presented by: mike bailey pe director of engineering
DESCRIPTION
Presented by: Mike Bailey PE Director of Engineering. Lessons Learned: Why data is not Always enough. Case Study #1. First Case Study. Oregon based co-op food processor with two plants U tility provided 15-minute electric data Multiple products with mix of equipment and processes - PowerPoint PPT PresentationTRANSCRIPT
total energy and sustainability management
Presented by: Mike Bailey PEDirector of Engineering
LESSONS LEARNED: WHY DATA IS NOT ALWAYS ENOUGH
2
First Case Study
• Oregon based co-op food processor with two plants
• Utility provided 15-minute electric data
• Multiple products with mix of equipment and processes
• Digital process controls with in plant control technicians
• Full year operation (little seasonality)
• Full year, stable workforce
• Capital available for projects
Case Study #1
3
Plant A Energy Use
• Energy Sources• Electricity• Steam (from utility co-gen
plant)• Natural Gas
• Production and Energy Use• Electricity and Steam
• Seasonal Energy Use• Natural Gas
Jan-03
Jul-03Jan
-04Jul-0
4Jan
-05Jul-0
5Jan
-06Jul-0
6Jan
-07Jul-0
7Jan
-08Jul-0
8Jan
-09Jul-0
9Jan
-10Jul-1
0 $-
$20,000
$40,000
$60,000
$80,000
$100,000
$120,000
$140,000
$160,000
$180,000
$200,000
Electricity kWh by Service Point Steam Purchases ($)
Natural Gas Purchases ($)
Case Study #1
4
Plant B Energy Use
• Energy Sources• Electricity• Diesel
• Production and Energy Use• Operational Changes
• Switched from diesel to electric boiler in mid-2009
• Electricity Energy Intensity• ~3 times greater than
Plant A per Vat• Production Cost
• ~4 times the production cost of Plant A per Vat
$-
$50,000
$100,000
$150,000
$200,000
$250,000
$300,000
$350,000
$400,000
$450,000
$500,000
Electricity Diesel
Case Study #1
5
Rebates and Incentives (at time of study)
• BPA Energy Smart Industrial (ESI) Program• Incentive Programs and Pilot Programs
• Custom Projects• $0.25/kWh up to 70% of project cost
• Energy Project Manager (EPM)• Potential incentive for Plant A is $100,000 • Potential incentive for Plant B is $270,000
• Track & Tune (T&T)• High Performance Energy Manager (HPEM)• Northwest Lighting Trade Ally Network (TAN)• Green Motors Initiative
• Business Energy Tax Credit (BETC)• Option 1: Credit taken directly by co-op
• Up to 35% of project costs (before utility incentives) over a five year period
• Option 2: “Pass-through” to a third party• Up to 25.5% of project costs (30.5% for smaller projects)
Case Study #1
6
Example Energy Measures• EEM 1: Lighting
• Estimated simple payback: Immediate
• EEM 2: Refrigeration• Estimated simple payback: 2.2 years
• EEM 3: Compressed Air System• Estimated simple payback: Immediate
Case Study #1
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Example Energy Measures
• EEM 4: Heated Regenerative Dryers• Estimated simple payback: Immediate
• EEM 5: Waste Water Treatment Blower Replacement
• Estimated simple payback: 2.8 years
• EEM 6: Heat Recovery• Estimated simple payback: 2.4 years
• EEM 7: Motor Efficiency• Estimated simple payback: Immediate
• EEM 8: Boilers• Estimated simple payback: 0.6 years
Case Study #1
8
Results
• Very little progress on facility equipment or process optimization – staff focused on capital expansion projects
• Lack of upper management attention to utility costs
• No owner for utility energy data or utility cost management
• Did not use real time utility data - did not allocate energy use between process and products
• Implemented some measures such as lighting but did not proceed with energy manager position (funded by BPA)
Case Study #1
9
Second Case Study
• NW based co-op food processor with multiple plants
• Utility provided 15-minute electric data
• Multiple products with mix of equipment and processes
• Manual and electric controls – no centralized process control
• No in-plant controls staff
• Seasonal products
• Seasonal work-force with moderate turn-over
• Little capital available for projects
Case Study #2
10
Many Different CropsCase Study #2
11
Seasonal Utility UseCase Study #2
12
Poor Understanding of Energy Drivers
• Refrigeration Issue Example• Staging condensing tower fans and pumps
(200 hp total) based on compressor discharge pressure (3,000 hp total)
• Boiler Issue Example• 400 BHP 1980’s Boiler used three
months per year• 600 BHP late 1990’s Boiler used four
months per year• 3 year old audit study recommending
controls upgrades and stack heat recovery – unfunded due to 5 year pay-back
Case Study #2
13
Identified Utility Cost Drivers
$326,000 , 32%
$409,820 , 41%
$94,993 , 9%
$84,054 , 8%
$103,000 , 10%
Boiler
Refrigeration
Line Motors
Baseload Elec.
Water Use
Boiler and Refrigeration systems drive 73% of total Utility cost
Combined electrical is 58% of total Utility cost
BOILER
REFRIGERATION
Boiler value does not include cost of make up water - only natural gas costs
Case Study #2
14
Estimated Utility Cost by Product
Total Utility Cost 2007
$93,064.55 , 9%
$27,479.98 , 3%
$167,201.89 , 17%
$700,034.29 , 71%
Baseload
Asparagus
Peas & Sugar Snaps
All Carrot & Lima Beans
“Carrots Don’t Care”
Case Study #2
15
Now for the data…
• Plant Energy Manager Team established
• Utility real time data owner assigned
• Worked with utility to understand tool, work out communication issues
• Serve as resource for internal staff to understand data
• Each process owner responsible for managing energy drivers
• Process owners worked with utility data owner to “break
apart utility use”
• Team created control charts real time data flagged issues
and trends
• Regular summary reporting to plant management
Case Study #2
16
Boiler Recommendations
• Only use one Boiler• Eliminate “Hot standby” spare• Manage production volume during carrots to avoid needed to operate
two boilers
• Add Stack Economizer – Boiler Feed-Water pre-heater to one boiler• Payback less than 1 year – if boiler used full season
• Add boiler combustion controls• Manage blanchers to reduce boiler demand
RESULT: Capital approved to fund ONE boiler upgrade
Case Study #2
17
Refrigeration Recommendations
• Do NOT stage condenser tower fans & pumps – run as much as possible to reduce condenser pressure
• 200HP total for condenser towers• >3000HP total compressor capacity
• Stage Compressor controls• Always have smallest compressor as Trim• Large compressors should be fully loaded if
on
• Install VFD on ONE compressor and dedicate that to Trim
• Track Compressor Log to incremental electrical meter data
Booster Compressors
Compressor Size Load Stage1 2 3 4 5 6 7
#2 250 hp T T T T T T T#4 250 hp X X X#6 300 hp X X X#8 350 hp X X X XT = Trim Compressor, X = compressor operating at full load
High Stage Compressors (no VFD)
Compressor Size Load Stage1 2 3 4 5 7 8 9
#10 250 hp T T T T T T T T#3 350 hp X X X X#5 400 hp X X#7 400 hp X X X#9 500 hp X X X X XT = Trim Compressor, X = compressor operating at full load
High Stage Compressors (with VFD)
Compressor Size Load Stage1 2 3 4 5 7 8 9 10 11
#10 250 hp X X X X#3 350 hp X X X
#5 (VFD) 400 hp T T T T T T T T T T#7 400 hp X X X X#9 500 hp X X X X X XT = Trim Compressor, X = compressor operating at full load
Case Study #2
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Lessons Learned
Why was #2 Successful but #1 was not?
• Upper management Serious about managing utility costs
• “Seek First to Understand” what drive energy use
• Data is not helpful if it is not converted to information
• Begins and ends with people!
• Once system and drivers are known, data used to manage
• Data without systems knowledge is useless
• Decisions makers must be will to ACT on the data –
PARTICULARLY when it contradicts old assumptions
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Data Is Necessary But Not Sufficient…