Self-Help Energy Analysis for Your Plant
Warren M. Heffington, PE, CEM Industrial Assessment Center
andEnergy Systems Laboratory,
Mechanical Engineering DepartmentTexas A&M UniversityCollege Station, Texas
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Energy Analysis
No-cost, low-cost projects and resources:What you can doWhat you can expect of others⌧U.S. Dept. of Energy⌧Consultants⌧Vendors⌧Utilities
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Background
Industrial Assessment Center (IAC) Program
440 assessments by A&M60% project implementation rateImplemented savings average $26K/yr/plantMostly no cost, low cost projects
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Energy AssessmentsHow others can help
Take advantages of DOE Best PracticesDOE works with industry to identify plant-wide opportunities for energy savings and process efficiency
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DOE Best Practices Program includesNew and emerging technology implementation, and tech transferPlant assessmentsSoftware tools, clearinghouse, publications library, and databaseShowcases
http://www.oit.doe.gov/bestpractices/
Energy AssessmentsHow others can help
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Examples of emerging technologies:Ultrasonic tank cleaningMethanol recovery from hydrogen peroxideAdvanced turbine systemsAdvanced burner systems for emission controlAnd many others--available at⌧http://www.oit.doe.gov/chemicals/bp⌧http://www.oit.doe.gov/petroleum/bp
Energy AssessmentsHow others can help
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Energy AssessmentsHow others can help
Downloadable software from Best PracticesMotormaster +3.0*PSAT (Pumping System Assessment Tool)*Steam System Assessment Tool (SSAT 1.0.0)*Steam System Scoping Tool*Industrial insulation program 3E Plus*
*Download from http:/www.oit.doe.gov/bestpractices/software_tools
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Energy AssessmentsHow others can help
Additional useful software tools available AirMaster+ (available via CD)ASDMaster (available via CD)Process Heating Assessment Tool (under development)
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Best Practices provides plant assessmentsNo-cost industrial assessments are available from centers
Energy AssessmentsHow others can help
around the nation
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Call a nearby IAC for a no-cost energy assessment if you meet 3 of 4:
Energy bills under $2 million annuallyGross annual sales under $100 million annuallyEmployees under 500No-in house expertise for energy analysis
Energy AssessmentsHow others can help
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Even if you don’t meet 3 of 4--too large?--we might be able to helpLocally, contact
[email protected]@esl.tamu.edu
IAC national contact info:http:/www.oit.doe.gov/bestpracticeshttp://oipea-www.rutgers.edu
Energy AssessmentsHow others can help
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Energy AssessmentsWhat You Can Do
Looking at the forest is sometimes not too helpful
Raw materials
Labor
Overhead
Energy
IndustrialProcesses
Product 1
Product x
Product 2
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Sometimes--just look at a few dying individual trees and treat themHowever, it is a good idea to look at whole subsystems
process heating--not just product qualityelectrical--not just motorssteam--not just steam trapsair--not just lack of airwater--not just the new wastewater treatment facility
Energy AssessmentsWhat You Can Do
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For example, consider the whole of the electric motor subsystem.Problems can be costing $$ in any of these
subparts, so look at everything together
Elecin
Meter Power Fact corr
Switchgear
Cond-uctors
Motor
Gear-box
ChainsBearingsLubri-cation
Other friction
Product moved
Energy AssessmentsWhat You Can Do
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The Texas A&M IAC recently visited several refineries and chemical plantsSome projects are complex
replace natural gas fired enginesinstall flare gas compressor systeminstall variable frequency drivesinstall turbines
All require additional engineering
Energy AssessmentsWhat You Can Do
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Simple projects not requiring engr. assist.Repair steam trapsRepair leaks--steam, water, airTurn off unused equipment and lightsRepair insulationUse synthetic lubricantsUse LEDs for exit lights where possible
List is from chemical plants and refineries
Energy AssessmentsWhat You Can Do
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Repair steam trapsPurchase an ultrasonic detector for about $1,500 to $5,000 and use itRecommended 5 times in 8 large plantsAverage savings $300,000/yrPayback less than a month
Energy AssessmentsWhat You Can Do
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Energy AssessmentsWhat You Can Do
Repair leaks#
ProjectsAvg
Savings($/yr)
SimplePayback
(yrs)Steam 4 105,000 0.1
Nitrogen 1 140,000 0.4Water 1 30,000 0.1
Air 2 2,000 0.5
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Turn off unused equipment
Implementation requires employee education and possibly switches or sensorsObvious safety issues with lights
Energy AssessmentsWhat You Can Do
#Projects
AvgSavings($/yr)
Motors 2 33,000Lights 8 4,000
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Repair/add missing insulationRecommended 3 times in 8 large plantsSaves $24,000/yrPayback usually a few months at most
Energy AssessmentsWhat You Can Do
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Use synthetic lubricantsRecommended 6 times in 8 large plantsSaves $21,000/yrLast longer but cost more, so the implementation cost turns out to be about the same as petroleum based lubes.
Energy AssessmentsWhat You Can Do
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Install LEDs in exit lampsGreat, small projectSaves energy, demand, supplies and laborBig help to code compliance
Energy AssessmentsWhat You Can Do
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Consider performing your own assessmentAssistance available on webhttp://oipea-www.rutgers.edu/documents/doc_m
Self-assessment workbook for small manufacturersModern industrial assessments: a training manual
Energy AssessmentsWhat You Can Do
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Energy AssessmentsWhat Others Can Do
Outside assistanceConsultants--Tune-up specialists for the whole system or subsystemsVendorsUtilities
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Energy AssessmentsWhat Others Can Do
Identify, quantify and report cost saving projects primarily related to energy.
Cost savings is key: some cost saving projects may not reduce energy consumption.
Pollution prevention benefit
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Energy AssessmentsTypes of Energy Assessments
Screening or walk-throughDetailed
Low-cost, no-costCapital-intensive measures
Formal, expect documentation
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Energy AssessmentsWhat Others Can Do
Preliminary activities before the formal assessment of your systemReview 12 months (or more) historical data
Utility billsEquipment logs
Review emissions data and attainment planReview capital expenditure planPerhaps a site screening visit
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Energy AssessmentsWhat Others Can Do
What can you expect from an initial utility consumption review?
ErrorsCorrect tariffOutstanding featuresGraphs of energy, demand and cost
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Detailed Assessment
Additional site visit(s)
Extensive data gathering, perhaps with dataloggers recording data for week or more
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Detailed Assessment
What should you expect?
Formal, technical report whose heart is projects recommended for implementation
To save moneyTo save energyTo decrease emissions
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Detailed Assessment
Project descriptionsIndividual, for each projectCalculations intelligible to your technical staffDetailed cost, energy, demand and emissions calculations
Beware the 10% disease
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Detailed Assessment
Implementation informationConceptual designSufficiently detailed for budget decisionsInformation about utility rebates if available
Financial analysis
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An Energy Analysis of Your System
What you can do to make your system cost less to operate
Take advantage of Best PracticesLook at subsystems as wholeImplement some obvious projects
What others (particularly consultants, but also vendors and utility reps) can do to help make your system cost less to operate
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Energy Analysis Resources
DOE ⌧http://www.oit.doe.gov/bestpractices/
• http:/www.oit.doe.gov/bestpractices/software_tools⌧http://www.oit.doe.gov/chemicals/bp⌧http://www.oit.doe.gov/petroleum/bp⌧http://oipea-www.rutgers.edu
• http://oipea-www.rutgers.edu/documents/doc_m
Texas A&M University IAC⌧http://www.mengr.tamu.edu/links/IAC/index.html⌧[email protected]⌧[email protected]
