Tip Sheet Developed by The Bloom Centre for Sustainability (BLOOM) and Marbek Resource Consultants Ltd. With support provided by the Government of Ontario

www.bloomcentre.com www.marbek.caJuly 2012

Energy Saving Tip

An upgraded boiler maintenance and monitoring program, including optimizing the air-to-fuel ratio, burner maintenance, boiler tune up, and tube cleaning. Periodic measurement of �ue gas oxygen, carbon monoxide, opacity and temperature provides the fundamental data required for a boiler tune-up.

Monitoring and tracking energy use provides the necessary information to develop energy reduction targets and enable informed energy management. Energy management and setting targets lead to continuous improvement in energy e�ciency.

Smart defrost controls that use sensors so that defrost is initiated only when necessary and terminated just when the �n block is clear of ice, are more e�cient than timed defrosting, as they adjust to the varying levels of ice build-up that normally occur.

Regular compressed air leak survey to identify air leaks. Repairing air leaks result in reduced energy waste.

Since pumps are often conservatively designed, the impellers are larger than they need to be, and require more power than if they were properly sized. Impeller trimming o�ers the opportunity to customize the size without having to buy expensive parts. This is an appropriate measure for pumps that; have many open system bypass valves indicating that excess �ow is available; need excessive throttling for �ow control; have high levels of noise or vibrating; or are operating far from their design points.

High-intensity discharge (HID) lighting, such as the metal halide lamp, is the most widely used lighting type in industrial facilities. Recent advances in the development of high-bay T5 high-output �uorescent lighting indicate that replacing HID lighting with T5 high-output lighting is a promising e�ciency measure.  Other bene�ts of T5 high-output lighting over HID lighting are better colour rendering and longer lamp life. E�cient options include high output T5 or pulse-start metal halide �xtures instead of

Premium E�ciency ASD Compressors come with built-in adjustable speed drive (ASD) control that allows the compressor output to match the plant air demand. These compressors may save as much as 40% over standard compressors which typically use modulated control.

Process control systems use information gathered from processes, to adapt the process conditions to be utilized to the maximum potential of the whole system. Applications of advanced, automated control and energy management systems are applicable to all industrial sectors.

Ventilation optimization ensures ventilation is adequate for the application and minimizes the amount of natural gas required to heat make-up air. Optimized ventilation generally includes any of the following elements: minimize make-up air and exhaust �ow rates to necessary �ow rates; balance make up and exhaust �ow rates to minimize negative or positive air pressure in the working space, including redesign and/or control measures; optimal distribution of air, and interlocking air supply with process to operate only when required.

Cooler air requires less energy to compress it than warmer air. Outdoor air typically is cooler than the air in the compressor room. There is potential for energy savings when the air compressor uses this cooler outdoor air at the compressor intake thereby increasing e�ciency.

Heat loss through convection and radiation can cause signi�cant reduction in process heating e�ciency. Insulation of equipment and pipes increases the amount of energy available for end uses by decreasing the amount of heat lost from the system.

Steam traps are important to the performance of both end-use equipment and the distribution system. Traps provide for condensate removal with little or no steam loss. If the traps do not function properly, excess steam will �ow through the end-use device or the condensate will back up into it. Excess steam loss will lead to costly operation while condensate backup will promote poor performance and may lead to water hammer. Traps can also remove non-condensable gases that reduce heat exchanger e�ectiveness. Regular steam trap surveys are an important measure to identify faulty steam traps and steam leaks. Repairing the steam leaks and faulty steam traps will minimize steam losses and improve

Exhaust gas heat recovery increases e�ciency because it extracts energy from the exhaust gases and recycles it back to the process. For lower and medium temperature applications, heat recovery from �ue gas can be used to preheat make-up air, feed product or ventilation make-up air. Heat wheels are used at a number of facilities to recover the heat. The actual energy savings and costs depend on the heat wheel implemented. For high-temperature applications there are mainly four widely used methods: direct heat recovery to the product; using a recuperator to transfer heat from outgoing exhaust gas to incoming combustion air; using a regenerator to store thermal energy for future use; and using a waste heat boiler. For boilers, economizers are used to recover �ue gas heat and preheat make-up air.

TypicalEnergy Savings

2 - 5% ofboiler energy use

5 - 20% of total plant energy use

Up to 15% of cooler energy use

Up to 15% of compressed air energy

use

Up to 25% of motive power energy use

Up to 20% oflighting

energy use

15 - 40% of compressorenergy use

8 - 30% ofenergy use

Up to 20% ofventilationenergy use

1 - 5% of compressor energy use

Up to 5% of process heating energy use

4 % ofsteam system

energy use

Up to 15% ofheating

energy use

Relative Capital Cost

None - Low

Low

Low

Low

Low

Medium

Medium

High

Medium

Low

Low - Medium

Medium

High

Typical Simple Payback Period

4 - 6 months

4 - 10 months

< 3 months

4 - 6 months

6 - 8 months

1 - 4 years

3.5 - 6.5 years

1 - 2 years

1 - 2.5 years

6 - 15 months

8 - 10 months

1.5 - 3.5 years

2.5 - 4 years

EnergyEnd Use

Boilers

Total PlantEnergy

Chillers and Compressors

Compressed Air

Motors - Pumps

Lighting

Compressed Air

Process Control

Heating, Ventilation and

Air Conditioning

Compressed Air

Process Heating

Steam Systems

Boilers and Direct Fired Process Heating (Incl. Ovens, Dryers,

Kilns and Furnaces)

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ENERGY SAVING TIPS FOR THE INDUSTRIAL

SECTOR

Energy Saving TipTypicalEnergy Savings

Relative Capital

Cost

Typical Simple

Payback Period

EnergyEnd Use

Install low-�ow �xtures. Replace standard showerheads with low-�ow models, add low-�ow faucet aerators and use ultra low-�ow pre-rinse spray valves in food service applications.

25 - 75% of water heating energy use per �xture

Low 3 - 5 months

Water Heating

Lighting is typically the second largest energy use in commercial buildings in Ontario, and is typically responsible for 30-50% of building electricity use. Replace the incandescent lamps with compact �uorescent lamps in "architectural" applications such as displays, task lighting, signage, lobbies, corridors, utility spaces, hotel rooms and retail spaces. Other e�cient options for architectural lighting include white LEDs, ceramic metal halide lamps and

Up to 75% lighting energy use

Low 6 - 12 months

Lighting

Space heating is typically the largest energy use in commercial buildings in Ontario. Air sealing can help reduce heat loss from your building. Blocking air leaks brings many non-energy bene�ts such as increased comfort, protection of the building structure and reduction of noise and dust from outdoors. Air sealing typically involves the systematic e�ort of applying insulating foam, caulking and weather stripping to improve the integrity of the building envelope system, and involves identifying and sealing air leakage paths within the building envelope. In addition to easily identi�able leaks through and around doors and windows and mechanical penetrations, air may leak at the wall/roof interface, plumbing stacks and elevator shafts that can channel air directly from the ground

Variable. 5% of space heating energy is typical.

Low 1 - 3 yearsSpace Heating

Install programmable thermostats in place of standard thermostats to control packaged heating, ventilation and air conditioning (HVAC) equipment. Programmable thermostats provide improved control, scheduling and setpoint reset capability.

Up to 10% of HVAC energy use

Low 1 - 3 yearsHVAC

Recommissioning is a process which applies building commissioning procedures to an existing building in operation. This process ensures that the previously commissioned systems are still maintained and operated in accordance with the original design intent. It is also an opportunity to optimize operations beyond the intent of the original designers using the experience of operating the building as a guide. The vast majority of commercial buildings can bene�t from recommissioning.

Variable. 15% of building energy use is typical.

Medium 4 - 12 months

All

Institutional buildings which produce steam to satisfy space heating or process loads can typically realize signi�cant energy savings through steam plant e�ciency measures. Steam plant e�ciency measures generally include combustion e�ciency improvements, heat recovery, steam distribution and condensate return improvements, and equipment operations and maintenance improvements.

Up to 15% of space heating energy

Medium 1 - 3 yearsSpace Heating

If your organization runs several servers, consider server virtualization. Virtualization is a process of installing software which allows a server to run multiple operating systems or instances of the same operating system concurrently. This allows single machines to perform multiple concurrent operations, resulting in a reduced number of servers required for operations. If virtualization is not appropriate, consider purchasing ENERGY Star servers (and personal computers).

Up to 50% of server energy use

Low Less than 1 year

Computers

Choose high e�ciency high bay lighting in applications such as warehouses, "big box" retail stores and gymnasiums. E�cient options include high output T5 or pulse-start metal halide �xtures instead of standard metal

Up to 20% of lighting energy use

Medium 1 - 4 yearsLighting

When replacing �uorescent lighting systems, choose high-performance T8 lighting instead of standard T8 lighting. High performance T8s operate with an e�cacy of up to 100 lumens per Watt and have a longer lamp life than standard T8 systems. If your building still uses T12 �uorescent lighting, it is generally economically attractive to replace these �xtures with high-performance T8 �xtures immediately.1

Up to 35% lighting energy over T12 �uorescent

lighting, up to 15% over T8 �uorescent lighting.

Medium 2 - 5 yearsLighting

Much of the energy used to provide space heating is used to heat up outdoor ventilation air. Demand controlled ventilation systems use CO2 sensors to supply outdoor air (OA) based on the actual building occupancy, while preserving indoor air quality. Energy is saved because lower volumes of OA are introduced during periods of low occupancy. In practice, volumes of OA can often be reduced by as much as 50% in buildings with variable occupancy patterns.

Dependent on ventilation levels. Typical savings are 25%

of ventilation energy, or 8 - 20% of total space heating

energy.

Medium 2 - 4 yearsSpace Heating

Install air-to-air heat recovery equipment to reduce the amount of heat being exhausted from your building. Energy recovery ventilators (ERVs) and heat recovery ventilators (HRVs) are air-to-air heat exchangers used to recover the energy contained in air exhausted from buildings. The co-bene�ts of air-to-air heat recovery include improved indoor air quality and reduced total HVAC equipment capacity.

Dependent on ventilation levels. Typical savings are 50% of ventilation energy, or 15 - 40% of total space heating

energy.

Medium 4 - 6 yearsSpace Heating

The fans and pumps that move heated or cooled air or water to condition spaces use a signi�cant portion of a building's energy. In most commercial buildings, HVAC fans and pumps are the second largest users of electricity after lighting. Adjustable speed drives (ASDs) allow motor-driven loads such as fans and pumps to operate in response to varying load requirements, instead of simply operating in "on/o�" mode. ASDs increase e�ciency and

Up to 35% of energy used by HVAC fans and pumps

Medium 2 - 4 yearsHVAC

Choose high-e�ciency gas rooftop units. In heating mode, high e�ciency rooftop units employ high-e�ciency heat exchangers and modulating burners and maintain steady state e�ciencies by avoiding “on-o�” cycling. They operate their heating sections continuously and modulate the heating output to match heating requirements. In cooling mode, high e�ciency rooftop units can achieve a cooling energy e�ciency ratio (EER) of up to 12.8, compared with a standard EER of 10.2.

Up to 20% of space cooling and 10% of space heating

energy

High 2 - 5 yearsHVAC

Space Cooling is a major energy use, and can contribute to summertime peak loads. High-e�ciency chillers feature oil-free centrifugal compressors, magnetic bearings and variable speed drives to deliver cooling more e�ciently than conventional chillers.

Up to 30% of space cooling energy

High 7 - 10 yearsSpace Cooling

When replacing boilers, choose condensing boilers. Condensing gas boilers feature additional advanced heat exchanger designs and materials that extract more heat from the �ue gases before they are exhausted. The temperature of the �ue gases is reduced to the point where the water vapour produced during combustion condenses back into liquid form, which releases its latent heat and improves energy e�ciency and represents a signi�cant energy-savings potential.

Up to 14% of space heating energy

High 3 - 6 yearsSpace Heating

1 Note that waste heat from lighting �xtures has the "interactive e�ect" of supplementing space heating and adding to cooling load. Installing more e�cient lighting �xtures will increase space heating requirements and reduce space cooling requirements. Low-end payback estimates do not take these interactive e�ects into account, while high-end estimates do take interactive e�ects into account.

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ENERGY SAVING TIPS FOR THE

COMMERCIAL & INSTITUTIONAL

SECTORS