Slide 1
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Energy / Facilities Connections 2011
May 12, 2011
Layne McWilliams
Water/Wastewater Sector Specialist
Energy Smart Industrial
Energy Saving Opportunities in
Water & Wastewater
Infrastructure
Slide 2
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Roadmap
• The ESI Program
– Why do conservation incentive programs exist?
– What’s in it for me and why should I care?
– Ok, now that I care, how do I proceed?
• Getting Started & Energy Audits
• Typical Savings Opportunities
– Hint: It’s not just VFD’s . . .
Slide 3
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Why does conservation matter?
• Water/Wastewater sourcing, treatment, distribution,
collection, conveyance, treatment, and disposal
accounts for about 3% of the nation’s energy
consumption.
• BPA capacity is becoming constrained, and
conservation is the lowest cost resource.
• ―Tiered‖ rate structures start FY2012– so local utilities
(BPA’s customers) want to keep their base allocation
open to keep rates low, attract new customers, and
allow for growth.
Slide 4
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Why should you care?
• Your electric rates are going to go up. (Have they ever gone down?)
• Electrical costs associated with pumping and treatment is often the
highest non-labor cost for a municipality– and one of the few costs
that can be reduced without impacting water quality.
• The lifetime costs of most equipment is incredibly dependent on its
efficiency.
• Systems are designed for 20 year predicted flows and built by low
bid project delivery methods.
– Chances are you’re running at less than best efficient point on much of
your equipment.
– Often that means equipment is working harder than it needs to.
• The SRF grants and loans have ―green‖ requirements now, and
energy projects qualify.
Slide 5
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
What’s in it for you?
• Depending on utility, up to 25 cents per kWh saved based on first year’s energy consumption.
– This is about $1600 per horsepower on a 24/7 basis.
• So, if we can take an aeration system pulling on average 45 hp down to 35 hp, there is a potential incentive of roughly $16,000 available.
– The incentive is capped at 70% of the project cost.
• Assistance from the program with identifying opportunities, handling paperwork and approvals, post-project M&V, and shepherding projects.
Slide 7
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
• Ongoing energy savings for life of the measure.
• Often reduced maintenance cost from turning off or
turning down equipment.
• Aesthetic and comfort improvements – e.g. better
lighting, better HVAC.
• Conservation: The gift that keeps on giving!
You’ll also get:
Slide 8
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
How do I get started?
• Do you buy electricity from a ―public‖ or an ―investor
owned‖ utility?
– If an IOU, call them and ask to talk with a conservation
specialist.
– If it’s a public utility, they are probably in the program, so ...
• Call or email me, and I can get the process started.
– 971-244-8581
• Or call your local utility representative and let them
know you are interested.
Slide 9
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
ESI Utilities Within WashingtonWASHINGTON (WEST)
Blaine, City of
Centralia City Light
Clallam County PUD
Clark Public Utilities
Cowlitz County PUD
Eatonville, Town of
Grays Harbor PUD
Klickitat PUD
Lakeview Light & Power
Lewis County PUD
Mason County PUD #1
Mason County PUD #3
McCleary, City of
Orcas Power & Light Cooperative
Pacific County PUD #2
Peninsula Light
Port Angeles, City of
Seattle City Light
Skamania County PUD #1
Snohomish County PUD
Sumas, City of
Tacoma Power
Tanner Electric Coop
Wahkiakum PUD
Whatcom County PUD #1
WASHINGTON (EAST)
Asotin County PUD
Benton PUD
Benton REA
Big Bend Electric Coop
City of Cheney Light & Public Works
City of Chewelah Electric Dept.
Columbia REA
Consolidated Irrigation District
Coulee Dam, Town of
Ellensburg, City of
Ferry County PUD #1
Franklin PUD
Grant County PUD
Inland Power & Light
Kittitas County PUD
Modern Electric Water Co.
Nespelem Valley Electric Cooperative
Okanogan Co PUD #1
Pend Oreille County PUD
Richland, City of
Vera Water & Power District
Slide 11
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Energy Management - Pilot
Energy Project
Manager (EPM)
Addresses
End User
Staffing
Track and Tune
(T&T)
Addresses
O&M
Savings
High
Performance
Energy Mngt.
(HPEM)
Addresses
Corporate
Management
And Culture
Trade Ally Driven
Small
Industrial
(SI)
Addresses
Small
Projects
NW Trade
Ally Network
(NW TAN)
Addresses
Lighting
Projects
Technical Service Proposal (TSP) ConsultantsProvides Technical Consulting
Energy Smart Industrial Partner (ESIP)Face of the program
Custom
Projects
Traditional
Capital
Projects
Energy Smart Industrial Program Components
Green
Motors
Initiative
Motor
Rewinds
Slide 12
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Custom Projects
• Pumps
• Fans
• Compressed Air
• Refrigeration
• Lighting
• Motors
• Variable Frequency Drives
• Control Upgrades
• Process Upgrades
- Incentives for traditional capital projects.
Slide 13
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
-Depending upon utility, but up to $0.25 per kWh saved
in first year.
-Capped at 70% of project cost
-You get the lesser of 25 cents / kWh OR 70% of
project cost.
-Project cost can include design fees, and can be
incremental cost between ―baseline‖ and ―efficient‖
equipment for new construction
-Paid based on Measured and Verified (M&V) savings.
-The payment comes after the project is complete,
so capital funds still needed upfront to cover the
project.
Slide 14
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Energy Management - Pilot
Energy Project
Manager (EPM)
Addresses
End User
Staffing
Track and Tune
(T&T)
Addresses
O&M
Savings
High
Performance
Energy Mngt.
(HPEM)
Addresses
Corporate
Management
And Culture
Trade Ally Driven
Small
Industrial
(SI)
Addresses
Small
Projects
NW Trade
Ally Network
(NW TAN)
Addresses
Lighting
Projects
Technical Service Proposal (TSP) ConsultantsProvides Technical Consulting
Energy Smart Industrial Partner (ESIP)Face of the program
Custom
Projects
Traditional
Capital
Projects
Energy Smart Industrial Program Components
Green
Motors
Initiative
Motor
Rewinds
Slide 15
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
What is Small Industrial?
• Addresses small industrial projects
– Independent of facility or sub-system size
• Utilizes simplified analysis tools
– Ex. Compressed Air ≤ 75 hp
– Additional tools in development (refrigeration, VFDs)
• Rapid review and approval process
• Leverages trade allies
• Treated as custom projects for incentives
• No M&V is required
– There will be spot checks to fine-tune process
Slide 16
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Energy Management - Pilot
Energy Project
Manager (EPM)
Addresses
End User
Staffing
Track and Tune
(T&T)
Addresses
O&M
Savings
High
Performance
Energy Mngt.
(HPEM)
Addresses
Corporate
Management
And Culture
Trade Ally Driven
Small
Industrial
(SI)
Addresses
Small
Projects
NW Trade
Ally Network
(NW TAN)
Addresses
Lighting
Projects
Technical Service Proposal (TSP) ConsultantsProvides Technical Consulting
Energy Smart Industrial Partner (ESIP)Face of the program
Custom
Projects
Traditional
Capital
Projects
Energy Smart Industrial Program Components
Green
Motors
Initiative
Motor
Rewinds
Slide 17
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
What is NW TAN?
• Existing TAN program currently provides high level
support to utilities and trade allies
• The goal of the KAMs is to increase the number and
magnitude of industrial lighting projects for BPA utility
customers
• Project specific support on industrial lighting projects
• Industrial lighting is often extremely low hanging fruit
with quick paybacks.
Slide 18
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Energy Management - Pilot
Energy Project
Manager (EPM)
Addresses
End User
Staffing
Track and Tune
(T&T)
Addresses
O&M
Savings
High
Performance
Energy Mngt.
(HPEM)
Addresses
Corporate
Management
And Culture
Trade Ally Driven
Small
Industrial
(SI)
Addresses
Small
Projects
NW Trade
Ally Network
(NW TAN)
Addresses
Lighting
Projects
Technical Service Proposal (TSP) ConsultantsProvides Technical Consulting
Energy Smart Industrial Partner (ESIP)Face of the program
Custom
Projects
Traditional
Capital
Projects
Energy Smart Industrial Program Components
Green
Motors
Initiative
Motor
Rewinds
Slide 19
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
What is the Green Motors Initiative?
• Participating utilities are offering incentives for rewinds identified by Green Motors Practices Group members as process compliant—Thereby retaining original nominal efficiency values
• Standard NEMA ratings from 15 hp - 5,000 hp with no core damages are eligible
• Incentive amount of $1.00 per hp per motor will be credited instantly on the rewind invoice
• Go to www.greenmotors.org for list of shops
• Saves up to 40% (or more) of the cost of buying new motors
• Recycles 98% of motor materials
Slide 21
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Where have I been?
• Do you know your local power and gas account rep?
• Your rep can provide a printout of historical usage and
associated charges.
– Is there a trend?
– Any ―step‖ changes – e.g. switching from chlorine disinfection
to UV . . .?
Slide 22
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Where have I been?
• Other issues associated with billing:
– Who reviews and pays your monthly power bill?
– What percentage of your operating costs goes towards
energy?
– How much am I paying for demand vs. consumption?
– Where am I using energy?
Slide 23
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Where have I been?
• Has your facility ever performed or received an energy
study or audit?
• Dust off those old energy studies.
– Similar or same equipment still in use? – Probably!
– Ideas that were good then are usually still good now.
Slide 24
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
• The Basics – Your Power Bill
– What rate are you paying?
– How is power measured?
– What is a ―demand charge‖ and how can I control it?
– What is ―power factor‖ and does it matter?
Where am I now?
Slide 27
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Billing Terminology
• kWh = kilowatt hour = 1000 W for 1 hour (or 45 hp for 1
minute!)
– 1 hp = 0.746 kW; 10 hp motor consumes 7.5 kW at full load
– That means a 15 kW unit heater is like a 20 hp motor
• Demand Charge
– The highest 15 - 30 minute average operating load during the
billing month
– Utilities have to have capacity to provide that amount of power,
so it helps pay for the infrastructure.
– ―In-rush current‖ at motor start does not typically impact demand
charge.
• Power Factor
– Think of pulling a rail car.
Slide 28
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Power Factor = Real Power / Apparent Power
- the closer this is to 1.0, the happier your utility will be . . .
Slide 31
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Where am I now?
• Benchmarks can be used for your ―Energy Dashboard‖
Slide 32
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
kWh
Peak kW x 24 x days in billing period X 100 Load Factor =
EPA
Portfolio
Manager
kWh / 1000
lbs. BOD
Removed
kWh /
Million
Gallons
Treated
Real Time
kW
Reading
Monthly kWh to date
Slide 34
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Where am I now? - Benchmarking
• Some lessons learned:
– Benchmarks are great for tracking your facility’s performance
over time. They are of limited value in comparing your facility to
another.
– You will need to include the energy you produce on-site as well
as the energy you buy to obtain a true picture of your facility’s
efficiency.
– Complicated benchmarks can be useful simply as a tool that
forces you to gather data in a regimented manner.
– Benchmarks are powerful marketing and communication tools.
– Be Consistent! They are only useful if they are developed using
the same methods during each reading.
Slide 35
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Where am I headed?
Audits can help you identify opportunities and focus
efforts.
Slide 36
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Where am I headed?
Types of audits:
– Plant-wide scoping
• Typically, a walk-through where an energy specialist will look for and
identify common inefficiencies – essentially help tag the low-hanging
fruit.
• Often available without charge from your power company.
– System audit
• Often performed by specialist, e.g. air compressor or pump vendor.
• Focused on one portion of the plant, and will usually involve data
logging or other power monitoring over a period of time.
– Comprehensive audit / tune-up
• Can include workshop / teaching opportunities
• Generally identifies several O&M opportunities as well as capital
projects
Slide 37
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
You don’t need to wait for an audit, and you
can often find truly great opportunities because
of your knowledge of the plant!
Slide 38
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Guidelines for finding conservation
opportunities
• Find loads that run continuously or nearly continuous
• Look at your electrical diagram and pick out big motors
• Look at equipment more than 10 years old
• Systems that are run on simple (or no) control
• Seasonal loading / permit changes
Slide 39
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
O&M Opportunities
• Four easy ideas for immediate O&M savings within your
facilities.
• Engage your O&M staff to help identify more
opportunities – e.g. scavenger hunts for inefficient
motors; awards & recognition for good ideas and
practices
Slide 40
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
O&M Opportunities
• #1: Reduce operating pressure and flow of plant wide
fluid and air systems.
– E.g. compressed air, reclaimed water, plant water systems
– On a +/- 100 psig air system, 2 psig reduction saves 1% in
energy costs
– Reclaimed water isn’t ―free‖!
– Lewiston, Idaho: Reduced plant water pressure from 106 psig
to around 60 psig, and performed an ―intentional analysis‖ of
where it was used.
– Will save about $6000 annually on power bill.
Slide 41
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
O&M Opportunities
• #2: Use your efficient equipment first and most often.
– ―Identical‖ equipment in a line-up isn’t identical in operation!
• Manufacturing tolerances
• Wear
• Installation differences
– You may have multiple resources available.
• Multiple wells
• Surface water vs. ground water
– Portland Water Bureau cut 6% from booster station
consumption.
Slide 42
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
O&M Opportunities
• #3: Optimize control set points.
– A 0.5 mg/L reduction in D.O. level represents 6 – 7% energy
savings
• 2.0 is nominal, many run lower than that.
• Running above 3 mg/L? Or 5? How about 8?!?!
– Lift station or other low-head pumps can benefit from small
adjustments in wet well level
• E.g.: RAS pump with 20 feet TDH at normal operating point
• Setting wet well ―pump on‖ elevation 6-inches higher reduces head
(and power requirements) by 2.5%
Slide 43
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
O&M Opportunities
• #4: Now that spring is finally here . . .
. . . SPRING CLEANING!– Sensors for temperature, dissolved oxygen, pH and water
chemistry, ambient and occupancy lighting sensors
– Filters on air, water, and hydraulic systems
– Diffusers, air knives, distribution nozzles – anyplace where the
flow is supposed to be ―distributed‖
– Large impact of small losses in low pressure systems
• Moving a 10 psig aeration system to 9.8 psig results in 1.8% energy
savings
Slide 44
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
A few capital project ideas to consider. . .
Slide 45
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Project ideas
• Main idea:
– Pumping power equation:
• BHP (water hp) = (GPM * TDH’) / (3960 * pump eff.)
• Electrical hp = water hp / motor efficiency
– Similar equations for fans and blowers
– Power can be reduced by:
• Reduce flow rate
• Operate at lower differential pressure
• Higher efficiency equipment
Slide 46
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Project ideas – cont.
• Match power (& flow) to load
– VFD’s in lieu of control valves
– VFD’s in lieu of dampers on odor control or foul air systems
– Install an additional, smaller pump in lieu of internal recycle
flows
• Use efficient equipment
– Swap out old motors rather than rebuilding
– If you are rewinding, utilize Green Motors program
– Check that your pump impellers are correct for actual conditions
– Use your most efficient equipment first and most often
Slide 47
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Project ideas – cont.
• Reduce line pressure or pump lift
– Upsize sewer force main or water main size.
– Question: Why does the system pressure need to be XX psig?
• Identify specific demand locations and address them separately
• Run a lower pressure normally, and bump it up only when needed
– Compressed air systems generally present excellent
opportunities
– Most process pumps are fairly low head, so 2 or 3 feet of
pressure difference can be a good percentage of total head.
Slide 48
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Project ideas – cont.
• A project doesn’t have to touch an electrical panel to be
an ―energy project‖
– Water conservation strategies
• Leak detection and repair programs
• Backwash / filter operational changes to reduce off-spec water
• Conservation rate structures(?)
– Wastewater reduction strategies
• Inflow / Infiltration reduction programs (?)
• Gray water reuse
• Industrial pretreatment (?)
Slide 49
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Project ideas – cont.
• Eliminating electrical consumption completely
– Replace lift station with gravity sewer
– Situate the treatment plant to take advantage of gravity
• Using control valves to control gravity flow is a great use of control
valves, since it doesn’t cost anything for the head you’re burning
– Possible to select groundwater source points to reduce or
eliminate pumping energy?
• Or – Use electricity instead of gravity
– Use VFD’s in lieu of reservoirs to avoid pumping up the hill and
then burning that hard earned elevation through a PRV.
Slide 50
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Nice ideas – but I want to know ………..
Does this stuff really work?
Slide 51
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
• 110 Refrigerated
Warehouses
• Building Tune Ups
• Energy Management
• Some Capital
Upgrades
• Some Efficient New
Construction
ESI Track and Tune Case Study – Sysco (first 44 months)
Total Distribution Center Energy Intensity
Jan
Feb Mar
Apr
May
Jun
Jul
Aug
Sep O
ctNov
Dec
kW
h/d
ay/1
000 f
t3
2005
2006
2007
2008
2009
Slide 52
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
ESI Track and Tune Case Study –
Example of Immediate Improvement at Single Site
Plantwide Impact of Commissioning: Before & After
400
500
600
700
800
900
1,000
1,100
1,200
10/05 10/10 10/15 10/20 10/25 10/30 11/04 11/09 11/14
Date
kW
Commissioning
Changes on 10/25
Slide 53
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Making Efficiency Part of Your Operating Strategy
DOES Work!
•Lighting Project
•Facility Tune
• Actual facility history from a Corporate Energy Management client
• 44% savings(Dec 10 vs. Dec 07)
• Lighting Project Oct 2008
• Almost 2 times the projected savings from facility tune-up so far
• Implemented NOcapital projects after tune up
Slide 54
B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Whether you think you can, or think
you can’t, you’re right.
-Henry Ford
Thanks!