TURI Conference
November 2016
• Cheryl Eakle Senior Engineer
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
• Utility Bills – Analysis & Energy Balance – Training
• Energy Savings Opportunities –Recommendations –Awareness
3
Assessments and Training
Understanding Utility Bills
November 2016
• Overview (why bother)
• Natural Gas – Utility – 3rd Party Purchasing
• Electricity – Rates & Types of Charges – Example Bills
• Questions (any time)
Understanding Energy Bills
5
• 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
6
7
Natural Gas
• 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
8
Natural Gas Purchasing
• 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
9
Natural Gas Third Party
• 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
10
Natural Gas Utility Service
Natural Gas Questions?
11
12
Electricity
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
13
• 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-
14
• Customer Charge • Distribution Charge (delivery to facility)
– On Peak (kWh) – Off Peak (kWh)
• Transition Charge
• Transmission Charge (generator to
distributor)
Distribution Electric Service Charges
15
Other Electric Service Charges
• Energy Efficiency Charge
• Renewable Energy Charge
• Distribution Demand Charge
16
Energy Units – Electricity Analogy
Electrical Charges typically have two metered components:
Demand (Power)
Consumption (Energy)
17
• Demand is measured in 15-minute increments
• Demand charge will be the peak demand for billing period
18
Demand Measurement
19
National Grid Bill—Page 1
20
National Grid Bill—Page 2
Highest demand in kW during the peak period OR 90% of the highest demand in kVA during the
peak period
21
National Grid Demand Charges
Electricity Questions?
Understanding Energy Bills
22
Major Energy Saving Opportunities
November 2016
• Implement an Energy Management Program and Energy Team (1-3%)
• Lighting Upgrades
• Compressed Air
Major Opportunities
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
• 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
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
28
• Top Management Support
• Empowerment
• Baseline and Measurement
Keys to a Successful Energy Team
Lighting Upgrades
Courtesy of Cox Interiors Campbellsville, KY
30
Metal Halide
LED
≥ 50% energy savings 10-20% increased light levels Increased life expectancy, reduced maintenance Reduced HVAC costs Most are dimmable
31
LED Lighting
Replace incandescent and CFL lighting with LEDs
Replace or convert exit signs to LED
Other Lighting Opportunities
32
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
33
81,000 kWh saved results in 248 metric tons of CO2 reduced
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
34
9,200 kWh saved results in 84 metric ton of CO2 reduced
• Other requirements for rebates • Look for guarantee
• Bypass ballast vs “plug-n-play”
• $$-requires some shopping
LED Considerations
35
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
36
Kentucky’s Resource Center for Environmental Sustainability
Lighting Questions?
It’s not free! 4th Utility (electric, natural gas, water, air)
Often the most expensive
Compressed Air
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
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
Where does the compressed air go?
Compressed Air Leaks
• Pipe joints/valves/fittings • Point-of-Use devices • Hoses & couplings • Quick disconnects • Condensate drains • Regulators • Tubing
Compressed Air Leak Rates
Compressed Air Leak Costs ($0.07/kWh)
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
• Audible (large leaks) • Liquid Solution
Finding Compressed Air Leaks
• Implement a PM system – Log/track leaks and repairs – Inspect hoses/tools
• Reduce leak rate to ≤ 10% • Use zero-loss drains
Managing Air Leaks
Inappropriate Use of Compressed Air
What is the worst “offender” for an inappropriate use of compressed air?
Inappropriate Use of Compressed Air
Inappropriate Use of Compressed Air
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
Excessive System Pressure
Reduction of set point by 2 psig reduces electric consumption 1%
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
• 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
• 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
Compressed air questions?
Energy Savings Opportunities
November 2016
• Cheryl Eakle, CEM Senior Engineer
• [email protected] • 502-852-3485
• www.kppc.org