energy audits · 2020. 12. 23. · • energy – reduced availability of water threatens...

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Energy Audits Day 1

Expert Training on Energy System Optimization (ESO)

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1. Detailed Energy Audit (ISO 50002) 1.1 Pakistan Energy Sector

1.2 ISO 50002 Overview

1.3 Energy Audit Types

1.4 Energy Audit Planning and Support

1.5 Data Collection, Measurement Plan

1.6 On site surveys

1.7 Analysis

1.8 Economic Analysis: Project Packaging

1.9 Reporting

1.10 Baseline Development: Industrial Benchmarking Techniques

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2. Electrical Energy 2.1 Electrical Energy: Overview

2.2 Electric Lighting Introduction

2.3 Existing Lighting Technologies

2.4 Lighting Energy Management Opportunities

2.5 Electric Motors Fundamentals

2.6 Electric Motors Energy Management Opportunities

2.7 Power Quality

3. Thermal Energy 3.1 Fundamentals and Pshychrometry

3.2 Building Envelope

3.3 Heat Flow and Insulation

3.4 Refrigeration

3.5 Heat Transfer

3.6 Steam Systems

3.7 Renewable Energy

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4. Mechanical Energy 4.1 Mechanical Energy: Overview

4.2 Compressed Air Systems Demand Side

4.3 Compressed Air Systems Supply Side

4.4 Compressed Air Systems Treatment & Distribution

4.5 Compressed Air Systems Case Studies

4.6 Pump Systems: Enhancing Centrifugal Pumps Efficiency

4.7 Variable Speed Drives: Application

4.8 Fan Systems: Overview

5. Energy Management 5.1 ISO 50001: Requirements

5.2 ISO 50001: Implementation

5.3 Energy and Demand

5.4 Electric Cost Components

5.5 Energy Management Stages

5.6 Measurement and Verification

5.7 Software and Instrumentation

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PAKISTAN ENERGY SECTOR

Overview

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Climate Change Impact

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• Ranks 7th in the Global Climate Risk Index 2017

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• Agriculture and livestock - 80% of the major crops are grown on 23mha. 1/3 of the land (6.5mha) has been degraded.

• Energy – reduced availability of water threatens hydropower generation and thermal power plant cooling. Energy infrastructure is vulnerable to floods, storms, hurricanes and sea-level rise.

• Karachi – 17 mln people, the port accounts for 42% of GDP, generates ½ of tax revenues, priciest real estate. Risks of flooding, drought, extreme heat events, sea level rise,

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Why does this matter to the Business

• Climate Resilience Investments • Agriculture

• crop genotypes and livestock breeds with greater tolerance to climatic stress.

• Implementing best management practices for climate resilience

• Industry

• Investments in EE/RE to mitigate energy availability and volatility

• Investments in clean technologies

• Tourism

• climate change risk considerations into coastal development and land use planning

• climate change considerations into existing loan products to the tourism sector

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The Sector

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The Sector - Generation • Gas network – provides about 4 mil ft3 per day (demand is 6). Pakistan was gas sufficient until 2005,

due to increased demand, lack of alternative fuel and price subsidies, there are gas shortages.

• 30% of the gas is used for power generation, followed by households – 23%, industry – 20%, fertilizers – 18%.

• Oil - domestic production is not enough. As a result Pakistan imports oil and oil-based products from Middle East countries especially from Saudi Arabia.

• Transport (51%) and power (41%) are the two major users of oil;

• Renewable Energy - Alternative Energy Development Board (AEDB) is the representing agency of the federal government, established with the main objective to facilitate, development of Renewable Energy.

Wind power Plants Solar Power Plants Co-generation Plants

No. Capacity MW

No. Capacity MW

No. Capacity (MW)

In Operation 6 308.2 1 100 5 160.1

Under Development or Initial phase 52 2,589.2 28 956.8 30 1,043.4

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Energy Generation

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Issues in the Energy Sector

• Lack of Integrated Energy Planning & Demand Forecasting, seriously worsening the gap between energy supply and demand;

• Circular Debt, amount of cash shortfall within the Central Power Purchasing Agency (CPPA) that it is unable to pay to the power supply companies;

• Imbalanced Energy Mix with heavy reliance on gas and oil (72% imported);

• Non-utilization of vast indigenous resources of Thar Coal and Hydel potential;

• Lack of effective project structuring, planning and implementation of identified and viable projects;

• Transmission/distribution losses/thefts; • Inadequate revenue collection by DISCOs.

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Pakistan Vision 2025 • Eliminate current electricity supply-demand gap by 2018, and cater to growing

future demand by addition of 25,000 MW by 2025 • Optimize energy generation mix between oil, gas, hydro, coal, nuclear, solar,

wind and biomass – with reference to its indigenousness, economic feasibility, scalability, risk assessment and environmental impact

• Tap Pakistan’s huge potential for alternative energy • Focus on demand management and conservation to ensure prioritization in

allocation, elimination of wasteful use, incentives to use more energy efficient equipment and appliances and achieve better balance between peak and off-peak hours

• Introduce institutional reform and strengthen regulatory frameworks to improve transparency and efficiency.

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Objectives of Power Policy 2015

• To provide sufficient power generation capacity at the leas cost • To encourage and ensure exploitation of indigenous resources • To ensure that all stakeholders are looked after in the process; a win-win

situation • To be attuned to safeguarding the environment

• Currently no energy conservation policy exists in the country. • The energy conservation bill (ECB) has been approved by the standing

committee of National Assembly and is pending for approval from the parliament.

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Recommendations for improvement of Energy Sector • Promote domestic alternate sources of energy including hydro, solar, wind, coal and

agriculture biomass/biodiesel; • Energy conservation and demand management programs; • Coping with the circular debt and better management of the power sector financial flows;

• Existing power plants to be overhauled to achieve maximum efficiency; • Undertake policies/programs to improve governance/performance of energy sector entities

• Decrease costs and Increase cash flows;

• Ensure operational/financial integrity of the sector;

• Implement international best practices including smart metering / automated meter reading (AMR) systems and Time of Use (TOU) tariff;

• Resolve tariff and subsidy disputes between provincial governments and CPPA/DISCOs;

• Penalties for electricity thefts; • Political appointment culture needs to be replaced with professionalism/merit; • Fuel allocation policies be introduced;

• Relocation of imported furnace oil with gas into power production;

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WHY EE?

• Energy Efficiency can apply “Proven” & cost effective technologies to supply the World’s projected electricity growth for Next 20 Years!

• EE is the “Cleanest” and “Cheapest” Energy; • Don’t generate EE = “0” GHG Emissions!! • Costs less than 50% of Generated Power • Quick paybacks = “Paid-From-Savings”;

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EE/RE Technologies Investment

High Low

Investment

High Low

Savings

High Low

Payback Period

Low

High

USD/Ton CO

2 Avoided

High Low

Investment

High Low

Savings

High Low

Payback Period

Low

High

USD/Ton CO

2 Avoided

1. Renewable Energy. 2. Cogeneration and Tri-Generation. 3. Supply Side Efficient Technologies. 4. Waste to Energy and Recovery Systems.

1. Efficient Lighting Technology. 2. Automation and Controls. 3. Drives and VSD. 4. Boilers and Steam Systems. 5. Efficient Cooling Systems.

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DETAILED ENERGY AUDIT (ISO 50002)

Overview

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Energy Audit Process

Why reinvent the wheel?

Excellent tools and guides available

Easy to use, easy to read, reliable, well researched

Most are free

Guidance and Tools for Energy Audits

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Energy Audit Process • Energy Audit and Energy System Guides

• ASHRAE

Procedures for Commercial and Building Energy Audits

• Association of Energy Engineers (AEE)

Certified Energy Auditor Body of Knowledge

Energy Management Handbook, Dr. Wayne C. Turner

• and many, many more…

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Energy Audit standards Examples of Standards

ISO 50002

AS/NZS 3598

BS EN 16247-1:2012

Many others Which one is best? Answer: None of them. They are all similar and promote

the same basic steps!

Do we need a reference framework for energy audits? YES

Do all energy audits need to have exactly the same approach, details, etc.?

NO – All energy audits are different! Different objectives, different

budgets, different systems, etc.

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Energy Audit Process • Definition of an Energy Audit

Typical objectives / components:

Develop an energy balance of a facility and determine the consumption intensity and demand profile of energy sub-systems

Preliminary identification of opportunities for further study and investment targeting

Diagnose the performance of an energy system

Detailed study to demonstrate feasibility and justify investment in an energy efficiency measure (s)

Identification of the risk profile of a project for a load application

Verification of performance of an existing energy efficiency investment

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Energy Audit Process ISO 50002 - Energy audit steps

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ENERGY AUDIT TYPES

Selecting appropriate level of audit

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Pre-Feasibility Study / Simple Facility (ISO 50002 -Level 1 Energy Audit)

Source: Adapted from Natural Resources Canada,2005, Retscreen Clean Energy Project Analysis Textbook

Measurement & Verification (M&V) of Savings

Detailed Feasibility Study / Complex Facility (ISO 50002 -Level 2 Energy Audit)

Advanced Feasibility Study / Large Facility / Complex Energy Sub-System (ISO 50002 -Level 3 Energy Audit)

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Level 1

Accuracy •-30% to -50% Savings •+30% to + 50% Costs

Uses •Monitoring •Scoping •Qualification •Key feasibility study for small facilities or simple energy systems

LOE (Typical) •Small-Medium Building •1 days on site •1 week office report writing •Large Building •2 days on site •2 weeks office report writing

Level 2


Uses •Detailed feasibility •Firm internal funding requests

LOE (Typical) •Small-Medium Building •1 week on site •2 weeks office report writing

•Large Building •2 Weeks on site •4 weeks office report writing

Level 3


Uses •Advanced Investment Feasibility Study – more detail for a larger, more complex facility •External Funding Requests •System Specific Detailed Feasibility Study

LOE generally the same as Level 2 •LOE determined by detail required and / or complexity of a sub system

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Energy Audit Process Selecting the Audit Detail Key Points:

Level 1 audit is always conducted!

Level 1 energy audit is low cost investment and typically used for planning a more detailed audit or as a stand alone audit on simple facilities

More detailed audits should not be performed until a firm commitment to projec implementation under agreed upon investment qualification criteria has been made

The audit detail should depend on the current risk level of the project and / or accuracy of the energy balance required. Risks depends on:

- Complexity of the facility and measures - Availability of funding - Accuracy of data used to analyze opportunities and develop design concept- Capacity of resource available to implement projects

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Application

Small energy budgets

Preliminary for large organizations

• Needs Addressed

Indication of potential savings from more detailed audits

Awareness

Identifying strategic areas of focus

Defining scope for a more detailed audit

Determining scale of opportunity

Developing a better understanding of the stakeholders

• Data Collection

Skills: basic technical training and understanding of systems

Using existing data and meters—rules of thumb based on basic parameters

Establishing basic energy performance indicators

Site equipment list, schedules, duty factors and load factors

Level 1 Audit

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• Effort and Methods

Level of effort: 1-2 days on site, 1-2 weeks in the office

Relies mainly on readily available documentation (drawings, utility

bills, maintenance logs, etc.)

Accuracy: - 30% to -40% savings and +30% to 40% costs

Use rules of thumb and/or benchmarking for analysis and savings

calculations

Establish schedules, operating hours, loading mainly through

observations and personnel interviews

Level 1 Audit

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Application › Larger facilities › Further development of opportunities prioritized in Level 1 audit for investment

Needs Addressed › Evaluating a range of specific opportunities › Identifying complex opportunities that require a more detailed study (Level 3) › Auditor is typically outsourced and has appropriate technical skills and familiarity

with particular facility › Understanding operational factors in detail – budget, procurement, leadership,

approvals process etc. Data Collection

› Requires detailed data including daily profiles › Detailed variables for production, occupancy, weather correlated to energy use › Sub-metered data—site data can be sufficient, but temporary metering may be

needed › Data required: design data, O&M data, capital plans, instrument configurations,

automation details

Level 2 Audit

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Level of effort: 1-2 weeks on site 4 weeks in office

Detailed analysis of utility bills, collect available sub-meter

data, extensive spot measurements

Accuracy: -15% to -10% savings and 15% to 10% of costs

Using detailed modeling techniques; developing detailed

energy balance

Level 2 Audit

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Application › Highly detailed – requires significant input from client › Cost effective for customers with very large energy spendings › Can be a focused assessment on a very specific system (compressed air) Needs Addressed › More detailed evaluation of a range of specific opportunities › Detailed cost-benefit analysis with energy and non-energy factors considered › Must consider strategic business objectives › Auditor is highly skilled and often a specialist of the specific system; often requires

outsourcing to specialist Data Collection › Detailed load profiles examined; examining variables in parallel › May need to instrument key processes › Development of detailed energy mass balance could be required for process › Data required: design data, O&M data, capital plans, instrument configurations,

automation details

Level 3 Audit

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Level of effort: 1-2 weeks as necessary on site and 4 weeks

in the office

Detailed analysis of systems using specialized instruments,

outside technical specialists, temporary sub-metering

Accuracy: - 5-10% of savings and + 10% of costs

Level 3 Audit

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Project Life

Development Construction Period

Performance Period

Costs

Benefits

(Energy, Operations Savings)

(Operations, Energy, M&V, Debt Service) (EAs, implementation planning, finance planning)

Energy Efficiency Project Cycle Costs and Benefits

Key Point: Energy audits are necessary, but the develop and verification costs reduce the size of energy efficiency measures . The level of effort for an EA and other development activities should always be minimized. Development and performance verification costs are categorized as “transaction costs” and are a key burden and deterrent to energy efficiency project implementation.

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Optimizing Audit & M&V costs

= Larger Net Customer Benefit!

Net Benefit =

Utility / Operations Savings – (Implementation Costs + M&V Costs

+ Audit Costs)

Energy Efficiency Project Cycle Costs and Benefits

Energy Audit Process

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Quantifying Other, Non-Energy Savings Benefits is Important:

• Reduces emissions and other environmental impacts

• Increases the availability of non-renewable resources

• Lowers energy costs for consumers, reducing not only consumption but also the overall need for investment in energy supply

• Improves competitiveness and overall productivity

Energy Efficiency Project Costs and Benefits

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Planning and support

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Step 1: Energy Audit Planning

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2

3

4 5 6 7 8

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Stakeholder Communication

Determine the energy audit objectives, scope, roles, responsibilities, data requirements, resources, timeframe, issues Investment criteria Selecting audit type/detail, reporting format, approval

process

Energy Audit Planning

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Review the strategic business context for energy

How is energy use related to: • General business operations • Market positioning • Technology pressures • Work environment • Productivity • Quality • Energy and resource security


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Outcomes Higher Management Support Agreement to move forward with audit Terms of reference

• Scope • Roles and Responsibilities • Deliverables • Preliminary data (basic utility data, production data, site plan, etc.) • Time frame

Key contacts Obtain basic facility data


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Data Collection, Measurement Plan

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Step 2/3: Opening Meeting and Data Collection Initiation

1

2

3

4 5 6 7 8

ISO 50002 Energy Audit Process Steps

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Step 2/3: Opening Meeting and Data Collection Initiation

Data required and when Access to facilities (security, safety) Timeframes for data collection on site Organize copying, retrieving documents, etc. Key personnel on site to access specific areas

Review Roles, responsibilities and expectations for cooperation (should be documented in TOR from Step 1)

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Step 4: Measurement Planning

1

2

3

4 5 6 7 8


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Utility bills (Do not go to site without first reviewing!)

Review of drawings and specifications

Review of specific operational issues / delayed maintenance items

Develop an initial data collection plan

Perform preliminary benchmarking

Pre-Site Visit Data Collection

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Analysis of EUIs Comparison with similar facilities / industry

• Find an appropriate database for benchmarking • Is the energy usage less or more than the average building / enterprise of

same type? • Providing an indication of the potential for energy efficiency improvement • EUI Examples:

• kWh / m2

• kWh / guest

• kWh / unit products

Key Point: Making benchmark comparisons to other facilities is often difficult because EUIs tend to be unique to a particular facility context (climate, product/process type, etc.)

Pre-Site Visit Data Review

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Analysis of EUIs – Key points What is the important energy use driver / EUI indicator?

• Is it a building? .....use energy consumption / floor area (e.g. kWh/m2)

• Is it a factory? ........consider using energy consumption / unit produced (e.g. kWh / kg)

Realistic benchmark comparisons to other facilities for a manufactured product can be complex or even impossible

If benchmark comparisons are not possible at the facility level – focus on benchmark comparison at the energy sub-system levels: • Compressed air production • Hot water production • Steam production • etc.


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Analysis of EUIs – Key points From manufacturing try to compare the production indicator

against best practice • - Comparisons must be “apples to apples” • - Manufacturing operations must be similar • - Typically only mainstream commodities can be compared with BAT

(cement, milk, steel, aluminum, etc.)

Examples of industrial benchmarking programs and tools: • US Energy Star (https://www.energystar.gov/buildings/facility-owners-and-

managers/industrial-plants) • Cement Industry Benchmarking Tool by LBNL (BEST – CEMENT)

(https://china.lbl.gov/tools/benchmarking-and-energy-saving-tool-cement) • Wine Industry Benchmarking Tool by the University of Oregon (formerly by

LBNL) (http://solardat.uoregon.edu/OregonBestWinery.html) • IFC Food Processing Benchmarking

Tool:(http://www.ifc.org/wps/wcm/connect/region__ext_content/regions/europe+middle+east+and+north+africa/ifc+in+europe+and+central+asia/countries/about+the+ifc+food+processing+benchmark+tool)

• Websites: LBNL Benchmarking site (http://energybenchmarking.lbl.gov/)


https://www.energystar.gov/buildings/facility-owners-and-managers/industrial-plants

https://www.energystar.gov/buildings/facility-owners-and-managers/industrial-plants

https://china.lbl.gov/tools/benchmarking-and-energy-saving-tool-cement

http://solardat.uoregon.edu/OregonBestWinery.html

http://www.ifc.org/wps/wcm/connect/region__ext_content/regions/europe+middle+east+and+north+africa/ifc+in+europe+and+central+asia/countries/about+the+ifc+food+processing+benchmark+tool



http://energybenchmarking.lbl.gov/

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Checklists

Equipment

Safety, Site requirements

Site Coordination

Key considerations for designing measurements:

Savings potential

Measurement boundary

Usage groups

Accuracy vs. cost

Errors

Preparation

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On site surveys

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Step 5: Conducting the Site Visit

1

2

3

4 5 6 7 8


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Do we need to measure everything? NO

We need to measure enough data to estimate energy use and savings appropriate

for the required level of accuracy

Factors include:

- Project development stage

- Available resources

- Acceptable level of risk

• It is impossible within most audits to measure all parameters.

• The energy auditor must be an expert at making estimates based on incomplete

data.

Key Considerations for measurements to estimate energy USE

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Source: CEATI M&V Guide

Concept of Measurement Boundary

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Interactive Effects Concept

Heat AC Unit

Electricity Supply

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Consider the energy use patterns of facilities

- Constant load without changes in operating hours

- Operating hour reductions without changing load

- Both load and hours of operation are reduced

What is the Risk?

- Data collection must support operational and technical risks

Cost vs. Accuracy

- More accuracy = higher costs

- Is it worth it?

Key Considerations When Determining the Type and Resolutions of Measurements

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Spot Measurements: Power probe & multimeter: true RMS kW Air pressure gauge to measure fan statics Tachometer: fan RPM Light meter: foot-candles or lux Thermometers: temperatures Boiler stack gas analyzer: combustion efficiency

Measurement types

Short-term Monitoring Compact portable equipment monitoring

Electric current or power Lighting or motor runtime Occupancy schedules

Stand-alone battery powered Split-core CTs and other types of sensors CPU and sensors connected by twisted pair wiring

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Long-term Monitoring “Permanently” installed equipment with battery backup

Solid-core current transducers (CTs) and other types of sensors

Twisted pair wiring, power line carrier, or RF connections between sensors and CPU that may be

remotely located

Typically monitors high-value loads

Data from Existing Data Acquisitions Systems

BAS, EMS, SCADA

Review trends (HVAC / Process)

Use logger to record pulse outputs

Request 15 minute demand interval data from the utility if available

Measurement types

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kW

kW

30 Minute Interval Demand Data from a commercial site

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• Operational Assessment

Interviews with facility personnel

O&M assessment

Observation of facility users and behaviours/awareness of operational

personnel

Documenting of operating schedules

Confirm elements that are strategic to them

• Comfort, lighting level, operations, cost

Confirm open channel of communication

Solicit access and collaboration

Interviews and Meetings

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• Spot Measurements

Confirm key equipment operating parameters (e.g. flow rate,

power, combustion efficiency, lux level

do not take drawings and specs at face value

case study: heat exchanger shortfall of savings

• Short Term Logging (Audit Level 2/3 Only)

Useful for peak demand analysis

Usage pattern (what energy is used out of normal

operating hours)

Confirm the energy usage of variable load equipment

(e.g., VSDs, equipped fans or pumps)

Source: esis.com.au

Lighting meter time of use

On-site Survey and Measurements

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Lighting Measurements Develop a spot measurement plan for some typical rooms

For each type of space:

• do inventory of fixture types (lamp type, nameplate wattage, number of lamps of

each type, ballast type, nameplate wattage of ballasts, number of ballasts/fixtures)

• identify the type of control switching

identify installed retrofits or system changes

perform spot measurements (lux, W, amps, V, power factor)

Lighting systems can vary a lot compared to the drawing (change in ballast, tube, zone

rewiring during renovations, etc.)

You will calculate the lighting W/m2 and later at the office

Also measure actual operation time and/or occupancy with loggers (level 2 /3)

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Floor Room Number

Dimension Area (m2)

Lux Quantity of Fixtures (units)

Fixture Type Number of Lamps/Fix.

(units)

Power per Lamp

(W)

Power per Ballast

(W)

Hours/ Period (hrs)

Right Orchid -Ground Floor – 1-2 101-109 630 150 108 CFL13-Compact fluorescent lamp 1 13 2 15 Right Orchid -Ground Floor – 1-3 101-109 630 100 54 I75-Incandescent 1 lamp x 75 W 1 75 0 15 Right Orchid -Ground Floor – 1-4 101-109 630 90 27 ELV36-Extra Low Voltage 1 50 16 15

Right Orchid -corridors 101-109 180 85 27 I40-Incandescent 1 lamp x 40 W 1 40 0 15 Left Orchid -Ground Floor – 1-2 101-109 630 105 108 CFL13-Compact fluorescent lamp 1 13 2 15

Apartment Ground Floor 21 84 150 7 I40-Incandescent 1 lamp x 40 W 1 40 0 8






Apartment First Floor 27 84 200 7 I40-Incandescent 1 lamp x 40 W 1 40 0 8

On-site Lighting Survey Form - EXAMPLE

On-site Survey and Measurement

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Lighting Measurements

Example Classroom survey:

• Installed power: 158 W

• Area: 95 m2

Lighting Energy Density: 1.66 W/m2

Compared to best practice of 0.75 W/m2


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Mechanical System Measurement Develop a spot measurement plan Identify installed retrofits or system changes Perform spot measurements (W, amps, V, power factor,

RPM) Systems with variable loads must be tested at different

points of operation Nameplates Operating schedules Setpoints Control systems


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Equipment Survey Form - Example


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Electrical Systems

Confirm voltage of primary service, secondary service, tertiary service

• from nameplate data

Transformer loss

• sometimes written as wattage loss

• sometimes as a class of transformer

Inspect transformers

• note general condition of equipment

• floor around transformer should be dry

• transformer fins should be clean

• oil leaks?


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Analysis

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Step 6: Analysis

1

2

3

4 5 6 7 8


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Energy Analysis

Preliminary / Rough Analysis (Level 1 Audits / Non-Core Measures):

Developing target scope for a more detailed study Time and resources are limited The project values are low The facility / energy system and operating profile is simple

Detailed Analysis (Level 2 Audits / Core Measures):

Projects with internal funding available Firm budget commitments for project implementation have been made Moderate complexity systems and operating profiles

Advanced Analysis (Level 3 Audit / High Value / High Risk Projects ):

Projects that require solicitation of external funding Moderate complexity systems and operating profiles Where project modifications have significant financial, health and human

safety, or environmental risks (e.g. modifications to process, critical environments, etc.)

Analysis Detail

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Energy Analysis

› Evaluations at ± 30 - 50% at the Level 1 stage

• Preliminary analysis tools can be used, i.e. Retscreen

• Benchmarking with previous projects or best practices

• Back of the envelope calculation

› Identify the range of potential savings - Not a single figure

› Always write down your hypothesis and source for preliminary calculations

• More advanced studies and lager investments can take a long time to be approved

• Document your thinking.

• Identify the hypothesis that will require refinement during the next, more detailed energy audit.

Level 1 Analysis Techniques

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Actual consumption

Quantity of energy saved annually

› Any cross effect to consider?

› DO NOT oversell the project if you're not confident that results will be achieved

Monetary value of energy saved based on tariff structure

Cost of modifications

› Preliminary stage: emphasize the costs are based on “budget” estimates and are rough

› Often based on :

• Savings x payback period (benchmark from other projects)

• Rules of thumb (cost per installed kW for boilers, chillers, per m2 for lighting, etc.)


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Criteria to Select EE measures based on: • Financial profitability • Risk • Alignment with strategic business priorities • Potential integration with other measures • etc…

Rules of thumb to identify potential are shown in this section:

• Experienced auditors can rapidly determine the list of potential EE

measures

• Technologies are detailed in a future section


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E.g.: Lighting Estimation Techniques

• Benchmarking with reference values of W/m2

• For example, Classroom: existing: 19 W/m2

efficient retrofit: 8,6 W/m2

Use a luxmeter to check the current level of lighting in different zones

• Identify over-lighted or under-lighted zones


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Energy usage and demand calculations

Method A : kW loading

› This method must be used for constant load equipment

• lighting

• fixed flow and head pump

• single speed motors

2 OPTIONS:

A-1: Equipment nameplate nominal power x Assumed loading factor

A-2 : Direct kW measurement

Electrical Equipment – Analysis By Usage

Detailed Analysis Techniques

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Motor Load – Option A-1 › Estimates kW load based on motor nominal kW/HP, loading and efficiency › Estimates load factor and motor efficiency › Load factor (l.f.) = 75% (assumed) › Efficiency = 0.92 (assumed) › Calculation: 100 HP x 0.746 kW/hp x 75% l.f. / 0.92 = 61 kW or 75 kW x 75 % l.f. / 0.92 = 61 kW

Motor 100 HP / 75 kW

From nameplate

Electrical Equipment - Analysis By Usage


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Motor Load – Option A-2

• kW measurement is direct

• Using the kW we can get the:

› Energy: 54.2 kW x 4500 hrs/yr = 243 900 kWh

› Peak demand day: 54.2 kW x 90% = 48.8 kW

› Peak demand night: 54.2 kW x 10% = 5.4 kW *Diversity 90% with 10% to be assumed

54.2 kW From hand-held kW

Electrical equipment - analysis by usage


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Description Qty (a)

Unit load W (b)

total W (c)= axb

Hrs / Per. (d)

kWh/ period

(e)= dxc /1000

Div’ty factor –

day (f)

Peak W (g)= fxc

Div’ty factor –

night (h)

Peak W night (i)= hxc

Offices 50 50 2500 290 725 .90 2,250 .10 250

Warehouse 30 450 13,500 250 3,375 .90 12,150 .10 1,350

Corridor 5 50 250 129 32,25 1.00 250 .50 125 Total n/a n/a n/a n/a 4,132 n/a 14,650 n/a 1,725

Summary table: Electrical equipment (except motors)



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Summary table: Motors


Description Qty

motor h.p.

motor load

%

Efficiency

%

Total kW

DayHrs/Per.

Day& night div’ty factor

Day kWh/

period

Day peak kW

Night Hrs/ Per

Night kWh/per

Night Peak kW

(a) (b) (c) (d) (e) (f) (g) (h)= fxe (i)=exg (j) (k)=exj (l)= exg

5 hp air com-pressor

1 5 75 85 3.29 120 0.5 395 1.6 40 132 1.6

Total n/a n/a n/a n/a n/a n/a n/a 395 1,6 n/a 1,6

Note: kW total (e) = (a) x (b) x 0.746 x (c) ÷ (d)


81

Method B for Electricity: Current-Voltage Method › Option B-1 : From nameplate

• from nameplate data (e.g., coolers, small motors, appliances) when kW load is not known

• nameplate information: amps, volts and phase

• load and power factor are estimated

› Option B-2 : From measurement • measured amps and volts: good info on loading

• power factor: estimated

Note 1: Auditors generally do not repeat the voltage measurement on each equipment as it does not vary much in the same mechanical room or facility

Note 2: Power factor is assumed



82

Step 6: Energy Analysis

SHAFTEND BRG - 6318C3 OPD END BRG - 6315C3

MODEL

P28059-4

SERIAL 89147/01

RPM 1775

H.P. 150

VOLTS 575

PHASE

3

AMPS 145

HERTZ 60

PUMP

VOLTS 600

PHASE 3

AMPS 139

HERTZ 60

LEROY SOMERS ODP

Disconnect switch should be 200 amps


Pump Name Plate Example


Option B-1: Current-Voltage Method Using Nameplate Data

83

• Current-Voltage Option B-1 – Nameplate (3 phases)

FLA: Full load amps (we use this one) LRA: Locked rated amps (no interest for IGA) Estimated power factor: 90% Estimated load factor: 75% Calculation: 600 V x 120 A x 90% x 75% x √3 x 1/1000 = 84 kW

FLA: 120 LRA: 500

VOLTS 600

Phase 3




84

• Single Phase Motors

FLA: Full load amps

LRA: Locked rated amps

Estimated power factor: 90%

Estimated load factor: 70%

Calculation:

240 V x 60 A x 90% x 70% x 1/1000 = 9.1 kW

FLA: 60 LRA: 300

VOLTS 240

Phase 1




85

• Measured amps: 95 amps

• Measured voltage: 600 volts

• Estimated power factor: 90%

Calculation:

• 600 V x 95 A x 90% x √3 x 1/1000 = 89 kW

95 A 600 V 3 Ø Replace by actual meter reading


Option B-1: Current-Voltage Method Using Voltage and Amps Measurement


86

Description Qty

Volts

A

Ph

PF

Total kW

DayHrs/Per

Day Div’ty factor

Day kWh/

period

Day Peak kW

Night hrs/ per

Night Div’ty factor

Night kWh/ per.

Night PeakK

W

(a) (b) (c) (d) (e) (f) (g) (h) (i) = gxf (j)= hxf (k) (l) (m)=kxf (n)= fxl

Rooftop 10 575 15 3 ,85 127 242 0,6 30730 76,1 20 0,5 2540 63,5

Total n/a n/a n/a n/a n/a n/a n/a n/a 30730 76,1 n/a n/a n/a 63,5

Note: (g) includes the mean daily diversity factor

Summary table : Voltage/Current method



87

Lux: Verify adequate lighting (e.g.: office = 660 lux)

Compare occupancy with actual hours of operation

Benchmark your kWh/m2 with best design for similar facilities: potential identification

IMPORTANT: Check power factor measured. Low power factors are common for low-cost ballasts

LIGHTING – ANALYSIS BY USAGE


88

Motor efficiency is very difficult to measure directly in the field * • It’s done mainly in the lab by manufacturers • Testing is costly • Not cost-effective or feasible for an audit

Motor efficiency is usually estimated by: • using typical motor efficiency curves • taking into consideration the motor loading • efficiency varies with loading

*Some specialized companies offer an indirect method that requires testing the resistance of a motor coil when stopped (very uncommon)

Motors - Analysis By Usage


89

Motor Efficiency Terms • Nominal efficiency Average efficiency obtained by testing a representative group of motors

Requirements of standards are to meet or exceed nominal efficiency

• Minimum, guaranteed, or guaranteed minimum efficiency Accounts for variations in the population

Allows for losses up to 20% more than nominal



90

› Motor load influence efficiency › Equation to determine motor load for a three phase motor

90

Pi = measured/estimated motor input power in kW η = motor operating efficiency (fraction) HP = nameplate rated horse power kW = nameplate rated power in kW Load = output power as a % of rated power

With the nameplate in HP

With the nameplate in kW

Load = Pi x η /kW



91

• Input Power (Pr) Determination

Where:

Pr = input power at full rated load in kW HP = nameplate rated horse power

= efficiency at full rated load



92

• Electrical power (Pi) Single-phase systems:

• Electrical power (Pi) 3-phase systems:


Pi = V × I × PF /1000

93

Fan efficiency – Information required › Flow › Pressure differential › Motor power (output shaft power)

• AMP measurement only

• AMP, volt and PF

• Direct kW measurement

• Optional : RPM for motors (sometime used to evaluate motor loading by the slip between nominal and actual RPM)

Input power x assumed motor η

Energy Analysis By Usage: HVAC SYSTEM


94

Pump efficiency – Information required › Flow (insertion probe, doppler, ultrasonic) › Pressure differential (input vs output) › Motor output power (shaft power)

Energy Analysis By Usage: PUMPS


Powershaft [kW] = Q [m³/h] x ρ [kg/m³] x 9.81 [m/s²] x head [m]

3 600 000 x η [fraction]

Note: Precise measurement of water temperature inlet and outlet also enables to measure efficiency (energy lost is transformed into heat)

95

Let’s analyze this point: 72% efficiency 35 m head 400 m³/h

Energy Analysis By Usage: PUMPS Using the Manufacturers Pump Curve


96

Pump curve analysis

Powershaft = 400 [m³/h] x 1000 [kg/m³] x 9.81 [m/s²] x 35 [m]= 53 kW

3 600 0000 x 0,72

• To calculate the total energy consumption divide the Powershaft by the efficiency of the motor: 53 kW/0,88 = 60,2 kW

• Energy [kWh] = 60,2 kW x 2 000 h/year = 120 400 kWh

ENERGY ANALYSIS BY USAGE: PUMPS


97

Energy Analysis By Usage: CHILLER


98

Compressor supply efficiency – Information required • Flow rate • Motor load • Simplified analysis: just use kW per l/s of compressed air provided (instead of

percentage efficiency) • Flow measurement is tricky

• Ultrasonic cannot be used on all systems (lower pressure)

• Pulsation from reciprocating unit

Source : DV Systems

Energy Analysis By Usage: Air Compressor


99

Boiler Efficiency Determination

• Usual method: combustion efficiency test

• Efficiency varies with loading

• Measures only the portion of fuel energy leaving in the flue gas (is NOT the

actual boiler efficiency)

• Actual boiler efficiency considers

loss through the boiler’s skin

blowdown loss (surface and bottom)

waterside ash/scale accumulation

Energy Analysis By Usage: Boiler


100

Two quick (easy) methods to calculate heat and cooling load:

• Degree-Day Method: correlates the outside temperature with the energy required for heating based on the assumption that heating is required when the average daily temperature is less than 18oC (T balance)

• Bin Method: must be used when several parameters, such as efficiency of the HVAC system, vary with the outdoor temperature. A bin is then a temperature interval around which conditions are constant

Energy Analysis By Usage: HVAC


101

Energy Analysis By Usage: HVAC Degree Day

Annual heating energy cost

Annual heating energy estimation


AH = Annual heat flow in MJ Q = Maximum heat flow rate (kJ/h) HDD = Heating degree days 24 = Hours per day to convert degree days to degree hour (T1-T2) = Temperature difference for which Q is calculated

102

Energy Analysis By Usage: HVAC Degree Day Detailed Analysis Techniques

AC = Annual Cooling Energy in MJ Q = Maximum cooling load (kJ/h) CDD = Cooling degree days 24 Hours per day to convert degree days to degree hour (T1-T2) = Temperature difference for which Q is calculated

Cost = Annual refrigeration energy cost ($) RE = Refrigeration energy consumption per unit of cooling 1000 MJ = 1 GJ

Annual cooling energy estimation

Annual heating energy cost

103

Conversion Factor to kBtu

Input Unit 1 kWh 3.412142

Input Unit 2 therms 100

Input Unit 3gallons (propane) 91.33

Combined Output Units kBtu 1Building Gross Floor Area 99,999

Floor Area Units ft 2̂

Input Energy Units Combined Energy Use

End Use kWh thermsgallons

(propane) kBtu %Air Compressors 25,000 - 85,304 1%Cooking 36,000 - 9,800 1,017,870 6%Cooling 445,996 - 1,521,800 10%Heating 699,993 20,640 4,452,455 28%Lighting (Exterior) 68,455 - 233,578 1%Lighting (Interior) 371,996 - 1,269,304 8%Miscellaneous - - 5,600 511,448 3%Office Equipment 350,856 - 1,197,170 8%Other Plug Loads 305,997 - 1,044,105 7%Process - 27,620 2,761,972 18%Pumps 56,525 - 192,871 1%Refrigeration 38,500 - 131,367 1%Ventilation 146,999 - 501,580 3%Water Heating 22,000 6,970 772,059 5%

Total Estimated 2,568,316 55,229 15,400 15,692,885 100%Historical Billing 2,575,020 56,800 15,500 14,466,334 Percent of Actual 99.7% 97.2% 99.4% 108.5%Total per ft^2 25.7 0.6 0.2 156.9

Assumptions / Notes / Conclusions

Combined Fuel End-Use Breakdown

Air Compressors1%

Cooking6%

Cooling10%

Heating28%

Lighting (Exterior)1%

Lighting (Interior)8%

Miscellaneous3%

Office Equipment8%

Other Plug Loads7%

Process18%

Pumps1%

Refrigeration1%

Ventilation3%

Water Heating

5%

Source: ASHRAE

Energy Balance

104

0

500

1000

1500

2000

2500

J F M A MA JU J A S O N D

Con

sum

ptio

n (k

Wh)

Reference year InvoicesCalculated

Energy Balance


105

Key Considerations • Accuracy • Conservativeness • Cost evaluation

Consider the potential risks

• miscalculations

• technology failures

• time to repair; foreign equipment

• operator control of the measure; training

• need for continuous supervision; real-time metering

M&V

• select M&V method

EMO Elaboration


106

ECONOMIC ANALYSIS

Project Packaging

107

Project Packaging

• Several facility owner prefer to implement EMO at their own pace • Often one measure at a time • Often they skip one year or two in their program due to evolving

priorities • They generally do not realize the quantity of monetary savings

they left on the table over the years • The next figure is often used by some ESP to provide rationale for

a single large and integrated project.

Integrated Project

108

Order Of Project Completion

Project Packaging

Project in lighting control and technology change

Current Consumption 80 kW

4,000 hrs

Future consumption

2,000 hrs

60 kW

109


If we select control first – Lighting project:

• Hours reduced by 50% : 2,000 hrs vs. 4000 hrs

• Baseline power: 80 kW

• Control cost: 43,200 EUR

• Energy Savings: 80 kW x 2,000 hrs = 160,000 kWh

• Monetary savings : 0.54 EUR / kWh x 160,000 kWh = 86,400 EUR

• Payback: 6 months

110

The economics of the fixture replacement will be less appealing:

Operating hours: 2,000 hours

Power savings: 20 kW

Cost of fixtures : 207,360 EUR

Savings: 20 kW x 2000 hrs = 40,000 kWh

Monetary savings : 0.54 EUR / kWh x 40,000 kWh = 21,600 EUR

Payback: 9.6 years (rejected)


111

But, if fixture is replaced first:

Hours of operation : 4,000 hours

Power savings: 20 kW

Cost of fixtures : 207,360 EUR

Savings: 20 kW x 4,000 hours = 80,000 kWh

Monetary savings :0.54 EUR / kWh x 80,000 kWh = 43,200 EUR

Payback : 4.8 years (well, much better)


112

Control is then replaced:

Hours reduced by 50% : 2,000 hrs

reduction

Reduced power power : 60 kW

Cost of control : 43,200 EUR

Savings: 60 kW x 2,000 hrs = 120,000 kWh

Monetary savings : 0.54 EUR / kWh x 120,000 kWh = 64,800 EUR

Payback : 0.66 years (still quite good)


113

If bundled into one measure:

200,000 EUR in savings

250,560 EUR in costs

1.25 years (perfectly acceptable)

• Order of calculation and presentation matters


114

Lighting And Effect On Cooling Load

Lighting project should be calculated before AC system improvement

The reduced load may result in lower chiller or ice storage capacity

In this case inverting measures do not equal the lighting control and fixture

measures

It will be more costly to calculate chiller replacement first as the chiller will

have excess capacity

115

Solar Films And Chillers

Measures of solar films should be calculated before the AC system improvement

Reduced AC load should be considered

Inverting measures are not equivalent here either

Less chiller capacity results in better economics

116

Hot Water Flow Reduction And Solar Water Heater

Aerators, low-flow showerhead and heat recovery measures should be

considered before sizing solar hot water systems.

117

Cost of Modifications

• Include and detail all costs by item

• These costs are actual costs, without administration, management, or contingent profits

• Finally, a global cost including overhead, profit, performance guarantee premium and financing will be determined and presented

Costs to be determined by the Project Manager

› Engineering: professional services for the preparation of drawings and specifications

› Proposal implementation: include specialists required to execute the work

› Work supervision

› M&V

› Project management

EMO Elaboration

118


Reporting

119

• Ensure that the energy audit requirements have been met • Identify the relevant measurements made during the audit • State the source of the information (calculations, simulations or estimates) • Summarize the analyses detailing any estimates, assumptions and uncertainty • State the limits of accuracy for savings and costs • Provide a prioritized list of energy performance improvement opportunities. • Suggest recommendations for the implementation of opportunities.

Reporting needs

Source: ISO 50002. Energy audits. Requirements with guidance for use. ISO 2014.

120

I. Executive summary

II. Introduction

III. Facility Description and Condition Assessment

IV. Energy Systems Analysis

V. Performance Improvement Alternatives Analysis

VI. Conclusions and Recommendations

VII. Appendices

Suggested Report Content

121

I. Executive summary

II. Background

III. Energy Audit Details

IV. Opportunities for Improving Energy Performance

V. Conclusions and Recommendations

Suggested Report Content (As per ISO 50002)


Note: Presented only to show what is in the ISO 50001 standard. The previous format is preferred.

122

Summary of energy use and consumption

Summary of recommended measures with energy savings and costs

Summary of project economic performance indicators (e.g. NPV, IRR, etc.)

Summary of implementation approach and next steps

I. Executive Summary


123

Overview of the organization

Rationale for the energy audit and description of initiatives it

supports

Descriptions of methods and accuracy

Description of audit team and details about time frames

Recognition of cooperation and assistance

II. Introduction and Background


124

Location of facility, function, overview of processes, etc.

Description of facility development history and capital planning as relevant

Description of schedules, production modes, etc.

Description of climatic data

Overview of utility use (all utilities related to energy)

Description of utility supply arrangements

Description of utility charges and tariff structure

Description of key activities and drivers of energy use

Description of energy system arrangement overview and integrations

Individual energy systems descriptions and assessment of condition

Operations and maintenance practices and description of behaviors key to energy management

Description of outsourced O&M arrangements as relevant

III. Facility Description and Condition Assessment

125

Present the key energy intensity indicators at the facility level (e.g. kWh/m2, kWh / kilogram of product, kWh / guest, etc.)

Present the energy balance - state boundary considered, all assumptions, sources or error, operating modes analyzed, etc.)

Present key energy performance indicators at the system level as relevant and as the detail / accuracy requires

Discuss and deprecation of equipment efficiencies due to physical condition or operational practices (e.g. is the equipment operated as designed / at full load?)

Discuss interactive effects between energy system that affect performance Discuss energy source conversion efficiency and waste Examine facility level and system level energy use patterns Conduct a detailed utility rate analysis and affect of energy use patterns on

energy charges Detail of analysis for each system according to strategic business goals

(should be indicated in planning)

IV. Energy Systems Analysis

126

Reporting Follows energy systems analysis Performance improvement measures presented to improve indicators and reduce cost

drivers identified in analysis Discuss scenarios for implementing measures with view on technical, economic, and

strategic impacts

Measures should be presented as integrated project scenarios and the relative costs/benefits

All presented alternatives should discuss implementation risks: • Financial • Technical • Construction • Operational • Etc.

Present economic performance indicators for each scenario as relevant

Present the final recommended scenario and rational for selection Discuss finance planning and investment arrangements as relevant

V. Performance Improvement Alternatives Analysis

127

Present an overview of key findings of energy systems performance and

utility costs

Summary of strategic business challenges and how energy system

performance are inter-related

Summarize the recommended performance improvement measures

including costs and benefits

Discuss recommended implementation strategies including specific

technology solutions and potential partners

Discuss immediate next steps

VI. Conclusions and Recommendations

128

VII. Appendices

Place any data here that is lengthy and make the main narrative untidy

Extended lists of data Extended calculations if necessary More detailed schematics and plans

129

BASELINE DEVELOPMENT Industrial Benchmarking Techniques

130

Best Available Practice (BAP) / Best Available Technologies (BAT), Concept and History • Variously referred to as:

• Best Available Technology • Best Available Techniques • Best Available Practice • Etc.

• Reduce environmental emissions through establishment of proven, cost effective technologies / techniques / practices

• Implementing BAT viewed as key to achieving de-carbonization targets • BAP / BAT has the potential to reduce emissions by 12% - 23% • BAT was first used in the 1992 OSPAR Convention for marine environmental protections

from industrial installations • Concept used in the US clean Air Act which requires certain industries to use Best Available

Control Technology to control emissions • Introduced in the EU with Directive 84/360/EEC for air pollution from large industrial

enterprises – then superseded by the “Integrated Pollution and Control Directive” or IPPC 96/61/EC

131

BAP / BAT , Examples of Key Programs and Organizations

Program / Resource Type / Resources Organization(s)

EU - IPPC Directive (2008/1/EC) - Best Available Practice Reference Document (BREF)

General European Union

Super Efficient Equipment and Appliance Deployment (SEAD)

Appliance Minimum Efficiency Performance Standards (MEPS)

International Partnership for Energy Efficiency Cooperation (IPEEC), Clean Energy Ministerial

Top Tens Task Group on Global Energy Efficiency Best Practice

BAT / BAP knowledge sharing initiative

IPEEC

Energy Technology Transfer for Industry (2009)

BAT / BAP Strategy Guide International Energy Agency

132

BAP / BAT

BAP / BAT Process Specific

Iron / Steel Cement Pulp & Paper Aluminum

BAP / BAT Non-Process Technical Area

Combustion Steam Heat Recovery

Motor Drive Systems Compressed Air Pumping HVAC Lighting Drying

BAT / BAP Organizational Level

Energy Management System O&M Process Control Energy Audit /

diagnosis Benchmarking Communication Process Design

BAT / BAP Policy Level

MEPS Benchmarking / Data Collection Energy Management Finance / Incentives R&D Training Government Green

Procurement

133

Industrial Benchmarking, Barriers

Common Barriers

Information is often sensitive / proprietary

Integration of processes / difficulty draw boundary

Values are often regional specific

Lack of comparable metrics

134

Industrial Benchmarking, Sector Specific Indicators

135

Industrial Benchmarking, Strategies

136


137


138


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