practical case studies in energy efficiency projects

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Practical Case Studies in Energy Efficiency Projects

Dan Lienhoop

Indiana Conference on Energy Management

August 15, 2017

2Internal Use Only

Cummins global presence

Employeesworldwide

55,400190+ Countries

and territories

6continents

148Fortune 500 rank

Founded & headquartered in Columbus,

Indiana

19194

Operating Segments

Public Use 2

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“…we believe that our survival in the very long run is as dependent upon responsible citizenship in our communities and in the society, as it is in responsible technological, financial and production performance.”

- - J. Irwin MillerFormer Chairman and CEO

1972

Cummins legacy and core values

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Energy footprint & goal

12,500,000gallons diesel fuel

1,490,000,000cubic feet natural gas

$150 million total energy spend

919,000,000kWh electricity

770,000 metric tons CO2e emissions

12,500,000gallons diesel fuel

1,490,000,000cubic feet natural gas

$150 million total energy spend

919,000,000kWh electricity

770,000 metric tons CO2e emissions

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Global footprint – 2016

Public Use

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5Public Use

Comprehensive energy strategy

Estimated savings of$40 million per year from energy efficiency efforts

6Public Use

Enhance energy management

Upgrade facilities & equipment

Efficient new construction

Increase renewable energy

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Enhance Energy Management

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Training

Tools

Best practices

Tech support

Employee engagement

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Enhance Energy Management

ISO 50001: Energy Management

System

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Upgrade Facilities & Equipment

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2020 Plan

• Capital investment ($12M/year)

• Project hopper• Campaigns

Investment criteria

• >11% IRR, and• <$1000/ton

CO2e, or• Strategic value

Declining rate of return

• 2016: 33% IRR• 2020: 22% IRR

(projected)

IRR = internal rate of return

Compressed Air Optimization

– Supply Side

– Demand Side

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Upgrade Facilities & EquipmentPractical Case Studies

Most of the work

is lost in heat!

Why Focus on Optimizing Compressed Air Systems?

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– Supply Side Goals

• Limit blow-off to atmosphere

• Trim/Right size to plant demand

• Decrease supply pressure

– Supply Side Project Examples

• Centrifugal air compressor controls

• Rotary screw compressor addition

• Compressed air system volume & eliminate dead heads 11



– Supply Side Project Examples

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Centrifugal air compressor controls

Provide maximum turn down

based on supply air density

ability to turn down nearly ~40%

Manage multiple compressors

optimize required number needed

manage run-time

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– Supply Side Project Examples (Continued)

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Rotary screw compressor addition

Provide further turn down capabilities outside the range of centrifugales

further eliminates potential blow-off to atmosphere


– Supply Side Project Examples (Continued)

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Compressed air system volume & eliminate dead heads

Reduces pressure drop

potential for overall system pressure reduction

Important to engineer a volume needs solution

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– Demand Side Goals

• Find alternative energy source in lieu of compressed air

• Reduce compressed air system leaks

• Ensure new installations do not exceed 90 psi demand through management of change process

– Demand Side Project Examples

• Centrifugal blower system

• Yearly ultrasonic PM program15



– Demand Side Project Examples

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• Centrifugal blower system

• Eliminated 3 compressed air blow off stations

• two systems had 2” supply pipe, one system had 1” supply pipe

• Reduced an estimated total CFM reduction of 8,284 CFMs (1,700 MWh)

• Note: centrifugal blower systems still require electricity to operate!

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– Demand Side Project Examples (continued)

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• Yearly ultrasonic PM program

• Regularly maintained compressed air systems use only 7% more air of total capacity compared to 25% more of an unmaintained air system

• Ultrasonic allows for inspection during production, thus finding leaks otherwise not found when machines are off

Chilled Water System Optimization

• Goals

• Cooling Tower Efficiency

• Chiller trim capabilities

• Complete shutdown during heating months

• Project Examples

• Cooling Tower Replacement

• Trim Chiller Installation & Test Chiller(s) Installation

• Dry Cooler Installation 18


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• Project Examples

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• Cooling Tower Replacement• Increased condenser water capacity to

allow for future (trim) chiller

• Provide cooler condenser water to chiller system, resulting in more efficient chiller operation

• up to 47% less KW/Ton during design day compared to prior system

• Reduced electric usage of 5,381 MWh/year (about $500k/year)


• Project Examples (continued)

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• Trim Chiller Installation• Trim to plant cooling demand

• Saves estimated 230 MWh/year

• Test Chiller(s) Installation• Allows for test operations to supply

own colder and consistent chilled water for special testing

• Eliminated need for running additional 1200 ton chiller during certain engine testing (2,400 hrs/yr)

• Nets 1,944 MWh Savings/yr

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• Project Examples (continued)

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• Dry Cooler Installation (Free Cooling)

• Provides ability to cool air compressors via glycol to air heat exchange, when ambient air temps are under 55⁰ F

• Removes air compressor heat load from chiller system to cool ambient air, saving electricity and water

• Proved successful for future opportunities to reach stated goal

Building Envelope Improvement Examples

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Cal wall Project• Replaced existing single pane glass panels in Bldg 82• Increased R value from 1 to 10

Dock seal and rapid roll door• Replaced 21 inefficient dock seals throughout the facility• Replaced overhead door in dock 82 with rapid roll door• Energy Savings = $36,000/year or 474 mWh/year

Roof Project (Insulation)• Added insulation to various roofs • Improved roof R value from R12 to R25 average

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Manufacturing Group Involvement Example

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• Henry Filter System VFD Controls Project• Controls pumps to cutting fluid

demand

• Expected Pumping Energy Reduction: 2,510 MW-hr/yr / $210,000 Annual

Efficient New Construction & Renewable Energy

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• Cummins Downtown Indianapolis DBU HQ Office

• Seymour Engine Plant New Test Center

• Solar Installations @ Jamestown, NY (2 MW) & Bejing, China (3.6 MW)

Investigating UV Collector Technology• Supplemental heat source for steam/water boilers

• Supplemental heat source for production wash tanks

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Practical Case Studies in Energy Efficiency Projects

practical case studies in energy efficiency projects

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