total energy and sustainability management

Presented by: Mike Bailey PEDirector of Engineering

LESSONS LEARNED: WHY DATA IS NOT ALWAYS ENOUGH

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First Case Study

• Oregon based co-op food processor with two plants

• Utility provided 15-minute electric data

• Multiple products with mix of equipment and processes

• Digital process controls with in plant control technicians

• Full year operation (little seasonality)

• Full year, stable workforce

• Capital available for projects

Case Study #1

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Plant A Energy Use

• Energy Sources• Electricity• Steam (from utility co-gen

plant)• Natural Gas

• Production and Energy Use• Electricity and Steam

• Seasonal Energy Use• Natural Gas

Jan-03

Jul-03Jan

-04Jul-0

4Jan

-05Jul-0

5Jan

-06Jul-0

6Jan

-07Jul-0

7Jan

-08Jul-0

8Jan

-09Jul-0

9Jan

-10Jul-1

0 $-

$20,000

$40,000

$60,000

$80,000

$100,000

$120,000

$140,000

$160,000

$180,000

$200,000

Electricity kWh by Service Point Steam Purchases ($)

Natural Gas Purchases ($)

Case Study #1

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Plant B Energy Use

• Energy Sources• Electricity• Diesel

• Production and Energy Use• Operational Changes

• Switched from diesel to electric boiler in mid-2009

• Electricity Energy Intensity• ~3 times greater than

Plant A per Vat• Production Cost

• ~4 times the production cost of Plant A per Vat

$-

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000

$400,000

$450,000

$500,000

Electricity Diesel

Case Study #1

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Rebates and Incentives (at time of study)

• BPA Energy Smart Industrial (ESI) Program• Incentive Programs and Pilot Programs

• Custom Projects• $0.25/kWh up to 70% of project cost

• Energy Project Manager (EPM)• Potential incentive for Plant A is $100,000 • Potential incentive for Plant B is $270,000

• Track & Tune (T&T)• High Performance Energy Manager (HPEM)• Northwest Lighting Trade Ally Network (TAN)• Green Motors Initiative

• Business Energy Tax Credit (BETC)• Option 1: Credit taken directly by co-op

• Up to 35% of project costs (before utility incentives) over a five year period

• Option 2: “Pass-through” to a third party• Up to 25.5% of project costs (30.5% for smaller projects)

Case Study #1

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Example Energy Measures• EEM 1: Lighting

• Estimated simple payback: Immediate

• EEM 2: Refrigeration• Estimated simple payback: 2.2 years

• EEM 3: Compressed Air System• Estimated simple payback: Immediate

Case Study #1

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Example Energy Measures

• EEM 4: Heated Regenerative Dryers• Estimated simple payback: Immediate

• EEM 5: Waste Water Treatment Blower Replacement

• Estimated simple payback: 2.8 years

• EEM 6: Heat Recovery• Estimated simple payback: 2.4 years

• EEM 7: Motor Efficiency• Estimated simple payback: Immediate

• EEM 8: Boilers• Estimated simple payback: 0.6 years

Case Study #1

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Results

• Very little progress on facility equipment or process optimization – staff focused on capital expansion projects

• Lack of upper management attention to utility costs

• No owner for utility energy data or utility cost management

• Did not use real time utility data - did not allocate energy use between process and products

• Implemented some measures such as lighting but did not proceed with energy manager position (funded by BPA)

Case Study #1

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Second Case Study

• NW based co-op food processor with multiple plants

• Utility provided 15-minute electric data

• Multiple products with mix of equipment and processes

• Manual and electric controls – no centralized process control

• No in-plant controls staff

• Seasonal products

• Seasonal work-force with moderate turn-over

• Little capital available for projects

Case Study #2

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Many Different CropsCase Study #2

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Seasonal Utility UseCase Study #2

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Poor Understanding of Energy Drivers

• Refrigeration Issue Example• Staging condensing tower fans and pumps

(200 hp total) based on compressor discharge pressure (3,000 hp total)

• Boiler Issue Example• 400 BHP 1980’s Boiler used three

months per year• 600 BHP late 1990’s Boiler used four

months per year• 3 year old audit study recommending

controls upgrades and stack heat recovery – unfunded due to 5 year pay-back

Case Study #2

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Identified Utility Cost Drivers

$326,000 , 32%

$409,820 , 41%

$94,993 , 9%

$84,054 , 8%

$103,000 , 10%

Boiler

Refrigeration

Line Motors

Baseload Elec.

Water Use

Boiler and Refrigeration systems drive 73% of total Utility cost

Combined electrical is 58% of total Utility cost

BOILER

REFRIGERATION

Boiler value does not include cost of make up water - only natural gas costs

Case Study #2

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Estimated Utility Cost by Product

Total Utility Cost 2007

$93,064.55 , 9%

$27,479.98 , 3%

$167,201.89 , 17%

$700,034.29 , 71%

Baseload

Asparagus

Peas & Sugar Snaps

All Carrot & Lima Beans

“Carrots Don’t Care”

Case Study #2

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Now for the data…

• Plant Energy Manager Team established

• Utility real time data owner assigned

• Worked with utility to understand tool, work out communication issues

• Serve as resource for internal staff to understand data

• Each process owner responsible for managing energy drivers

• Process owners worked with utility data owner to “break

apart utility use”

• Team created control charts real time data flagged issues

and trends

• Regular summary reporting to plant management

Case Study #2

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Boiler Recommendations

• Only use one Boiler• Eliminate “Hot standby” spare• Manage production volume during carrots to avoid needed to operate

two boilers

• Add Stack Economizer – Boiler Feed-Water pre-heater to one boiler• Payback less than 1 year – if boiler used full season

• Add boiler combustion controls• Manage blanchers to reduce boiler demand

RESULT: Capital approved to fund ONE boiler upgrade

Case Study #2

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Refrigeration Recommendations

• Do NOT stage condenser tower fans & pumps – run as much as possible to reduce condenser pressure

• 200HP total for condenser towers• >3000HP total compressor capacity

• Stage Compressor controls• Always have smallest compressor as Trim• Large compressors should be fully loaded if

on

• Install VFD on ONE compressor and dedicate that to Trim

• Track Compressor Log to incremental electrical meter data

Booster Compressors

Compressor Size Load Stage1 2 3 4 5 6 7

     #2 250 hp T T T T T T T#4 250 hp X X X#6 300 hp X X X#8 350 hp       X X X XT = Trim Compressor, X = compressor operating at full load

High Stage Compressors (no VFD)

Compressor Size Load Stage1 2 3 4 5 7 8 9

     #10 250 hp T T T T T T T T#3 350 hp X X X X#5 400 hp X X#7 400 hp X X X#9 500 hp       X X X X XT = Trim Compressor, X = compressor operating at full load

High Stage Compressors (with VFD)

Compressor Size Load Stage1 2 3 4 5 7 8 9 10 11

     #10 250 hp X X X X#3 350 hp X X X

#5 (VFD) 400 hp T T T T T T T T T T#7 400 hp X X X X#9 500 hp         X X X X X XT = Trim Compressor, X = compressor operating at full load

Case Study #2

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Lessons Learned

Why was #2 Successful but #1 was not?

• Upper management Serious about managing utility costs

• “Seek First to Understand” what drive energy use

• Data is not helpful if it is not converted to information

• Begins and ends with people!

• Once system and drivers are known, data used to manage

• Data without systems knowledge is useless

• Decisions makers must be will to ACT on the data –

PARTICULARLY when it contradicts old assumptions

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Data Is Necessary But Not Sufficient…

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Thank you!

Mike Bailey PE mbailey@ecova.com