Watts in Your Business- GV - Apal

July 2014

Watts in Your Business

Program

Goulburn Valley Region

Energy Efficiency Information Grant

Watts In Your Business Program

• Purpose

� Empower SMEs to make informed decisions

about energy efficiency.

� Enable SMEs to achieve reductions in their

operational energy costs.

• Process

� Department of Industry to provide funding to

industry associations to develop and deliver

practical, tailored energy efficiency information

to SMEs.

Watts In Your Business Program

1. Market Survey and Analysis

• Identify “Temperate fruit sector representative” sites

2. Energy Audits

• Identify energy efficiency opportunities

3. Learning Tools - Fact Sheets and Case Stories

• Detailed ways to reduce energy for the largest energy

uses and examples of implementation

4. Shed Walks / Seminars

• Deliver the learning tools to the sector in a practical

and relevant manner – ‘hands on and on site’

Watts In Your Business Program

• Audited 30 sites across 10 regions

� 3 regions in VIC

� 3 regions in NSW

� 1 region in QLD, SA, WA, TAS

• Results provided relate to the Watts in Your Business

Program outcomes and averages

Energy Source Usage Costs

Electricity (kWh) 20,257,165 $3,700,501

LPG (Litres) 1,506,331 $541,521

Fuel (Litres) 1,015,653 $1,435,805

Total $5,677,827

Energy Usage and Costs

47%

14%

39%

Energy Usage

Electricity

LPG

Vehicle Fuel 65%10%

25%

Costs

Electricity

LPG

Vehicle Fuel

Electricity Usage Breakdown

64%

18%

8%

6%

3% 1%

Electricity Usage

Refrigeration

Irrigation Pumps

Grading Equipment

Controlled Atmosphere

Lighting

Other

Refrigeration Electricity

Breakdown

48%

27%

14%

9%2%

Refrigeration Usage

Compressors

Evporative Fans

Pumps

Condensors

Other

Program Electricity Outcomes

Aspect Program Total Average TotalCost Effective

Program Average

Electricity Savings

(kWh) 5,576,010 185,867 94,999

Cost Savings $965,763 $32,192 $16,281

Capital Investment $10,513,759 $350,459 $60,960

Simple Payback 10.9 10.9 3.7

% reduction of

electricity use27.5% 32.4% 14%

LPG Usage Breakdown

43%

31%

15%

11%

LPG Usage

Dryers

Hot Water

Controlled Atmosphere

Fork Lifts

Tariff Charges

65%

32%

3%

Sites with a Demand Charge

Usage

Demand

Fix97%

3%

Sites without a Demand Charge

Usage

Fix

Tariff Cold Store Irrigation GV Cold Store GV Irrigation

Usage- Peak (per kWh) $0.27 $0.31 $0.18 $0.27

Usage- Off-Peak (per kWh) $0.13 $0.15 $0.09 $0.11

Usage- Average Total (per kWh) $0.20 $0.22 $0.14 $0.15

Demand (per kVA or kW) $13.53 - $9.10 -

Fix (per annum) $1,791 $866.50 $1,682 $928

Interval Data

0

50

100

150

200

250

30000:1

5

01:3

0

02:4

5

04:0

0

05:1

5

06:3

0

07:4

5

09:0

0

10:1

5

11:3

0

12:4

5

14:0

0

15:1

5

16:3

0

17:4

5

19:0

0

20:1

5

21:3

0

22:4

5

00:0

0

Consumption (kW)

Time

Mon

Tue

Wed

Thu

Fri

Sat

Sun

Interval Data

0

50

100

150

200

250

300

35000:1

5

01:3

0

02:4

5

04:0

0

05:1

5

06:3

0

07:4

5

09:0

0

10:1

5

11:3

0

12:4

5

14:0

0

15:1

5

16:3

0

17:4

5

19:0

0

20:1

5

21:3

0

22:4

5

00:0

0

Consumption (kW)

Time

Summer

Autumn

Winter

Spring

Key Performance Indicators

(KPI)

Crop TypeElectricity

(kWh/tonne)

LPG

(ltr/tonne)

Fuel

(ltr/tonne)

Costs

($/tonne)

Apple & Pear 129 7 12 $52

Mix 224 11 14 $81

Stonefruit 323 12 28 $151

Goulburn Valley 179 13 13 $48

Program Total 193 9 17 $78

• A set of quantifiable measures that a company or

industry uses to gauge or compare performance.

• Program KPI’s is crop type per tonne of fruit

produced.

Key Performance Indicators

(KPI)

Orchard SizeElectricity

(kWh/tonne)

LPG

(ltr/tonne)

Fuel

(ltr/tonne)

Costs

($/tonne)

Small 271 13 27 $128

Medium 171 9 12 $63

Large 137 7 10 $44

• Alternative KPI’s separated by orchard size

based on tonne of fruit produced.

Top Ten Program Opportunities

Reference OpportunityAverage

payback

Reduction in site

electricity use

1 Off-Peak Irrigation (17%) 1.0 -

2 Variable Head Pressure (73%) 3.4 2%

3 Air Compressor Leak Maintenance (17%) 3.5 >1%

4 Automatic Cold Storage Doors (90%) 4.6 3%

5 VSDs on Irrigation Pumps (57%) 5.6 3%

6 Voltage Power Optimisation (37%) 5.6 8%

7 Lighting Upgrades (100%) 5.6 1%

8 VSD on Evaporative Motors (63%) 6.2 4%

9 Solar (93%) 6.2 8%

10 High Efficiency Motors for Irrigation (63%) 6.9 1%

11 Replacement of HCFC Refrigeration Systems 39.5* 7%

* Payback is only based on electricity savings and does not include maintenance

and refrigerant cost savings.

Top 5 Regional Opportunities

(Goulburn Valley)

1. Air Compressor Leak Maintenance

2. Automatic Cold Storage Doors

3. Lighting Upgrades

4. VSDs on Irrigation Pump Motors

5. Variable Head Pressure Control

Air Compressor Leak

Maintenance

• Consistent maintenance issue

• Educate staff to identify leaks

(through hissing sound)

• Create maintenance program

• Install shut off valves

Parameter Program Range Program Average GV Average

Electricity Savings (kWh) 111 – 2,076 825 1,234

Annual Cost Savings $17 - $228 $109 $159

Capital Costs $150 - $750 $380 $508

Simple payback (years) 2.5 – 10.0 3.5 3.4

Automatic Cold Storage Doors

ParameterProgram Average

(Electronic)

Program Average

(Rapid Lift)

GV Average

(Electronic)

Electricity Savings (kWh) 8,337 9,018 10,899

Annual Cost Savings $1,624 $1,743 $1,927

Capital Costs $7,435 $20,292 $8,464

Simple payback (years) 4.6 11.6 5.6

Lighting- Tubes

ParameterProgram

Average (T5)

Program

Average (LED)

GV

Average (T5)

Electricity Savings (kWh) 1,030 1,207 1,267

Annual Cost Savings $219 $285 $230

Capital Costs $1,022 $1,777 $1,152

Simple payback (years) 4.7 6.2 5.1

• T8 or T12 to T5

• T8 to LED

Lighting - High Bays

• High Bays to LEDs

Parameter Program RangeProgram

Average

GV

Average

Electricity Savings (kWh) 268 – 22,542 7,766 10,961

Annual Cost Savings $72 - $4,200 $1,533 $2,003

Capital Costs $800 - $44,800 $10,478 $15,596

Simple payback (years) 1.7 – 30.1 6.8 8.3

Variable Speed Drives on

Irrigation Pumps

• Variable Speed Drive (VSD)- regulate the frequency

of the electrical power supplied and match the

volume or pressure requirements of the refrigeration

system

0%10%20%30%40%50%60%70%80%90%

100%

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

50%

55%

60%

65%

70%

75%

80%

85%

90%

95%

100%

Energy Savings

Reduction in Fan Speed

VDSs on Irrigation Pump Motors

Parameter Program RangeProgram

Average

GV

Average

Electricity Savings (kWh) 925 – 285,000 40,557 31,733

Annual Cost Savings $167 - $40,755 $6,024 $5,213

Capital Costs $4,000 - $200,000 $37,090 $26,087

Simple payback (years) 4.8 – 45.5 6.2 5.4

Head Pressure Basics

• The head pressure (discharge pressure)

or condensing temperature of a

refrigeration system has a direct impact on

compressor power consumption

• At cooler ambient temperatures it is easier

to liquefy the compressed refrigerant due

to the temperature differential

Head Pressure Reduction

• Optimise the relationship

between the compressor

and condenser

• On average optimising the

head pressure of a system

can achieve a 3-12%

reduction in power

consumption

• Recommended to speak to

your refrigeration contractor

on how/when to implement

Variable Head Pressure Control

and Head Pressure Reduction

Parameter Program RangeProgram

Average

GV

Average

Electricity Savings (kWh) 540 – 110,000 13,393 37,875

Annual Cost Savings $195 - $15,730 $2,113 $4,899

Capital Costs $1,500 - $65,000 $8,813 $23,275

Simple payback (years) 1.1 – 13.3 5.2 6.1

Audit FAQs

• What is my demand charge? How can I reduce it?

� Demand is the largest amount of electricity being consumed at

any one point in time

� Load Shifting, Contract Negations, VPO, Power Factor Correction.

See Tariff Fact Sheet.

• Which refrigerant is the “best”?

� HCFC- (R22, R123,R401/2/3/8/9) Phase out

� R427A- R22 replacement initial estimates have 7% efficiency loss

� HFCs- (R143a, R404a, R407a, R410a)

� Ammonia- High capital cost/corrosive

� Natural Hydrocarbons- (propane mixtures) flammable

� CO2- No industry examples

Funding

• Federal Funding

– With the repeal of carbon tax there is some

uncertainty in this area

• State Funding

– VEET/VEEC

– Sustainability Victoria

• Private Funding

– Financing (e.g. CBA)

Acknowledgements