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This document was specifically prepared to aid Tech Resources’ clients that wish to inform their customers about available energy management solution options that these customers may wish to consider. Any other use of this material (in whole or in part) is not allowed without the expressed written consent of Tech Resources, Inc., 2025 Riverside Drive, Columbus, OH 43221. © 2009 Tech Resources, Inc. Energy Management Opportunities Reduce Energy Intensity and Carbon Emissions by Changing the Way You Use Energy
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  • 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

  • 2009 Tech Resources, Inc. 3

    Energy Management Benefits

    Bottom line cost savings today! Energy Maintenance

    Reduced noise levels Better indoor air quality Reduced air emissions

  • 2009 Tech Resources, Inc. 4

    Energy Management Opportunities

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

  • 2009 Tech Resources, Inc. 5

    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

  • 2009 Tech Resources, Inc. 6

    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.

  • 2009 Tech Resources, Inc. 7

    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%

  • 2009 Tech Resources, Inc. 8

    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

  • 2009 Tech Resources, Inc. 9

    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%

  • 2009 Tech Resources, Inc. 10

    Energy Basics

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

    energy (kWh)

  • 2009 Tech Resources, Inc. 11

    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

  • 2009 Tech Resources, Inc. 12

    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

  • 2009 Tech Resources, Inc. 13

    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

  • 2009 Tech Resources, Inc. 14

    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)

  • 2009 Tech Resources, Inc. 15

    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 > "

  • 2009 Tech Resources, Inc. 16

    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

  • 2009 Tech Resources, Inc. 17

    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

  • 2009 Tech Resources, Inc. 18

    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

  • 2009 Tech Resources, Inc. 19

    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.

  • 2009 Tech Resources, Inc. 20

    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

  • 2009 Tech Resources, Inc. 21

    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

  • 2009 Tech Resources, Inc. 22

    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

  • 2009 Tech Resources, Inc. 23

    Lighting

    Implementation Load(kWh)

    Peak(kW)

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

  • 2009 Tech Resources, Inc. 24

    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

  • 2009 Tech Resources, Inc. 25

    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

  • 2009 Tech Resources, Inc. 26

    Lighting

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

  • 2009 Tech Resources, Inc. 27

    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

  • 2009 Tech Resources, Inc. 28

    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)

  • 2009 Tech Resources, Inc. 29

    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%

  • 2009 Tech Resources, Inc. 30

    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

  • 2009 Tech Resources, Inc. 31

    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)

  • 2009 Tech Resources, Inc. 32

    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.

  • 2009 Tech Resources, Inc. 33

    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.

  • 2009 Tech Resources, Inc. 34

    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

  • 2009 Tech Resources, Inc. 35

    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)

  • 2009 Tech Resources, Inc. 36

    Heating Systems

    Industrial Heat PumpsProcess Key Enabler Applications

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

    Concentration Low (

  • 2009 Tech Resources, Inc. 37

    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

  • 2009 Tech Resources, Inc. 38

    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

  • 2009 Tech Resources, Inc. 39

    Motors and Transformers

    Implementation Load(kWh)

    Peak(kW)

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

  • 2009 Tech Resources, Inc. 40

    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

  • 2009 Tech Resources, Inc. 41

    Motors

    Right Size the Motor Motor efficiency plummets at 75 HP)

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

  • 2009 Tech Resources, Inc. 42

    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

  • 2009 Tech Resources, Inc. 43

    Compressed Air

    Implementation Load(kWh)

    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

  • 2009 Tech Resources, Inc. 44

    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

  • 2009 Tech Resources, Inc. 45

    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

  • 2009 Tech Resources, Inc. 46

    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

  • 2009 Tech Resources, Inc. 47

    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

  • 2009 Tech Resources, Inc. 48

    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

  • 2009 Tech Resources, Inc. 49

    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.

  • 2009 Tech Resources, Inc. 50

    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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