/kW)

Motor power (kW) = Horsepower x 0.746/efficiency A 10 HP motor = 10 HP x 0.746/0.90 = 8.3 kW A 10 HP motor costs about $4,850 annually (8.3 kW x 5,840 hr

x $0.10/kWh) when operating 16 hr/day Pay the price for improved energy efficiency!

The operating cost over the lifetime of a motor or light fixturecan far exceed the original purchase price.


Energy Basics

Load Factor Ratio of average load over peak load LF = kWAvg/kWP = kWh/hrs kWP

Assume 30-day billing(30 x 24 hrs = 720 hrs)

10,000 kWh load 21 kW peak LF = 10,000/720 21 kW LF = 66%


Energy Basics

Peak Demand Curtailment Separate loads into three categories:

Life, health, and safety-driven Mission critical Non-critical

Start by considering curtailment of non-critical loads Non-safety lighting HVAC

Consider installing sub-metering to identify highintensity loads


Energy Basics

Power Factor Real/active power (kW) does real work Reactive power (kVAR) bound up in magnetic fields Apparent power (kVA) must be supplied by utility to

accommodate reactive componentPF = kW/kVAkVA2 = kW2 + kVAR2

(kVA) = (kW) + (kVAR)= (75) + (75) = 11,250

Apparent Power = 11,250 = 106 kVA

Then: Power Factor = kW/kVA = 75/106 = 70.8%


Energy Basics

Power Factor Add capacitance to correct power factor Does not change demand (kW) or save much

energy (kWh)


Energy Basics

Carbon Footprint Metric tons (2,205 lbs or 19,550 ft3) of CO2

Natural Gas - 12 lbs CO2/ccfElectricity - 0.95 lbs CO2/kWhCarbon = CO2 3.67 (100 tons CO2 = 27 tons C)

Pine trees can absorb roughly 1 metric ton of carbon peracre per year

Direct emissions from company-owned stacks Indirect emissions from travel


Corporate Energy Management

Key Components of Energy Management Commitment by upper level management Clearly stated goals on energy efficiency, waste

reduction, and sustainability Delegation of responsibility and accountability to the

appropriate personnel Sustained tracking and assessment of energy use and

technology application Continuous investigation of potential energy reduction

projects


Corporate Energy Management

Energy Information Systems Measure and Evaluate

Knowledge is power If you can't measure it, you can't manage it!"

Access to real-time energy consumption/demand and cost dataacross multiple plants and facilities

Plan Benchmark

Against yourself Against similar facilities

Prioritize solutions Implement


Insulating Value

R-56R-28

R-14

R-7

R-3.5

0.000

0.050

0.100

0.150

0.200

0.250

0.300

0 5 10 15 20 25 30 35 40 45 50 55 60R-Value

U-Va

lue

(Btu

/ft.2

F h

r)

Insulation

Insulation has diminishing returns R-value is resistance to heat flow (additive)

R-7 + R-21 = R-28 (4 times R-7, and 75% better than R-7) R-7 + R-49 = R-56 (8 times R-7, but only 12% better than R-28!)

U-value is conductance of heat; inverse of R-value U(R-7) = 1/7 = 0.143 U(R-21) = 1/21 = 0.048

U(R-56) = 1/56 = 0.018 (87% less than R-7)U(R-28) = 1/28 = 0.036 (75% less than R-7)


Insulation

Type R-value per inch

Fiberglass 2.2-3.1

Vermiculite/perlite 2.4-2.8

Polystyrene 4.0-5.0

Polyurethane 6.0

Polyisocyanurate 6.0-7.1

Insulate steam pipes with at least " insulation For a 350F process steam pipe, savings are $5,000 for 2"

dia. and $10,000 for 4" dia. pipe Diminishing returns for insulation

thickness > "


HVAC

Implementation Load (kWh) Peak (kW)

Temperature Setback Economizers Heat/Energy Recovery Ventilators/Wheels Chiller Water Temperature New HVAC Equipment Geothermal Heat Pump Air Doors/Curtains


HVAC

Temperature Setback/Setforward Save 3% per F per 24 hrs 72F 68F (4F) for 12 hrs

saves 6%

Economizers Bring in Cool Outside Air Typical 2 to 5 year payback for economizers Most appropriate for large systems

(>5 tons in West and >11 tons in Midwest) Not very effective in high humidity climates


HVAC

Heat Recovery Ventilators Can recover about 60% to 70% of heat in exiting air A solution to ASHRAE 62 IAQ requirements

Photo source: George Retseck Illustrations


HVAC

Energy/Enthalpy/Desiccant Wheels

In mild climates, the cost of the additional electricityconsumed by the system fans and drum motor mayexceed the energy savings from not having to conditionthe supply air.

Can recover about 70% to 80% of the energy in theexiting air and deliver that energy to the incoming air. Desiccant wheels are most cost effective in climates with

extreme winters or summers, and where fuel costs are high.


HVAC

Narrow Your Chiller Water Temperature Set Points Typical conditions are chilled water temperature of 42F

and condensing water temperature of 80F to 85F. 2% savings per F that chilled water temperature is raised 5F to 10F increase is possible; more may cause damage and

reduce cooling capacity (ton rating) Efficiency benefits from lowering condensing water

temperature are offset by increased fan and pumpoperation, along with reduced cooling capacity. Variable Frequency Drives (VFDs) and oversizing the cooling

tower can help The larger the system, the greater the net energy savings


HVAC

Upgrade Older HVAC (10 to 15 years) Chillers: 0.8 kW/ton 0.5 kW/ton (37% less!) Unitary rooftop: 1.5 kW/ton 1.2 kW/ton (20% less!)

Geothermal or Water-Source HeatPump Roughly 30% savings compared to

AC/Boiler or AC/Furnacecombination

Geothermal requires higher capitalinvestment and requires significantamounts of real estateNew construction accommodates

verticals and pond loop


HVAC

Use Air Doors/Curtains A door 14 feet wide and 11feet high, indoor

temperature of 70F, outdoor temperature of20F, zero wind velocity, loses 600,000Btu/h at a cost of roughly $7 per hour

Any wind at all triples the loss! Air door recovers 75% of heat loss 1 to 2 year payback possible ($3,500 cap. + $100 op.) Exhaust fans (negative pressure) and wind tunnel

effect are problems


Lighting

Implementation Load(kWh)

Peak(kW)

Replace T12 with T8 or T5 Replace Metal Halide with T8 or T5HO Replace Incandescent with CFL


Lighting

Replace existing T12 fluorescent lamps with T8 fluorescent lamps (upto 30% savings).

No magnetic ballasts for new installations sold or manufactured afterMarch 2005.

More stringent magnetic ballast performance requirements after July2009.

No magnetic ballasts manufactured for replacement after June 2010.

Four-lamp T12 versus T8 Fixtures

Lamp Type FixtureWatts

FixtureLumens

LPW

F32T12 148 9,120 62

F32T8 113 10,600 94


Lighting

Super T8 lamps, with high-efficiency ballasts, are high lumen (>3,000versus 2,850 std.) and extended life (>24,000 versus 20,000 hrs std.)products.

Only saves energy when combined with a lower ballast factor ballast.

Group relamping recommended at 60% to 80% of rated life. Every 2 to 3 years for 20,000 hour fluorescents Can be 30% to 40% cheaper to group relamp due to labor savings

Type InitialLumens

InitialWatts

BallastFactor

FixtureLumens

FixtureWatts

T8 2,950 33 0.85 2,496 28Super T8 3,200 34 0.78 2,496 26


Lighting

Metal Halide (MH) versus Fluorescent for Highbay Probe start (PS) MH with low lumen maintenance (


Heating Systems

Implementation Load (Btu) Load (kWh) Peak (kW)

Gas Burner Air:Fuel Ratio Modern Gas Burners/Controls Steam Traps Stack Heat Recovery Infrared Booster Heaters Waste Heat Absorption Chillers Industrial Heat Pumps for Drying/Heating Radio Frequency/Microwave Drying/Heating Induction Process Heating


Heating Systems

Measuring Boiler Efficiency Fuel-to-steam efficiency is the best efficiency metric

Boiler output (Btu)/boiler input (Btu) Accounts for both combustion and thermal efficiency, radiation, and

convection losses

Efficiency mainly influenced by boiler design Number of passes more important than add-on (turbulator) Burner/boiler compatibility (accounts for geometry, heat transfer, and so on) Burner controls (independent control of fuel and air is best) Heating surface (square feet/boiler HP; 5 ft2/HP is desired)

Other factors Flue gas temperature directly correlates with efficiency Fuel hydrogen/carbon ratio (fuel oil > natural gas) Excess air (10% to 12%) Ambient temperature (every 40F ~ 1% efficiency change)


Heating Systems

Proper Boiler Air:Fuel Ratio

Efficiency improvements 82.8% 85.4% = 2.6% 68.2% 76.0% = 7.8%

Combustion Efficiency of Natural GasExcess % Temp. F (Flue-Comb.)

Air Oxy 200F 600 F

9.5 2.0 85.4% 76.0%

28.1 4.0 84.7% 74.0%

81.6 6.0 82.8% 68.2%


Heating Systems

Upgrade to Modern Burners Motor-controlled flue gas recirculation dampers Swirl vanes Turbulence enhancement Premixing chambers Leak-tight modulating air dampers Tangential diluent injection Rotating concentric blade air registers Fuel atomizers Venturi tube air registers Tapered burner tiles with baffles


Heating Systems

Use Electronic Burner Controls (typical savings) Linkless burners have no backlash (1%) Increased turndown (5%)

Burner on/off cycles and their associated cold air purges alsowill be reduced

A second PID control (10%) Some electronic fuel:air ratio controls have two internal

proportionalintegralderivative (PID) modulation circuits. If a plant does not run continuously then this second PID

controls setpoint can be used to switch the boiler to a lowersteam pressure or hot water temperature during periods ofreduced activity.

Adaptive oxygen trim (2% to 3%) Large boilers only (>$100,000 fuel per year)


Heating Systems

Use Electronic Burner Controls (contd) Fan speed control

With mechanical cam control and with basic electronic fuel:airratio controls, processors sacrifice combustion efficiency atlow fire to achieve an improvement in burner turn-down.

By adding fan speed control, burner turn-down can beincreased without compromising efficiency, and additional fuelsavings can be achieved.

Boiler sequencing (lead/lag) control andcommunication software Boiler sequencing control enables the plant operator to achieve

better utilization and additional energy savings are possible.


Heating Systems

Fix Broken Steam Traps One 1/8" diameter stuck-open steam trap

orifice on a large boiler can cost $1,000 (15psig) to $5,000 (140 psig) per year in increasednatural gas consumption

1 lb/hr ~ 1,000 Btu/hr There are Several Ways to Test Steam Traps

Plugged traps are cool while operating and leaking traps arehot. Use a non-contact, infrared thermometer.

In acoustic testing, an inspector listens for the variances in theacoustic patterns of working or failed traps.

The electronic procedure typically involves touching the trapon the downstream side with the instruments contact probeand adjusting the sensitivity to better hear the flow.


Heating Systems

Stack Heat Recovery Each 40F reduction in stack

temperature results in a 1%improvement in efficiency. Preheating combustion air A 200F air preheat saves 5%

Best applications >900F stack temperature 1,000F 800F results in 5% savings

Recuperators, regenerators, and heat exchangers Infrared Booster Heaters

Reduces curing times of coatings by 25% to 40% Best in conjunction with convection and for

thin simple shapes


Heating Systems

Absorption Chillers Fueled by waste heat but high

capital costs Best for high peak demand

charges, CFC or HCFCenvironmental concerns, wasteheat temperature >270F and>500 tons capacity

Yazaki Energy Systems (Plano, TX) and Thermax(Piscataway, NJ) claim to have low temperature (185Fto 203F) absorption chillers (20 to 30 ton maxcapacity)


Heating Systems

Industrial Heat PumpsProcess Key Enabler Applications

Separation Reduced column pressure enables distillationat low temperaturesPropane/propylene,butane/butylenes

Concentration Low (


Heating Systems

Radio Frequency/MicrowaveProcess Key Enabler Applications

Pre-drying Selective heating (water only) to avoid productdamage; Speed

Fiberglass packaging and mats;Dyed yarn spools; Ceramicfiberboard, powder, and extrusions

Post-drying(20%->8%)

Low final moisture content; Uniform (smalltemperature gradient) heating; No surfacecrust

Foods such as cookies, potatochips, and pasta; Dry pet foods;Polyurethane foam

Tempering Volumetric heating; Speed Frozen meats; Room temperaturebacon; Chocolate

Cooking Reduce drip loss (water, fat, nutrients, andflavor) Sausage, bacon

Curing Uniform heating; Precise temperature control;Speed Adhesives for wood and laminates


Heating Systems

InductionProcess Key Enabler Applications

Metallurgical processing(Hardening, Tempering,Annealing)

Selective heating; Speed;In-line continuous process

Gear teeth; Cutting blades;Pulleys; Axles; Camshafts;Galvanized sheet

Preheating prior to deformation(Forging; Swaging; Upsetting;Bending; and Piercing)

Reduced scale formation;Speed

Turbine engine blades; Billets; Millrolling of slabs and strips

Melting Speed; Flexibility Steel; Iron; Copper alloys;Aluminum; Zinc

Brazing and SolderingLocalized heating; Precisetemperature control anduniformity

Dissimilar materials; Carbide tips;Turbine blades; Eyeglass frames


Motors and Transformers


Peak(kW)

Replace motors Use variable speed drives Right size the motor Disconnect unused transformers


Motors

Repair or Replace Motors Replace motors 65% of new motor Replace motors last rewound before 1980

Variable Speed Drives/Adjustable Speed Drives Best for variable torque loads often found in variable flow

applications (pumps, fans, and blowers) and greater than2,000 hours operation

Horsepower varies as the cube of speed/flow Cut speed/flow by 50%, you cut energy consumption by

nearly 90%! (0.5 x 0.5 x 0.5 = 0.125) Converts 60 Hz to 120 to 400 Hz in pulse width modulation

Pulse-width modulation most common Current-source inverter used for 100+ HP motors


Motors

Right Size the Motor Motor efficiency plummets at 75 HP)

NEMA Premium Efficiencymotors are 1% to 3% basispoints more efficient thanbaseline (EPACT 1992)


Transformers

Transformer Losses Remove power from unused transformers

Full load losses (FL) Heat losses, or IR losses, in the

winding materials Roughly 5x NL losses (600 watts on a 50 kVA transformer)

High-Efficiency Transformer Paying a little more upfront ($400 to $4,000) leads to long term

savings (>$20,000 for a 1500 kVA transformer)

No load losses (NL) Caused by the magnetizing current

to energize the core Do not vary according to the loading

on the transformer


Compressed Air


Peak(kW)

Only use when there is no other option Fix leaks Right size Use variable speed compressor motor drives Implement heat recovery

Use two-stage, lubricated or centrifugal


Compressed Air

Compressed Air energy cost for 6,000 hrsat $0.10/kWh = $125/CFM At 4 CFM/HP, a 250 HP compressor costs about $125,000 annually

Only use compressed air when it is absolutelynecessary! If possible, switch to motors, mechanical actuators, and other means

to accomplish the same function

Leaks often account for 20% to 30% of compressoroutput A 1/32" leak in a 90 psi compressed air system would cost

approximately $185 annually


Compressed Air

Compressors operate at highest efficiency at full loador off Optimum controls results in big savings For example, at 50% full-load flow, kW input varies from 51% to 83%.

Percent kW Input at Operating Capacityfor Lubricant-Injected Rotary Screw

% Full-Load Flow

Load/No-load(5 gal/cfm) Modulation

VariableDisplace

VariableSpeed

90% 95% 97% 92% 91%

80% 92% 95% 83% 81%

70% 85% 90% 78% 71%

60% 78% 85% 68% 61%

50% 72% 83% 63% 51%

40% 63% 80% 60% 42%

Source: Improving Compressed Air System Performance: A Sourcebook for Industry, DOE


Compressed Air

Variable speed is best applied to compressors thatoperate primarily as trim units, or as single units withloads below 75% to 80% demand Below 85% loading, variable displacement units

become less efficient than variable speed, and arevery poor at loads below 50%

Reducing system pressure by 10 psi saves 8% to 10% Use " diameter hose for >3 HP tools or >50' lengths


Compressed Air

Heat Recovery Air-cooled compressors offer recovery efficiencies of

80% to 90% Ambient atmospheric air is heated by passing it across the

systems aftercooler and lubricant cooler. As a rule, approximately 50,000 British thermal units per hour

(Btuh) of energy is available for each 100 cfm of capacity (atfull-load).

Air temperatures of 30F to 40F above the cooling air inlettemperature can be obtained.

Space heating or water heating. Water-cooled compressors offer recovery efficiencies

of 50% to 60% for space heating only. Limited to 130F


Compressed Air

Reciprocating air cooled compressor has lowest first cost, but isinefficient

Spend a little more for a two-stage unit and achieve better efficiency Lubricated compressors are often more efficient than a similar non-

lubricated unit, but they contribute oil content to the system and mayimpact the compressor air quality

Air Compressor Efficiency Benchmarks

Reciprocal Rotary Screw Centrifugal

Aircooled

Watercooled

Watercooled

Lubricated Lubricated Non-lube


Questline

Go to www.questline.com Provided by:

Tech Resources2025 Riverside DriveColumbus, OH [email protected]

This document was specifically prepared to aid Tech Resources clients that wish to inform their customers about availableenergy efficient options that these customers may wish to consider. Any other use of this material (in whole or in part) is notallowed without the expressed written consent of Tech Resources, Inc., 2025 Riverside Drive, Columbus, OH 43221.


Whats Next?If you would like more information about the four strategies to increase cash flow,contact your local Manufacturing Extension Partner.

This document was specificallyprepared to aid ManufacturingExtension Partnerships and theircustomers. Any other use of thismaterial (in whole or in part) is notallowed without the expressed writtenconsent of Tech Resources, Inc.,2025 Riverside Drive, Columbus, OH43221.

Arizona Manufacturing Extension Partnership

California Manufacturing Technology Consulting

Maryland Technology Extension Service

Montana Manufacturing Extension Center

The Oklahoma Manufacturing Alliance

Rhode Island Manufacturing Extension Services

South Carolina Manufacturing Extension Partnership

Texas Manufacturing Assistance Center

University of Tennessee Center for Industrial Services

West Virginia Manufacturing Extension Partnership

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Industrial Energy Management Vc

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