TURI Conference Cheryl Eakle - TURI - TURI · KPPC is a state-mandated technical service center and...
Transcript of TURI Conference Cheryl Eakle - TURI - TURI · KPPC is a state-mandated technical service center and...
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TURI Conference
November 2016
• Cheryl Eakle Senior Engineer
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KPPC is a state-mandated technical service center and Kentucky’s primary resource to help businesses, industries and other organizations develop environmentally sustainable, cost-saving solutions for improved efficiency. KPPC is based at the University of Louisville J.B. Speed School of Engineering, and provides technical information and assistance that is free, confidential and non-regulatory.
Who is KPPC – Kentucky Pollution Prevention Center
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• Utility Bills – Analysis & Energy Balance – Training
• Energy Savings Opportunities –Recommendations –Awareness
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Assessments and Training
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Understanding Utility Bills
November 2016
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• Overview (why bother)
• Natural Gas – Utility – 3rd Party Purchasing
• Electricity – Rates & Types of Charges – Example Bills
• Questions (any time)
Understanding Energy Bills
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• Who pays the bills? • Can’t manage it if you don’t measure it!
• Develop an energy management program
– Up-to-date records of cost and use – A separate record for each type of energy (i.e. natural gas, electric, propane, etc.)
Why You Should Understand Your Energy Bills
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Natural Gas
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• Energy Units – Natural Gas Service – CCF – One hundred cubic feet – MCF – One thousand cubic feet – MMBtu – million British thermal units (10 ccf per MMBtu) – Dth – dekatherm (~10 ccf = 1 dth)
• Purchasing Options – Third Party Purchasing – Utility Service
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Natural Gas Purchasing
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• Agreement with NG wholesaler • Units are typically MMBtu or Dth • Price determined by market • Forecast use
- Underestimate → buy additional NG at market price - Overestimate → Vendor buys back gas (usually at
lower price) • May need to pay transport fee to local NG utility
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Natural Gas Third Party
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• NG Charges typically have two metered components: - Supply/Purchase Adjustment – The cost to purchase
natural gas from wholesalers - Distribution/Transportation – The cost to deliver
natural gas to the customer • Miscellaneous fees and taxes • Typically in CCF or MCF
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Natural Gas Utility Service
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Natural Gas Questions?
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Electricity
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Utility companies classify electric service according to rate types
• Residential • Commercial
− General Service − Power Service − Time-of-Day
• Industrial − Power Service − Time-of-Day
Billing and Rate Structure--Tariff
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• kW = unit used to measure
electrical demand (power)
• kWh = unit used to measure electrical energy (use) 1 kWh = 1,000 Watts of power used for 1 hour
Energy Units – Electric Service-
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• Customer Charge • Distribution Charge (delivery to facility)
– On Peak (kWh) – Off Peak (kWh)
• Transition Charge
• Transmission Charge (generator to
distributor)
Distribution Electric Service Charges
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Other Electric Service Charges
• Energy Efficiency Charge
• Renewable Energy Charge
• Distribution Demand Charge
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Energy Units – Electricity Analogy
Electrical Charges typically have two metered components:
Demand (Power)
Consumption (Energy)
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• Demand is measured in 15-minute increments
• Demand charge will be the peak demand for billing period
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Demand Measurement
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National Grid Bill—Page 1
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National Grid Bill—Page 2
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Highest demand in kW during the peak period OR 90% of the highest demand in kVA during the
peak period
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National Grid Demand Charges
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Electricity Questions?
Understanding Energy Bills
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Major Energy Saving Opportunities
November 2016
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• Implement an Energy Management Program and Energy Team (1-3%)
• Lighting Upgrades
• Compressed Air
Major Opportunities
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No Cost Incidental activities No purchase required Minimal labor Low Cost Purchases within existing O&M budget Some dedicated labor needed Capital Cost Sometimes it takes money to make money
Implementation Considerations
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• Institute a written energy policy
• Form an Energy Team − Plant Manager − Production Supervisor/Operations Manager − Hourly Personnel − EHS Representative − Accounting Representative − Utility Representative
Implement and Energy Management Program
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7-Step Process for E2 Management Program MANAGEMENT TECHNICAL
SET GOALS
ACTION PLAN
IMPLEMENT PLAN
EVALUATE PROGRESS
MONITOR & MEASURE
DEVELOP BASELINE
for Energy Use & Costs
E2 OPPORTUNITY ASSESSMENTS RECOGNIZE
ACHIEVEMENTS
COMMITMENT TO CONTINUAL
IMPROVEMENT
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• Top Management Support
• Empowerment
• Baseline and Measurement
Keys to a Successful Energy Team
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Lighting Upgrades
Courtesy of Cox Interiors Campbellsville, KY
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Metal Halide
LED
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≥ 50% energy savings 10-20% increased light levels Increased life expectancy, reduced maintenance Reduced HVAC costs Most are dimmable
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LED Lighting
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Replace incandescent and CFL lighting with LEDs
Replace or convert exit signs to LED
Other Lighting Opportunities
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Metal Halide vs LED
Metal Halide LED Fixtures 40 40 Fixture Power 458 Watt 120 Watt Total Power 18.32 kW 4.8 kW Annual Energy Use 109,800 kWh 28,800 kWh
Cost @ $0.10/kWh $12,078 $3,168 Annual Savings $8,900 Payback on $245/fixture ($9800)
1.09 Years
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81,000 kWh saved results in 248 metric tons of CO2 reduced
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T-8 Fluorescent vs LED
T8 LED Fixtures 100 100 Fixture Power 86 Watt 40 Watt Total Power 8.6 kW 4.0 kW Annual Energy Use 51,600kWh 24,000 kWh
Cost @ $0.10/kWh $5,676 $2,640 Annual Savings/shift $3,036 Payback on $20/lamp Installation
8 months
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9,200 kWh saved results in 84 metric ton of CO2 reduced
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• Other requirements for rebates • Look for guarantee
• Bypass ballast vs “plug-n-play”
• $$-requires some shopping
LED Considerations
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Other Lighting Opportunities—Occupancy Sensors
Type of Room Energy Savings
Private Office 13-50%
Open-plan Office 20-28%
Classroom 40-46%
Conference Room 22-65%
Restroom 30-90%
Corridors 30-80%
Storage Area 45-80% US DOE
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Kentucky’s Resource Center for Environmental Sustainability
Lighting Questions?
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It’s not free! 4th Utility (electric, natural gas, water, air)
Often the most expensive
Compressed Air
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Compressed Air Work vs Electric Work
• Compressed air: not the most efficient source
of energy in your plant
• To operate 1 hp air motor, you need 7-8
horsepower of electrical power into the compressor
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Annual Energy cost for 1 hp air motor vs 1 hp electric motor at $0.07/kWh
5 days/week 2 shifts/day
Compressed Air Work vs Electrical Work
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Where does the compressed air go?
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Compressed Air Leaks
• Pipe joints/valves/fittings • Point-of-Use devices • Hoses & couplings • Quick disconnects • Condensate drains • Regulators • Tubing
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Compressed Air Leak Rates
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Compressed Air Leak Costs ($0.07/kWh)
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At $0.07/kWh and 110 psi • Too small to be heard or felt $140
• Too small to hear $560
• Audible leak $980
Annual Cost of Air Leaks
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• Audible (large leaks) • Liquid Solution
Finding Compressed Air Leaks
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• Implement a PM system – Log/track leaks and repairs – Inspect hoses/tools
• Reduce leak rate to ≤ 10% • Use zero-loss drains
Managing Air Leaks
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Inappropriate Use of Compressed Air
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What is the worst “offender” for an inappropriate use of compressed air?
Inappropriate Use of Compressed Air
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Inappropriate Use of Compressed Air
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Alternatives to Compressed Air
Compressed Air Use Alternative Clean-up, Drying, Process Cooling
Low Pressure Blowers, Electric Fans, Brooms
Sparging Low/Medium Pressure Blowers Aspirating, Atomizing
Padding Transferring Material Pumps Vacuum Generation Vacuum Pump
Air-Operated Diaphragm Pumps Electric Pumps
Idle Equipment Positive Shut-off Valve Abandoned Equipment Disconnect Air Supply
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Excessive System Pressure
Reduction of set point by 2 psig reduces electric consumption 1%
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Reduction of set point from 100 psi to 90 psi 10 psi reduction in set point = 5% reduction in
energy consumption Use 43,200 kWh/year less electricity and save
$3,024
Excessive System Pressure
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• Reduce leak rate to 10% • Eliminate inappropriate use • Reduce pressure set point
– For high pressure user--booster or dedicated compressor
– For high volume intermittent user—additional storage
Summary
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• DOE Webinars/Training – www.doe.gov – http://www.compressedairchallenge.org/ – http://kppc.org/resource-library/kppc-video-
channel/
• AEE (Association of Energy Engineers) – www.aeecenter.org
Compressed Air Resources & Training
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Compressed air questions?
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Energy Savings Opportunities
November 2016
• Cheryl Eakle, CEM Senior Engineer
• [email protected] • 502-852-3485
• www.kppc.org