2008 Energy Efficiency Presentations Contents List

2008 Energy Efficiency Presentations Contents List

1. Tips for Starting an Energy Management Program (Click to go to PDF Page 2)

2. Energy Efficient Buildings (Click to go to PDF Page 15)

3. Industrial Heat Efficiency and Heat Recovery (Click to go to PDF Page 49)

4. Energy Efficiency in Steam Systems (Click to go to PDF Page 69)

5. Energy Efficiency Pumps and Fans (Click to go to PDF Page 98)

6. Motors and Compressors (Click to go to PDF Page 129)

Tips for Starting an Energy Tips for Starting an Energy

Management ProgramManagement Program

John S. Raschko, Ph.D.John S. Raschko, Ph.D.Mass. Office of Technical AssistanceMass. Office of Technical Assistance

www.mass.gov/envir/otawww.mass.gov/envir/ota(617) 626(617) 626--10931093

Fundamentals of Energy Efficiency:Fundamentals of Energy Efficiency:

An Introductory WorkshopAn Introductory WorkshopApril 2008April 2008April 2008April 2008April 2008April 2008April 2008April 2008

Return toContents List

Developing an Energy Developing an Energy

Management StrategyManagement Strategy

•• Use of formal energy management programs Use of formal energy management programs becoming more popularbecoming more popular

•• Number of resources available Number of resources available –––– DOE DOE Corporate Energy Management Corporate Energy Management (CEM)(CEM) program program ––

•• Modeled on quality management systemsModeled on quality management systems•• Moves accountability for energy outcomes to upper levels of Moves accountability for energy outcomes to upper levels of the firm; involves many areas of business activity (not just the firm; involves many areas of business activity (not just production)production)

•• Measure current performance, set goals, track savings, and Measure current performance, set goals, track savings, and reward improvementsreward improvements

•• http://www1.http://www1.eereeere.energy.gov/industry/.energy.gov/industry/bestpracticesbestpractices/corpora/corporate_energy.htmlte_energy.html

Developing an Energy Developing an Energy

Management StrategyManagement Strategy

•• Resources Resources (cont.)(cont.) –––– EPA/DOE ENERGY STAREPA/DOE ENERGY STAR®® program program ––

•• Guidelines for Energy Management Guidelines for Energy Management -- measure current measure current performance, set goals, track savings, and reward performance, set goals, track savings, and reward improvements; benchmarkingimprovements; benchmarking

•• Assessment tools Assessment tools –– for both corporate and facility levelsfor both corporate and facility levels

•• Other tools available Other tools available –– energy mgt. guidance, improving energy mgt. guidance, improving system performance (lighting, fans, etc.), financial system performance (lighting, fans, etc.), financial evaluation, computer power mgt.evaluation, computer power mgt.

•• Training Training –– webinars, prewebinars, pre--recorded training, selfrecorded training, self--guided guided presentationspresentations

•• Partnerships with industryPartnerships with industry•• http://www.energystar.gov/index.cfm?c=guidelines.guidelinehttp://www.energystar.gov/index.cfm?c=guidelines.guidelines_indexs_index

1.1. Assign ResponsibilityAssign Responsibility

2.2. Assemble DataAssemble Data

3.3. First Cut AnalysisFirst Cut Analysis

4.4. More Complex AnalysisMore Complex Analysis

5.5. Short and Long Term PlansShort and Long Term Plans

6.6. Examine ProcurementExamine Procurement

7.7. Monitor, Monitor, MonitorMonitor, Monitor, Monitor

DOER 7DOER 7--Step Energy Action Step Energy Action

PlanPlan

Identifying and Evaluating Energy Identifying and Evaluating Energy

Efficiency OpportunitiesEfficiency Opportunities

•• DOE Industrial Technology Program (ITP) tools DOE Industrial Technology Program (ITP) tools ––

–– Quick Plant Energy Profiler (QuickPEP)Quick Plant Energy Profiler (QuickPEP) -- run online at run online at

DOEDOE’’s website; meant to be a broad overview of the s website; meant to be a broad overview of the

energy profile for a plant. energy profile for a plant. http://www1.eere.energy.gov/industry/bestpractices/softwhttp://www1.eere.energy.gov/industry/bestpractices/software.htmlare.html

DOE QuickPEP ToolDOE QuickPEP Tool



•• DOE Industrial Technology Program (ITP) tools (contDOE Industrial Technology Program (ITP) tools (cont’’d) d) ––

–– Energy Use and Loss FootprintsEnergy Use and Loss Footprints -- developed for a number of developed for a number of

manufacturing industries; map the flow of energy supply, manufacturing industries; map the flow of energy supply,

demand, and losses in manufacturing facilities.demand, and losses in manufacturing facilities.

–– Software toolsSoftware tools -- evaluate energy saving opportunities in variety evaluate energy saving opportunities in variety

of systems, e.g., steam, motors, pumps, compressed air, fans, of systems, e.g., steam, motors, pumps, compressed air, fans,

process heating, CHPprocess heating, CHP

•• Massachusetts Energy Efficiency Partnership (MAEEP) conducts Massachusetts Energy Efficiency Partnership (MAEEP) conducts

trainings on these toolstrainings on these tools



•• Energy Audits (gas and electric) Energy Audits (gas and electric) –––– Comprehensive assessment for determining the best energy Comprehensive assessment for determining the best energy

measures measures ––

•• Detailed evaluation of energy use, including load profileDetailed evaluation of energy use, including load profile

–– Providers Providers ––

•• DOE Save Energy Now programDOE Save Energy Now program –– 3 day assessment involving 3 day assessment involving training on DOE software tools; 0.3 trillion Btu/yr training on DOE software tools; 0.3 trillion Btu/yr totaltotal energy use; energy use;

typically no cost; apply onlinetypically no cost; apply online

http://www1.eere.energy.gov/industry/saveenergynow/assessments.hhttp://www1.eere.energy.gov/industry/saveenergynow/assessments.htmltml

•• Industrial Assessment Center (IAC) auditsIndustrial Assessment Center (IAC) audits –– 1 day, no cost, energy 1 day, no cost, energy costs $100,000 to $1.75 million/year, SIC 20 costs $100,000 to $1.75 million/year, SIC 20 –– 39 39 ((Dr. Beka Kosanovic (413) 545Dr. Beka Kosanovic (413) 545--06840684 http://www.ceere.org/iac/index.htmlhttp://www.ceere.org/iac/index.html))

•• Consultants Consultants

IdentifyingIdentifying and Evaluating Energy and Evaluating Energy


•• Energy Audits Energy Audits (cont(cont’’d)d) ––

–– Often subsidized by utilities through their energy efficiency Often subsidized by utilities through their energy efficiency

programs programs ––

•• Contact your utility account representatives for detailed informContact your utility account representatives for detailed information ation

on your provideron your provider’’s programs s programs

•• All investor owned utilities (IOUs) have programs (e.g., NSTAR, All investor owned utilities (IOUs) have programs (e.g., NSTAR,

NGRID, WMECO, Keyspan, Bay State Gas)NGRID, WMECO, Keyspan, Bay State Gas)

•• Municipal utility programs vary Municipal utility programs vary –– links to many at MA Division of links to many at MA Division of

Energy Resources (DOER) websiteEnergy Resources (DOER) website

•• Utilities can also assist with load managementUtilities can also assist with load management

Other ResourcesOther Resources

•• MA DOER MA DOER –––– information on energy resources, including energy information on energy resources, including energy procurement, fuel prices, conservation, and procurement, fuel prices, conservation, and renewablesrenewables

–– http://www.mass.gov/doer/http://www.mass.gov/doer/

•• Combined heat and power (CHP) Combined heat and power (CHP) --–– Northeast CHP Application Center Northeast CHP Application Center (@(@ CEERE) CEERE) ––

•• provides assessments and detailed information on CHPprovides assessments and detailed information on CHP

•• http://www.northeastchp.org/nac/index.cfmhttp://www.northeastchp.org/nac/index.cfm

–– EPA CHP Partnership EPA CHP Partnership ––•• Info on technologies, emissions, $$, decision toolInfo on technologies, emissions, $$, decision tool

•• http://www.epa.gov/chp/http://www.epa.gov/chp/

Other ResourcesOther Resources

•• Energy Service Companies (ESCOs) Energy Service Companies (ESCOs) –––– develops, installs, and finances projects designed to develops, installs, and finances projects designed to

improve the energy efficiency and maintenance costs improve the energy efficiency and maintenance costs for facilities over a seven to 10 year time period.for facilities over a seven to 10 year time period.

–– assume the technical and performance risk assume the technical and performance risk associated with the project associated with the project

–– National Association of Energy Service Companies National Association of Energy Service Companies (NAESCO)(NAESCO) http://http://www.naesco.org/about/esco.htmwww.naesco.org/about/esco.htm

Useful PublicationsUseful Publications

•• Rutgers SelfRutgers Self--Assessment Workbook for Small Assessment Workbook for Small

Manufacturers Manufacturers http://iac.rutgers.edu/database/technicaldocs/IAC_Manuhttp://iac.rutgers.edu/database/technicaldocs/IAC_Manualsselfassessment.pdfalsselfassessment.pdf

•• Wulfinghoff, Donald R., Energy Efficiency Wulfinghoff, Donald R., Energy Efficiency

Manual, Energy Institute Press, 1999Manual, Energy Institute Press, 1999

•• Mull, Thomas E., Practical Guide to Energy Mull, Thomas E., Practical Guide to Energy

Management for Facilities Engineers and Plant Management for Facilities Engineers and Plant

Managers, ASME Press, 2001Managers, ASME Press, 2001

ContactContact

John RaschkoJohn Raschko

(617) 626(617) 626--10931093

[email protected]@state.ma.us

Energy Efficient Buildings

by Jim Cain, OTA

April 15 and 30, 2008

Return to Contents List

20 Minute Snapshot

Buildings and Energy

• Energy is Becoming Costly

• Building Function and Business Type

• Energy Use Categories

• Environmental Factors

• Useful Literature

• OTA Fact Sheet

• Energy Predictions and Software

Dec. 2007 Mass. Average = 14.6 cents (all sectors) ; 13.2 cents (industrial) EIA report 3-13-08

Facility Energy Flow Diagram(waste heat and emissions not shown)

7%2%Office Equipment

22%1%Lighting

11%3%Machine Drives and Fans

7%2%Cooling:

Process and Space

35%25%Heating:

Process and Space

HighLowFacility Energy Use

EIA National Energy Surveys Show Wide

Variation in a Facility’s Proportionate Use By

Business, Function, Region, Site factors, etc

1. Capture waste heat

2. Supply air to equipment directly from outside

3. Reduce infiltration and increase insulation

4. Add economizers to A/C system (except when humid)

5. Identify and correct unwanted drafts through building

6. Use ceiling fanswhere appropriate

7. Separate / isolate adjacent rooms , if at different climates

8. Insulate heating and cooling ducts when economical

9. Use automatic and/or programmable controls

10.Shade east / west windows of building in summer and expose south windows (winter

11.Set thermostats cooler in winter and warmer in summer

HVAC (Heating, Ventilating, and Air Conditioning)

600 pages c. 2001 ASMEIntroduction to Energy ManagementBasic Scientific PrinciplesEconomics for Energy ManagementCombustion Systems and BoilersSteam SystemsHydronic and Pumping SystemsChillers and Chilled Water SystemsCooling Towers and Fluid CoolersAir Distribution and HVAC SystemsElectrical and Lighting SystemsCompressed Air SystemsRefrigeration SystemsHeat Recovery and Waste Heat MgtThermal Energy Storage SystemsEnergy Mgt and Control Systems

Building Energy: 345 Software Tools

http://www.eere.energy.gov/buildings/tools_directory/

• Whole Building Analysis– Energy Simulation– Load Calculation– Renewable Energy– Retrofit Analysis– Sustainability / Green Buildings

• Codes & Standards

• Materials, Components, Equipment, & Systems– Envelope Systems– HVAC Equipment and Systems– Lighting Systems

• Other Applications– Energy Economics, Atmospheric Pollution, Indoor Air, Training,

Ventilation / Airflow, Multibuilding Facilities, Utility Evaluation, Solar/Climate Analysis, Water Conservation, Validation Tools, Misc.

from EnergyPlus Trainingby NREL / DOE and

GARD Analytics / Univ of Illinois

eQUEST from doe.gov

Whole Building Integrated Energy Design

Input: Building Site Info and WeatherBuilding Shell, Structure, Materials, ShadesBuilding Operations and SchedulingInternal LoadsHVAC Equipment and PerformanceUtility RatesEconomic Parameters

http://www.sbicouncil.org/store/e10.php

• ENERGY-10™ calculates integrated energy performance and is best suited to buildings with one or two thermal zones. The interface is simple, the analysis thorough, and the results accurate and quick. Building types that are most frequently simulated using this software include retail and office buildings, warehouses, schools, restaurants, residences, lodging facilities, and more.

Verification of Energy-10 SimulationsThesis by Justin Ng Hsing Aik, NCSU 2005

Proposed Measures (School)

• Upgrade Heat Pumps No

• Install Economizer on Heat Pumps No

• Upgrade T-12 Fluorescents Yes

• Insulate Building Envelope No

• Setback Temp. April-October Yes

• Timer Fan / Heat Pumps - Winter Yes

• Increase Ventilation (15 cfm/person) Req

• Move Computer from Return Air Duct Yes

(170 pages)http://www.energystar.gov/index.cfm?c=business.bus_upgrade_manual

Introduction Business AnalysisFinancingRecommissioningTune-up all systems:

Lighting & Supplemental LoadsBuilding EnvelopeControlsTesting, Adjusting, BalancingHeat Exchange EquipmentHeating and Cooling System

LightingSupplemental Load ReductionsFan System UpgradesHeating & Cooling System Upgrades

Color Temperature of Various Light SourcesFrom Energystar Building Upgrade Manual

Lamp CharacteristicsFrom Energystar Building Upgrade Manual

Wulfinghoff’s Energy Manual Contents 1500 pages

Boiler Plant 12 topics 200 pagesChiller Plant 12 topics 200 pagesService Water Systems 3 topics 100 pagesAir Handling Systems, 9 topics 200 pagesRoom Conditioning Units &

Self-Contained HVAC Equipment - 100 pagesBuilding Air Leakage - 70 pagesBuilding Insulation - 30 pagesControl and Use of Sunlight - 100 pagesArtificial Lighting - 150 pagesIndependent Energy-Using Components – 40 pages

Reference Notes - 160 pagesEnergy Mgt ToolsEnergy SourcesMechanical EquipmentBuilding Envelope Lighting

How Can OTA Help You ?

Jim Cain, environmental Engineer

[email protected]

(617) 626-1081

Office of Technical Assistance and Technology

Executive Office of Energy and Environmental Affairs

100 Cambridge Street, Suite 900

Boston, MA 02114

www.mass.gov/envir/ota

Industrial Heat Efficiency and Heat Recovery

Michelle Miilu

MA Office of Technical Assistance

Fundamentals of Energy Efficiency and Renewable Energy – Holyoke, MA

April 15, 2008


Sequential Strategies for Heat

1) Reduce demand for heat

2) Where heat is needed, conserve

3) Recycle waste heat

Reduced Heat Options

• Alternatives to heat curing

• Eliminate need for thermal oxidizer

• Ambient temperature processes

Heat Efficient Equipment Ideas

• Energy Star productswww.energystar.gov/index.cfm?fuseaction=find_a_product.

(note period at end of link address!)

• Ovens and other process equipment

• Boilers and hot water heaters

• Controls

• Cafeteria equipmentwww.fypower.org/pdf/BPG_RestaurantEnergyEfficiency.pdf

Operation & Maintenance

• Maintain optimal control settings

• Clean heat transfer surfaces

• Fix leaks

• Turn off equipment when not in use

Sources of Heat Loss

• Conduction

• Convection

• Radiation

Reduce Heat Losses

• Fix leaks

• Minimize drafts into ovens, buildings, open process tanks, etc.

• Insulate piping, process tanks, water heaters, etc. containing heated substances

Leaks

• HVAC

• Steam systems

• Compressed air systems

• Heated process equipment

Drafts

• Cause Equipment to Use More Fuel to Maintain Temperature

• Corrosion Holes

• Entrance and Exit of Enclosed Process Equipment

• Open Doors, Windows, and Process Equipment

Sources

Result

Insulate

• Cover open process tanks – floats or lids

• Insulate steam and hot water systems including piping and valves

• Insulate buildings and

HVAC ductwork

U Dayton - IAC

energyconcepts.tripod.com/energyconcepts/

• Energy Efficiency measures may allow set temperatures to be reduced

Heat Recovery

• Are there opportunities to use waste heat?

– Pre-heating water or air

– Space heating

• Is waste heat available when there is demand for heat?

• How does the amount of waste heat match with application demand - flow and temp.?

Audience Question

• Name some sources of

waste heat

Waste Heat Source Examples

• Flue gas

• Motors

• Heated process equipment

• Sanitary and industrial wastewater

• Boiler blowdown

• Building ventilation

Wide Variety of Equipment

• Equipment choice will depend on:

Temperatures

Application

Liquid vs. gas

Contaminants in waste heat stream

• Heat recovery equipment overview:

www.pge.com/003_save_energy/003c_edu_train/pec/info_resource/pdf/HEATRECO.PDF

DHW: Special Case

• If heat recovery equipment will come in contact with domestic hot water, that equipment must be approved by the state Plumbers and Gas Fitters Board.

• List of approved equipment:

– license.reg.state.ma.us/pubLic/pl_products/pb

_pre_form.asp

Financials

• Paybacks for heat efficiency and heat recovery projects are often less than 2 years

• Funding is often available from your investor-owned gas utility

Resources

• Great efficiency ideas!– www.engr.udayton.edu/udiac/Documents/ProcHeat.doc

• DOE tip sheets and software (PHAST)

• Funding resources

– www.dsireusa.org

– KeySpan, Bay State, & NSTAR offer funding

or contact your gas utility

Questions??

Michelle Miilu

MA OTA

100 Cambridge St., Suite 900

Boston, MA 02114

(617) 626-1094

[email protected]

Energy Efficiency in Steam Energy Efficiency in Steam

SystemsSystems

John S. Raschko, Ph.D.John S. Raschko, Ph.D.Mass. Office of Technical AssistanceMass. Office of Technical Assistance

www.mass.gov/envir/otawww.mass.gov/envir/ota(617) 626(617) 626--10931093

Fundamentals of Energy Efficiency:Fundamentals of Energy Efficiency:

An Introductory WorkshopAn Introductory Workshop

April 2008April 2008

Return toContents List

SteamSteam Systems have Four Systems have Four

Basic ComponentsBasic Components

Generation, Distribution, End Use, RecoveryGeneration, Distribution, End Use, Recovery

Source – DOE

Steam System ComponentsSteam System Components

•• Fuel Storage and handling equipment Fuel Storage and handling equipment

•• BoilerBoiler

•• Boiler auxiliariesBoiler auxiliaries

•• Steam pipingSteam piping

•• Water treatment equipmentWater treatment equipment

•• Heat exchangersHeat exchangers

•• Pressure reducing stationsPressure reducing stations

•• Steam trapsSteam traps

•• Condensate recoveryCondensate recovery

•• TurbinesTurbines

Boiler Configurations Boiler Configurations ––

FireFire--tube Boilertube Boiler

Boiler Configurations Boiler Configurations ––

WaterWater--tube Boilertube Boiler

Establishing Boiler Cost and Establishing Boiler Cost and

Operations DataOperations Data

•• Determine the total cost of fuel supplied to Determine the total cost of fuel supplied to the boilers ($/year, $/month, and the boilers ($/year, $/month, and $/season).$/season).

•• Calculate the unit cost of fuel based on Calculate the unit cost of fuel based on energy ($/MMBtu).energy ($/MMBtu).

•• Compare the unit cost of fuel to other Compare the unit cost of fuel to other available fuel supplies.available fuel supplies.

•• Determine the unit cost of electricity Determine the unit cost of electricity supplied to the facility ($/MMBtu).supplied to the facility ($/MMBtu).

Establishing Boiler Cost and Establishing Boiler Cost and

Operations DataOperations Data

•• Compare the unit cost of fuel to the cost of Compare the unit cost of fuel to the cost of electricity supplied to the facility.electricity supplied to the facility.

•• Determine the typical steam production for Determine the typical steam production for the facility (lb/hr and lb/day).the facility (lb/hr and lb/day).

•• Determine the production cost of steam for Determine the production cost of steam for the facility ($/lb).the facility ($/lb).

•• Determine the amount of steam required Determine the amount of steam required to produce a product (lb steam/lb to produce a product (lb steam/lb product).product).

Boiler PerformanceBoiler Performance

Objective maximize efficiencyObjective maximize efficiency

•• Major sources of energy lossesMajor sources of energy losses–– Stack Gas LossesStack Gas Losses

–– Radiation and Convection LossesRadiation and Convection Losses

–– BlowBlow--down Lossesdown Losses

•• Design FactorsDesign Factors–– Stack Gas TemperatureStack Gas Temperature

–– Boiler Excess AirBoiler Excess Air

–– Radiation LossesRadiation Losses

•• Fuel PropertiesFuel Properties

•• Operating PracticesOperating Practices

Stack LossesStack Losses

•• Temperature and Combustion LossesTemperature and Combustion Losses

•• Combustion EfficiencyCombustion Efficiency is the method used is the method used

to determine stack lossesto determine stack losses

•• Combustion EfficiencyCombustion Efficiency is determined by a is determined by a

chemical analysis of the flue gas and flue gas chemical analysis of the flue gas and flue gas

temperature measurementtemperature measurement

Measuring Boiler EfficiencyMeasuring Boiler Efficiency

•• The basic unit measures OThe basic unit measures O22, CO, CO22, and ambient , and ambient and stack temperaturesand stack temperatures

•• Optional sensors: NO, NOOptional sensors: NO, NO22, SO, SO22 and high CO and high CO concentrationsconcentrations

Methods to Improve Boiler Methods to Improve Boiler

EfficiencyEfficiency

•• Some examples Some examples ––

–– Install economizerInstall economizer

–– Reduce boiler pressureReduce boiler pressure

–– Preheat combustion airPreheat combustion air

–– Automatic boiler combustion controlsAutomatic boiler combustion controls

–– Proper boiler water treatmentProper boiler water treatment

Install EconomizerInstall Economizer

Install Economizer Install Economizer -- ExampleExample

•• 600 hp boiler (~26 MMBtu/hr)600 hp boiler (~26 MMBtu/hr)

•• Fuel cost: $4.50/MMBtu (#2 fuel oil)Fuel cost: $4.50/MMBtu (#2 fuel oil)

•• Annual fuel use: 126,000 MMBtu (900,000 Annual fuel use: 126,000 MMBtu (900,000 gal)gal)

•• Efficiency increased from 78% to 82%Efficiency increased from 78% to 82%

•• Energy savings: 6,146 MMBtu/yrEnergy savings: 6,146 MMBtu/yr

•• Cost savings: ~$27,000Cost savings: ~$27,000

•• Implementation cost: ~$47,000Implementation cost: ~$47,000

•• Simple payback period: 1.8 yearsSimple payback period: 1.8 years

Reduce Boiler PressureReduce Boiler Pressure

Reduce Boiler PressureReduce Boiler Pressure

•• Saturated steam boiler pressure reduced Saturated steam boiler pressure reduced from 54 psig (301 F) to 30 psig (274 F)from 54 psig (301 F) to 30 psig (274 F)–– Flue gas temperature decreased by 38 F Flue gas temperature decreased by 38 F (which reduced the combustion loss (which reduced the combustion loss approximately 1.5%)approximately 1.5%)

–– Potential steam leak would be reduced by Potential steam leak would be reduced by 30%30%

–– Heat transfer loss from properly insulated Heat transfer loss from properly insulated pipe should decrease by more than 10%pipe should decrease by more than 10%

Preheat Combustion AirPreheat Combustion Air

•• A 40 F rise in combustion air temperature yields A 40 F rise in combustion air temperature yields

~1% increase in boiler efficiency~1% increase in boiler efficiency

Steam Header

Steam Header

Pressure

Control

Combustion

Air FanFuel Valve

Adjustable Cam

Boiler Combustion Control Boiler Combustion Control

(Semi(Semi--automatic)automatic)

Boiler Combustion Control Boiler Combustion Control

(Automatic)(Automatic)

Steam Header

Steam Header

Pressure

Control

Combustion

Air Fan

Fuel Valve

Adjustable

Cam

Oxygen

Sensor

In Flue Gas

Proper Boiler Water TreatmentProper Boiler Water Treatment

•• Hardness precipitates as a solid Hardness precipitates as a solid scalescale or solid or solid sludgesludge..

•• ScaleScale -- a continuous layer of material deposited on the water a continuous layer of material deposited on the water side of the boiler tubes that acts as an insulating material andside of the boiler tubes that acts as an insulating material anda barrier to heat transfer.a barrier to heat transfer.–– Scale must be mechanically or chemically removed offline. Scale must be mechanically or chemically removed offline.

•• SludgeSludge -- a general term applied to loose solid material found a general term applied to loose solid material found in boiler water.in boiler water.–– Sludge contributes to tube plugging and is removed by Sludge contributes to tube plugging and is removed by

blowdown.blowdown.

Bottom line Bottom line –– scale and sludge reduce heat scale and sludge reduce heat transfer (and transfer (and ∴∴∴∴∴∴∴∴ efficiency)efficiency)

Scale EffectScale Effect

•• 1/161/16”” thick scale thick scale

deposit reduces deposit reduces

heat transfer heat transfer

coefficient by 6%coefficient by 6%

•• As a result flue gas As a result flue gas

temperature will temperature will

increaseincrease

Steam Distribution SystemSteam Distribution System

•• Steam leaksSteam leaks

•• Heat transfer loss Heat transfer loss through insulationthrough insulation

•• Condensate lossCondensate loss

Steam Trap OperationSteam Trap Operation

•• Three types of steam trapsThree types of steam traps–– Mechanical or DensityMechanical or Density

–– Thermostatic or Temperature ControlledThermostatic or Temperature Controlled

–– Thermodynamic or Velocity ControlledThermodynamic or Velocity Controlled

Steam Loss Can Be ExpensiveSteam Loss Can Be Expensive

Testing Steam TrapsTesting Steam Traps

•• Visual testingVisual testing

•• Ultrasonic trap testingUltrasonic trap testing

•• Temperature testingTemperature testing

•• Conductivity testingConductivity testing

Recommended Testing IntervalsRecommended Testing Intervals

• HighHigh--Pressure (150 psig and above): Pressure (150 psig and above): Weekly to MonthlyWeekly to Monthly

•• MediumMedium--Pressure (30 to 150 psig): Pressure (30 to 150 psig): Monthly to QuarterlyMonthly to Quarterly

•• LowLow--Pressure (below 30 psig): Pressure (below 30 psig): AnnuallyAnnually

Condensate RecoveryCondensate Recovery

Why it Matters Why it Matters --–– The energy contained in the condensateThe energy contained in the condensate

–– Water commodity costWater commodity cost

–– Water treatment costWater treatment cost

–– Wastewater chargesWastewater charges

Condensate Recovery Condensate Recovery ––

Flash SteamFlash Steam

Additional Steam System Energy Additional Steam System Energy

Efficiency MeasuresEfficiency Measures

•• Consider steam turbine drives for rotating equipmentConsider steam turbine drives for rotating equipment

•• Replace pressureReplace pressure--reducing valves with backpressure reducing valves with backpressure turbogenerators (i.e., install Combined Heat and Power turbogenerators (i.e., install Combined Heat and Power [CHP])[CHP])

•• Upgrade Boilers with EnergyUpgrade Boilers with Energy--Efficient Burners Efficient Burners

•• Cover Heated, Open Vessels Cover Heated, Open Vessels

•• Install an Automatic Blowdown Control System Install an Automatic Blowdown Control System

•• Use Low Grade Waste Steam to Power Absorption Use Low Grade Waste Steam to Power Absorption ChillersChillers

DOE Steam ToolsDOE Steam Tools

LOTLOT of resources available of resources available --

–– Software Software –– Steam System Scoping Tool, Steam Steam System Scoping Tool, Steam

System Assessment Tool (SSAT), 3E Plus (insulation)System Assessment Tool (SSAT), 3E Plus (insulation)

–– Publications Publications –– guides, Tip Sheets, case studiesguides, Tip Sheets, case studies

–– http://www1.eere.energy.gov/industry/bestpractices/steam.htmlhttp://www1.eere.energy.gov/industry/bestpractices/steam.html

ContactContact

John RaschkoJohn Raschko

(617) 626(617) 626--10931093

[email protected]@state.ma.us

ENERGY EFFICIENCY

PUMPS AND FANS

Energy Conservation Opportunities

MA OTA

April 15, 2008


Energy EfficiencyEnergy Efficiency

Pumps and FansPumps and Fans

PRESENTATION BY

CECILE GORDON, P.E.MA OFFICE OF TECHNICAL ASSISTANCE AND

TECHNOLOGY

617-626-1092

[email protected]

Energy Efficiency

Pumps

• Involve all levels of employees in suggesting pump efficiency improvements

• Conduct an In-Plant Pumping System Survey

• Maintain Pumping Systems Effectively

• Correct inefficiencies in the system

Energy Efficiency

Pumps

Involve all Levels of Employees

Management

Supervisors

Operators

PUMPING SYSTEM SURVEY

The Department of Energy provides a software tool to assess the efficiency of pumping

systems called PSAT.• The DOE has obtained savings using PSAT in the

following industries however pumps are common to all industries.

Industry Average Energy savings Average Annual

# of Assessments Million BTU/year savings

• Aluminum (2) 1,882,500 $74,000

• Chemicals (1) 1,601,200 $106,000

• Forest Products 4,717,400 $186,500 Mining(7) 9,419,100 $410,700

• Petroleum (2) 1,150,000 $46,000

• Steel (2) 5,787,500 $231,500

Conduct an In-Plant Pumping

System Survey, this includes:

• Develop a system curve by measuring pressure

at selected points in the pipe at different flows.

• The selected points include suction and

discharge pressures.

• Obtain the performance curve of the pump from

the manufacturer if you do not already have it.

SCHEMATIC OF A PUMPING

SYSTEM

Energy Efficiency Energy Efficiency

PumpsPumps

• In-Plant Pumping System Survey, cont’d

InIn--Plant Pumping System Survey, Plant Pumping System Survey,

contcont’’dd

• Find out where the system curve intersects the performance curve.

• This point should be within 20% of the pumps best efficiency point (BEP).

• Average operating flow – check control valve opening.

Energy Efficiency Energy Efficiency

PumpsPumps

MAINTAIN PUMPING SYSTEMS MAINTAIN PUMPING SYSTEMS EFFECTIVELYEFFECTIVELY

• Packing.

• Mechanical Seals.

• Bearings.

MAINTAIN PUMPING SYSTEMS MAINTAIN PUMPING SYSTEMS

EFFECTIVELY, contEFFECTIVELY, cont’’dd

• Motor/Pump Alignment.

• Motor Condition.

CORRECT INEFFICIENCIES IN

THE SYSTEM

Conduct a detailed review of your plants pumping system if:

• The imbalance between the designed system requirements and the actual (measured) discharged head and flow exceeds 20%


THE SYSTEM

A pump may be incorrectly sized if:

� it operates under throttled conditions

� has a high bypass flow rate

� has a flow rate that varies more than 30% from its best efficiency point (BEP).

CORRECT INEFFICIENCIES IN THE SYSTEM

Efficient solutions include:

• using multiple pumps by adding smaller auxiliary (pony) pumps

• trimming impellers

• adding a variable speed drive.


THE SYSTEM

Reduce pumping costs through optimum pipe sizing -

• Frictional losses depend on:– Flow in pipe

– Overall pipe length– Surface roughness

– Fluid viscosity– Pipe diameter

• Keeping all other variables the same, the energy required to pump will decrease with increasing pipe diameter

Energy EfficiencyEnergy Efficiency

CORRECT INEFFICIENCIES IN THE SYSTEMCORRECT INEFFICIENCIES IN THE SYSTEM

•• Correct Imbalanced Pumping SystemsCorrect Imbalanced Pumping Systems

CORRECT INEFFICIENCIES IN THE CORRECT INEFFICIENCIES IN THE

SYSTEMSYSTEM

Trim or replace impellersTrim or replace impellers

•• Trimming involves machining the impeller to Trimming involves machining the impeller to

reduce its diameter. reduce its diameter.

•• Many pump manufacturers provide performance Many pump manufacturers provide performance

curves at different impeller sizes. curves at different impeller sizes.

•• Smaller impellers require less brake horsepower Smaller impellers require less brake horsepower

and therefore energy.and therefore energy.


SYSTEMSYSTEM

Different Impeller sizesDifferent Impeller sizes


SYSTEMSYSTEM

Variable Speed DrivesVariable Speed Drives: :

•• Will respond to the system flow Will respond to the system flow

requirements and therefore remove the requirements and therefore remove the

problem of using more power than the problem of using more power than the

system demands.system demands.

CORRECT INEFFICIENCIES IN CORRECT INEFFICIENCIES IN

THE SYSTEMTHE SYSTEM

VARIABLE SPEED DRIVE

Energy Efficiency - Fans

The Fan System Assessment Tool (FSAT).

• A DOE software tool to assess fan system efficiency

• Quantifies energy consumption and savings opportunities

• Simple and Quick - requires only basic information

• Calculates the amount of energy used; determines system efficiency and

savings potential.


• Perform periodic maintenance

• Ensure proper fan sizing

• Design with inlet and outlet ducts as straight as possible


• Consider Variable Frequency Drives (VFDs) to improve fan operating efficiency over a wide range of operating conditions

• Maintain proper belt tension and alignment

• Combine fans in parallel or in series where applicable to increase efficiency and reduce costs.

Common Maintenance Tasks Include:Common Maintenance Tasks Include:

• Periodic inspection of all system units

• Bearing lubrication and replacement

• Belt tightening and replacement

• Motor repair and replacement

• Fan and system cleaning

• Check ductwork leaks

Ensure Proper Fan SizingEnsure Proper Fan Sizing

• Compare pressure required by the end use to the pressure generated by the fan. If it is oversized it will generate more total pressure for the same airflow than a correctly sized fan.

FAN AND SYSTEM CURVES

• Generate a system curve to determine power consumption.

• Obtain the fan curve from the manufacturer.

• If the system curve intersects the fan curve at a point that is not near the best efficiency point (BEP), the fan is oversized.

Example of Fan System Components

VARIABLE FREQUENCY DRIVESVARIABLE FREQUENCY DRIVES

• improve fan operating efficiency over a wide range of operating conditions.

• provide an effective and easy method of controlling airflow.

• are able to retrofit to existing motors.

• eliminate fouling problems associated with mechanical control devices.

• One disadvantage is a low rotational speed risks unstable operation.

Fan Performance and System Operating Point

SUMMARY

• Energy Conservation for Pumps and Fans must involve all levels of employees.

• Conduct an In-Plant Pump or Fan System Survey

• Correct inefficiencies in the system

• Institute A Preventative Maintenance Program

• There are state and federal agencies that conduct free facility audits to identify areas where energy can be conserved.

• For more information contact OTA at: www.mass.gov/envir/ota or at 617-626-1060

References:

• DOE Pumping Systems TIP Sheets

• http://www1.eere.energy.gov/industry/bestpractices/tip_s

heets_pumps.html

• DOE and Hydraulic Institute: Improving Fan

System Performance: A Sourcebook for Industry

Resource Conservation

Training

Motors and Compressors

MA OTA

2008


Electric Motors

• Electric motors consume 64 % of the

electricity produced in this country

• Electric motors represent a significant opportunity area for energy conservation.

Electric Motors

• Process motor systems account for

63% of all electricity used in industry

• Because of the national energy implications , Congress enacted the Energy Policy Act of 1992, which set minimum efficiency standards for certain classes of electric motors.

Electric Motors

• EPAct rules for motors became effective Oct. 24, 1997.

• In June 2001, NEMA granted "better-than-EPAct" motors special recognition by creating a designation called

NEMA Premium™.

Electric Motors

• The DOE estimates there are 12.4 million motors bigger than 1 hp in service in U.S. manufacturing facilities

• 600,000 are replaced annually.

Electric Motors

• Using NEMA Premium motors as replacements could save 11-18 percent of current annual electrical usage

• 62 to 104 billion kWh per year, valued up to $5 billion

Electric Motors

� That efficiency increase could prevent the annual release of up to 29.5 million metric tons of carbon emissions

� Equivalent to keeping 16 million cars off the road for 10 years

Electric Motors

• Replacing failed motor with a Premium unit has a straightforward return on investment.

• Energy efficiency gains offset the price

differential in a short period

• Those savings continue as long as the motor remains in service.

Electric Motors

Economic Example

• 100 horsepower AC induction motor operating at standard SF 0.75 (56 kw)

• Two Shift Annual Operating Cost -4000hr x 56 kw x $0.14/ kwh = $31360

Electric Motors

Economic Example

• Standard Motor costs approximately $8450 Baldor CM4400T

• Premium Motor costs approximately $10427 Baldor CEM4400T

• $1977 cost differential

Engineering Data

93.0 90.2 25

95.8 94.1 250

95.0 91.7 100

94.1 91.7 50

91.7 87.5 15

91.1 84.0 10

89.6 84.0 5

84.0 78.5 2

82.5 78.0 1

Premium Efficiency Standard Efficiency Horsepower

Electric Motors

• 95.0% - 91.7% = 3.3%

• .033 x $31360/yr = $1035/yr. Savings

• $1977 cost differential

• Premium Motor Payback 1.9 yr, cost savings persist for the life

Electric Motors

Small Motor Example

• Changing motors solely on an energy conservation basis more beneficial with smaller motors.

• Ventilation Fan 10 hp motor at SF 1.0 –24/7 operation at 7.5 kw

Electric Motors

Small Motor Example

• Premium $1577 Standard Motor $1280

• (OEM choice)

Engineering Data

93.0 90.2 25

95.8 94.1 250

95.0 91.7 100

94.1 91.7 50

91.7 87.5 15

91.1 84.0 10

89.6 84.0 5

84.0 78.5 2

82.5 78.0 1

Premium Efficiency Standard Efficiency Horsepower

Electric Motors

Small Motor Example

• 6000 hr x 7.5 kw x $0.14 = $6300/YR

• 7.1 % Premium efficiency differential $450/yr

Electric Motors

Small Motor Example

• $1570 Cost, $450 annual savings

• Payback 3+ years with 10 year expected life.

• Perhaps $2700 cost avoidance over six additional years

Which motors to Target

• Motors driving variable loads

Pumps

Hydraulic systems

Fans

• Motor efficiency is often poor due to operation at low loads.

Which motors to Target

• Motors scheduled for replacement

• Motors greater than ten years old

Electric Motors

Small Motor Replacement

• Compromise – Spread out the effort

• Formal program to gradually install Premium motors

Another Option

• Variable Frequency Drives (VFD)

• Control the speed and torque of an AC electric motor

• Vary the frequency and/or voltage of the electricity supply.

• AKA Variable Speed Drives (VSDs)

Another Option

• VFDs replace inefficient mechanical speed controllers:

• belts and pulleys

• throttle valves

• fan dampers

• magnetic clutches

VSDs in Use

• VSDs are proven in the food, paper, automotive and consumer goods industries.

• They're used in crushers, grinding mills, rotary kilns, presses, rolling mills and textile machinery.

VFD Advantages

• No friction loss

• No moving parts.

• Instant and precise speed control

Gentle startups and gradual slowdowns

Small size facilitates retrofit

VFD Advantages

–Energy savings up to 20 percent

Compressed Air

• Very convenient and very inefficient

• Only 10-15% electrical to mechanical energy yield.

• Widespread use in industry offers potential energy conservation options associated with the motor.

Compressed Air

• There may be more substantial opportunities in system repair and maintenance.

• Leaks

• Pressure drop

Compressed Air

LEAKS

• Leaks are major source of wasted energy in compressed air systems.

• A plant may have a leak rate of 20-30% of total compressed air production capacity.

Compressed Air

LEAKS

• 1 hp yields about 3.5 SCFM at 100 psi

• A “small” leak at 1 scfm costs about

$0.75 a day (< 1/32” dia = pencil point)

• For 24/7 activity costs $250/year

100 HP Motor at 75% capacity

• Change to Premium Motor Saves

.033 x $31360/yr = $1035/yr

• A 20% leak reduction saves

0.2 x $31360/yr = $6272 /yr

• Limited capital investment

Repair and Maintenance

• Condensate Drains- Float and electric

• Filters/Separators- saturated elements cause pressure drop that costs energy

• Pipe Fitting Leaks

• Corrosion (Pressure Drop)

Leak Detection

• Tour the plant during down time

• Storage tank pressure decay

• Ultrasonic Leak Detectors

Pressure drop

• For every 2 PSI above need

energy costs rise 1%

• Consider other point of use equipment for low pressure applications

Low Pressure High Volume

• Vane Compressors

• Regenerative Blowers

• Low Pressure Guns and Nozzles.

Screw Compressors

• For medium pressure

• Load Matching through inlet throttling and

VFD speed control

Resources

• U.S. Department of Energy's Motor Challenge Program

• http://www1.eere.energy.gov/industry/bestpractices/motor_challenge_national_strategy.html

• DOE MotorMaster – Retrofit Database (with pricing!)

• http://www.compressedairchallenge.org/

OTA is Here to HELP YOU!

Gerry Podlisny

Process Engineer/Environmental Analyst

[email protected]

(617) 626-1098Office of Technical Assistance and Technology

Executive Office of Energy and Environmental Affairs

100 Cambridge Street, Suite 900

Boston, MA 02114

www.mass.gov/envir/ota