5 _ PPT _ Facility Planning _ Electricity and Energy Management

8/8/2019 5 _ PPT _ Facility Planning _ Electricity and Energy Management

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Most states have strict rules about what types of foodservice equipment do (and do not)qualify for sales tax exemptions.


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IN T H E K IT CH EN

UND ERS TA NDING A ND ME A S U R ING ELEC T R IC IT Y


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The inner workings of (a) A fluorescent lamp and (b) A simple fluorescent lamp circuit.


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V OLTA G E COMB IN AT ION S A ND LO A D FA C T ORS

Electrical equipment manufacturers design appliances with combinations of voltage andphasethat is, the force with which the amperes are pushed through the line and thenumber of alternating volt-ages available. Voltage and phase specifics should be partof any new appliance's service information, and are found on the nameplate of theappliance. As you will see, the more wires there are, the greater options for differentlevels of maximum voltage.You need to be somewhat familiar with these options because so many largeappliances require dual voltage more than one type. Perhaps the controls or motors need 120 volts, at the same time a heavy-duty heating element requires 208or 240 volts. Therefore, you must be sure your building's wiring can handle thechallenges, whether it's a brand-new facility or a remodel or even just replacement of an old piece of equipment with a newer one. The voltage supplied to each electricaloutlet will directly affect the performance of the appliance plugged in there, so it mustbe correctly specified when ordering the equipment. The most common voltagecombinations are:

1. Single phase: 110-120 volts. This system includes two wires, one "hot" and one"neutral. To-gether, the maximum amount of voltage they can generate is 125 volts.

2. Single phase: 220-240 volts. In this two-wire system, both are hotwires. Themaximum voltage between them is 250 volts.


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3. Single phase: 110-120/220-240 volts. This three-wire system includes twohot wires and one neutral wire. Between either of the hotwires and theneutral wire, the maximum voltage is 125 volts, but between the two hotwires, the maximum is 250 volts.

4. Three phase: 110-120/208 volts. This four-wire system is made up of threehot wires and one neutral wire. The voltage between any single hot wire and

the neutral wire is 125 volts, but the voltage between any two hot wires andthe neutral one is 208 volts (single phase) and the voltage between all threehot wires without the neutral is 208 volts (three phase).

5. Three phase: 220-240 volts. All three wires in this system are hot. Thevoltage between any two of them is a maximum of 250 volts.

6. Three phase: 440-480 volts. This is a three-wire system in which the voltagebetween any two of the wires is a maximum of 480 volts.


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7 . Three phase: 11 0-120/220-240 volts. This is a four-wire system, three hot and oneneutral. The voltage between any one of the hot wires and the neutral wire is amaximum of 125 volts; the voltage between any two hot wires is a maximum of 250volts.

8. Three phase: 440-480/2 77 volts. Finally, this is a four-wire system, three hot and oneneu-tral. The maximum voltage between each hot wire individually and the neutral is277 volts; between any two hot wires, a maximum of 480 volts; and between all threehot wires, a 480-volt maximum.

Now, let's put all this terminology into perspective. Generally, as you havelearned, single-phase circuits are used for most small or light-dutyappliances, such as a two-slice toaster. Heavy-duty appli-ances with largepower and heating loads are usually wired at the factory for three-phase,three-wire electricity. They sometimes include smaller fuses and circuitbreakers for different functions within the appliance. A complete wiringdiagram must be supplied by the manufacturer and should always be keptwith the appliance's service records. Countertop cooking equipment usuallyrequires a two-wire, single-phase circuit. In short, the requirements will bevery specific.


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It is critical that the equipment voltage matches the service voltage of thebuilding. To determine your restaurant's electric service voltage, you can:

Call your electric utility provider and ask! (This is the surest and safestmethod.)

L ook at the electric meter. Most of them are labeled to indicate if the meter

itself is a Delta (120/240 volts) or a Wye (120-208 or 277

-408).Check the nameplates on your cooking equipment for the electrical ratings.

Ask an electrician to check the large electrical wall outlets with a voltagemeter.


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The other key piece of information you should learn is the restaurant's load factor.Expressed as a percentage, it is the amount of power consumed (in kilowatt-hours),divided by the worst-case (high-est) consumption over a stated period of time (number of hours). The formula is:

The business should have a target load factor. Then, by tracking the load factor weeklyor monthly, you can see how well the business is doingor how well it could bedoing. L uckily, with today's computer-based metering systems, this kind of analysis ispossible. It's easy to calculate a target load factor;

1. Take into account all the hours the business is open (not just the business hours, butthe after-hours times that employees are there). If a business site is being used 14out of 24 hours a day, the target load factor is 14 divided by 24, which equals 58.3%.If you're calculating the target load factor for a full month, divide the total number of hours you're open that month by the total number of hours in the month. (In a 30-daymonth, there are 7 20 hours.) A restaurant open 15 hours a day, 7 days a week isopen 450 hours a month. Divide 450 by 7 20 and you get a target load factor of 62.5%.


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2. Now you're ready to compute the actual load factor. You'll need these figures for themonth: The total amount of power consumption (in kilowatt-hours)The demand meter reading (in kilowatts)The number of hours you're open in a day (not the whole month, just one day)

L et's plug them into the formula and see what happens:

In the case of the restaurant open 15 hours daily, its actual power use is15.2 7 percent higher than its target load factor. In the case of the businessopen 14 hours, actual power use is 19.4 7 percent higher than the target. In

either case, some energy-saving measures are overdueTracking your load factors will allow you to create a load profile for

the businessthat is, an ac-curate snapshot of how much power you need,and what times of day you need the most. L ater in this chapter, when wediscuss deregulation of the electric industry you will see that having a load

profile is necessary to get the best price for the electricity you buy.


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T H E ELEC T R ICA L SER VI CE E N T R A N CE

If there's a power outage, fire, or malfunction, you'll want to know enough tocorrectly describe it in these terms:

1. Connection Point: The exact site at which the wires touch the building.

2. Electric Meter: Records the kilowatt-hour consumption of the building.

3. D emand Meter: Records the maximum demand for kilowatts.

4. Master Service Switc h : Controls the flow of energy to the building and willautomatically shut off as a safety precaution if there's an overload or excessive demand. It's usually located on the outside of the building, and itis locked.

5 . T ransformer: As its name suggests, it changes incoming alternating currentinto whatever volt-age is usable for a particular facility. Not all buildings have(or need) a transformer; most very large ones do


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6. Maim Circuit Panel: Also called a distribution panel, this is the equivalent of the fuse box in your home. Separate switches, with circuit breakers, directpower to different areas of the building or pieces of equipment. Each panel

also has a master fuse or circuit breaker that controls power to the entirepanel.

7. Secondary Circuit Panel: Local codes may require separate circuits, inseparate locations, for one particular appliance o\' function in the building.This provides a way to shut off the air conditioner, for instance, or all heavyequipment, without interfering with other power use. It's especially handywhen repairs have to be made.

8. G round Rod: One low-impedance connection to the earth, which serves asa conducting body to which an electric circuit can be connected. A "ground"

is necessary to operate electronic equipment.


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The electrical service entrance of a building.


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CO N S U MP T ION CH A RG ES

Now that you know something about reading meters and converting differentquantities of energy you're ready for the most daunting testreading the electric

bill!Most foodservice establishments aren't large enough to qualify for lower, industrialrates. Instead, they are billed on a "commercial" or "small general" rate schedule.They are rarely charged a single rate for every hour of electricity they use. A singlerate, or uniform c h arge , is more likely to be seen on a residential power bill.

Instead, for commercial customers, you'll probably find a step-rate or declining-blockschedule: that is, a graduated schedule of rates that decreases as consumptionincreases.

A time-of-day option allows you to be billed based on what time of day your business is open. More power is used during weekdays, so that's when rates arehighest. However, businesses that operate mostly at nights, on holidays, or weekends can qualify for lower, off-peak rates by choosing a time-of-day plan.Another type of commercial rate is the demand c h arge. Remember the demandmeter? The demand charge multiplies that readingthe average peak demandbya charge per kilowatt-hour. The demand! charges may also be a declining step rate,depending on how much power is used; and if your facility exceeds its normaldemand, there will also be an additional charge for consuming more than usual.


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The utility provider may also impose additional charges on customers with low power factors. Your power factor (PF) is the ratio between what the demand meter says (real

power) and what the utility company says is the total capacity available to you (apparentpower). Most foodservice businesses don't run the kinds and amounts of equipment thatwould result in a low-power-factor penalty. If it is a prob-lem, however, capacitors can beinstalled to bring your voltage and current levels into closer sync with each other,increasing your power factor and lowering your power bill.

Fuel adjustment c h arges (sometimes called energy cost adjustments) will show upon your bill, too. Because energy costs fluctuate constantly, utility companies innonderegulated states are authorized to pass on these fluctuations to their customers.Sometimes it's a chargeother times it's a credit!

Finally, don't forget late charges, which will inevitably be tacked on if you don't pay thebill on time.

See why you need to keep a very close eye on your power bills? In fact, now let'sexamine one, line by line.


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CH A RT ING A NNU A L U T ILIT Y COS T S

Cont

In addition to regular meter readings, there are two useful methods that foodserviceoperations can use to track energy consumption. You may find them especially useful inpreparing cost estimates to open a new facility. They are utility costs as a percentage of total sales and an energy index of Btus per meal served.


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Industrial Power Bill

BSCS Rajd h aniPower Bill


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Industrial Lig h t Bill

BSCS Rajd h aniLig h t Bill


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To develop an energy index, we must convert all the different types of energy used into asimilar form, so the figures can be added together. This is where the Btu comes inhandy. The abbreviation stands for British thermal unit, which is the amount of heatneeded to raise the temperature of 1 pound of water 1 degree Fahrenheit. Thismeasurement is useful because all energy sources can be easily converted to Btus.Here's how:

ELEC T R IC IT Y: Multiply kilowatt-hours by 3413.N AT U RA L G A S: Multiply cubic feet by 1000.O IL: Multiply gallons by 140,000.S T EA M: Multiply pounds by 1000.

You will need two more monthly totals:

Th e total amount you paid for utilities

Th e total number of customers you served


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Cont

Energy T racking W orks h eet - 1


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Energy T racking W orks h eet - 2


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Using these charts, Chez Ralph owners discovered they had spent the followingamounts on energy in April:

Electricity $513Gas 223Oil 85

Total $821

From their utility bills, they calculated they had used 323 million Btus of energy.From their daily customer tallies, they knew they had served 9,500 customers.How much did they spend per customer on energy? Nine cents.

A final note about electricity costs: Any experienced restaurateur will tell youthey're tough to track under the best conditions. Unusual weather and rateincreases are just two of the factors that make forecasting difficult. In our experience, it is still preferable to monitor and pay your own utility bills than toagree to include utilities in a lease agreement and let the landlord keep track of them. L eases that include utility payments leave little or no incentive for conservation, and leave the door wide open for rent increases based on "higher

utility costs" you have no way of confirming.


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EN ER GY CO N SER VAT ION

There are thousands of ways to conserve energy but most can be grouped into four simple categories:

Improve efficiency of equipment.

Reduce equipment operating time.

Recover otherwise "wasted" energy.

Use a cheaper energy source.

Cooking efficiency means maximizing the quantity of heat that is transferred from thecooking equipment into the cooked product rather than the surrounding environment.This keeps your energy bills lower, and also keeps your kitchen temperature more

comfortable for employees.

The primary causes of inefficient cooking are:

Preheating equipment too long

Keeping equipment turned on when it is not being used

i hi h h


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Using higher temperatures than necessary

Opening appliance doors frequently, letting heat escape

For equipment, energy efficiency is measured in ratios (by percentage), and can becalculated any of three ways:

1. Combustion efficiency refers to fuel-fired equipment that uses gas, oil, or propane toproduce heat. The key here is to control both the heat that is lost "up the flue" of theappliance, and the radiant heat released into the atmosphere. There's a formula for

this:

2. Heat transfer efficiency means the amount of heat that is transferred into the cookedproduct, compared to the total amount of available heat the appliance can produce.This percentage depends in part to the cooking process that is being used, thedesign of the equipment, and how efficiently it is being operated. Again, the formula:


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3. Overall energy efficiency is the ratio of heat that is transferred to the cooked productin comparison to the amount of energy purchased for that appliance. The formula:


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L ittle wonder that, in the typical 24-hour coffee shop, nearly 60 percent of the energythat is used flows through the kitchen. We realize it has become popular to sear food quickly or to prepare dishes in-dividually: From a power consumption

standpoint, however, you realize the most savings by:

1. Cooking in the largest possible volume at a time

2. Cooking at the lowest temperature that can still give satisfactory results

3. Carefully monitoring preheating and cooking temperatures4. Reducing peak loading or the amount of energy used during peak demand times

(usually between 10 A.M. and 8 P.M.)

5. Using appliances (ovens, dishwashers) at their full capacity

6. Venting dining room air into the kitchen to meet kitchen ventilation requirements

7 . Using a heat pump water heater, which heats water as it cools (or dehumidifies) thekitchen


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8. Using an evaporative cooling system

9. Recovering heat from equipmentrefrigerators, the HVAC system, even kitchenventsfor reuse

10.Increasing the hot-water storage tank size

11.Keeping equipment clean and serviced


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CO N S T RU CT ING A N EN ER GY -EFF IC IEN T BUI LDING

There are two major advantages to building a new structure instead of moving into anexisting one:

1. You are free to select the most energy-efficient systems and designs on the market(as long as you can pay for them.)

2. You can design the building itself to minimize its energy requirements, using daylightand other lighting techniques to minimize the need for heating and cooling.


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Before construction begins, look at your blue-prints and designs and check the followinglist of items. Are you saving as much energy as you could be?

1. Plenty of daylight, minimizing the use of electric lighting

2. L ots of light switches and/or dimmers, allowing for flexibility in turning off lights thatare not needed

3. The most efficient types of lamps and fixtures; energy-efficient ballasts for fluorescentlights

4. High-pressure sodium lights in parking areas

5. Efficient exit signage

6. Timers, computerized or photoelectric controls for indoor/outdoor lighting

7 . Occupancy sensors for storerooms

8. Glazing for windows to reduce incoming heat and increase daylight penetration

9. Use of sufficient insulation for roof and walls

10.Use of light colors, both inside and outside


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11. Positioning of building so that, if possible, trees or sloping land provide an insulating shield fromwind and weather

12. Awnings or overhangs to shield windows from direct sunlight

13. Use of "spectrally selective" window film that cuts incoming heat in hot-weather areas

14. Adjustable shades or blinds and, if appropriate in your climate, windows that open

15. Caulking and weather stripping around doors and windows

16. Double doors or revolving doors at entrances

17 . Energy-efficient hot-water system, with tank located near main point of use and insulated pipes

18. L ow-flow and dripless faucets

19. Efficient HVAC system, organized in zones so that only areas in use are heated or cooled, withprogrammable wall thermostats and adjustable vents

20. L ocking covers on wall thermostats

21. Heat pumps, where appropriate

22. Restroom exhaust fans wired to go on/off with lights

23. Installation of a computerized Energy Management System for optimum energy control


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IN S U LAT ION A ND A IR Q U A LIT Y

Small weatherizing detailssuch as caulking andweather stripping can saveenergy and money.


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PO W ER F A ILU RES

1. Record the time the outage began.

2. Take periodic temperature readings (every 30 to 45 minutes) of the food that was prepared and being held atthe time.

3. Keep all refrigerator and freezer doors closed as much as possible. (It's handy to have a thermometer thatmeasures its internal temperature on the outside of the unit.)

4. Cover any open display cases in which food is iced or chilled.

5. Used canned fuel (like Sterno ) to keep hot foods hot. If the temperature of hot food on a steam table, for instance, drops below 140 degrees Fahrenheit for more than two hours, it should be discarded. If the outagedoesn't last that long, and the food has dropped to a temperature of less than 140 degrees R, reheat it rapidlyto 165 degrees F, then hold it at 140 degrees F. and serve as quickly as possible.

6. Discontinue cooking and serving if it is not possible to wash, rinse, and sanitize utensils.

7 . Discontinue cooking if there is not sufficient light to allow for safe food preparation, including cleaning and

sanitizing food contact surfaces.

8. Don't cook if there is no hot water or not enough water pressure.

9. Don't assume that cooking cold food stored at room temperature for too long will kill any microorganisms andmake it safe to eat. That is not the case. The rule is always, "When it doubt, throw it out."


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PO W ER O U T LOOK FOR T H E F U T U RE


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PO W ER O U T LOOK FOR T H E F U T U RE

Th e Impact of D eregulation


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A lternative Energy Sources

BUI LDING A ND G RO UND S


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BUI LDING A ND G RO UND S


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CO G EN ER AT ION A ND H EAT RECO V ER Y

One of the most intriguing ways to save energy dollars is to recapture and reuse heatthat would otherwise be wasted. This is called heat recovery, heat reclamation, or

cogeneration (the latter because it uses the same power for two jobs). Waste heat canalso be recaptured from HVAC systems, refrigeration compressors, and computers, andthe idea is adaptable enough that:

H ot ex h aust air can h eat incoming cold air.

H ot ex h aust air can h eat water.

H ot refrigerant can h eat air or anot h er liquid.

H eat from a boiler can h e used to make steam or to h eatair or water

Reuse of D ining Room A ir for Kitc h en Ventilation.


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Reuse of ining Room ir for Kitc en entilation.

Since dining room air is already condition, it can be used to meet hood ventilationrequirements above the hot line. This reduces the amount of (naturally hotter)kitchen air that must be conditioned. Air can be transferred from the dining area to

the kitchen using a single-duct system or transfer grills. After use in the exhausthood, the heated air can even be used to preheat incoming makeup air! However,the cost of this method makes it feasible only in restaurants that use the largestamounts of hood ventilation air.

H eat Pump W ater H eaters

A heat pump is a mechanical device that moves heat from one area to another.

In all restaurant types, this was cited as an effective way to use less energy to heatwater. An additional benefit of heat pump water heaters is the cool air from theevaporator, which can be routed to spot-cool the hottest areas of the kitchen. Theheat pump contains an evaporator, a compressor, a con-denser, and an expansionvalve (see Illustration 5-12), much like the refrigeration systems you'll learn about in

Chapter 10. Instead of cooling, however, the heat pump recovers heat from an areaand uses it to heat water.

The location of a heat pump water heater is important. It should be in a spacewhere the ambient temperature is between 45 and 95 degrees Fahrenheit to workat its best. If operating properly, and if its air intake filters are kept clean, this handyappliance is capable of producing 30 to 7 0 percent of the hot water needs of anaverage restaurant.


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Recovery of Refrigerator H eat .

Hot air released by refrigerators and walk-ins can be used to heat water.

However, because refrigerators and walk-ins run twenty-four hours a day, storage isnecessary to retain the heat during the hours when there's no demand for hot water.This is possible with a two-tank system that consists of a preheating tank that keepswater warm using air from the refrigerator, then! feeds it into a conventional water heater tank, which doesn't use as much energy because it doesnt have to work as hard. A sidebenefit of this system is that in warm months, the building's HVAC system) doesn't have

to work so hard to cool the space, either. The heat is being captured and used for Other purposes.

HV A C H eat Recovery ,

When the restaurant is being cooled (air-conditioned), the heat from the coolingprocess can be captured to heat water elsewhere in the building. Typically, more heat isgenerated than needed, so correctly sizing the storage tank is critical to the success of this method. This method also uses a two-tank system like the one mentionedpreviously.


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The inner workings of a heat pump water heating system

5 _ PPT _ Facility Planning _ Electricity and Energy Management

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