Workshop GG. Energy Savings Champions Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Medium-Sized Companies

Transcription

1 Workshop GG Energy Savings Champions Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Medium-Sized Companies Wednesday, February 20, p.m. to 3:15 p.m.

2 Biographical Information Angela M. Rybalt, Outreach Manager, Energy Efficiency Programs, AEP Ohio 700 Morrison Road, A: , Gahanna, OH Mrs. Rybalt is the Outreach Manager for the Solution Provider Network and the Bid4efficiency Program for the AEP Ohio Energy Efficiency Programs. Angie s responsibilities include Outreach and Education for the AEP Ohio Business Incentives across multiple sectors of architects, engineers, contractors, energy professionals and end users. Much of her time is spent effectively delivering energy efficiency solutions to Solution Providers, justifying ROI calculations and assisting with the overall sales process to gain energy efficiency incentives. Her key strengths include turnkey understanding of the sales process surrounding energy efficiency amongst different customer segments while utilizing national and local energy efficiency initiatives and incentives to implement projects. Mrs. Rybalt currently serves on the board of the local chapter of Association of Energy Engineers and has a BA in Business from The Ohio State University. Jeff Woolley, EHS Engineer American Fine Sinter, 957 N. Maule Rd., Tiffin Ohio ext. 203 Fax jwoolley@afsus.com Jeff started his EHS career in the hazardous waste remediation field predominately as a field sample technician in various locations through the U.S. Other duties included field and fixed base lab analyst from the corporate office in Findlay, Ohio. From there he progressed through the heavy equipment rental and large commercial bakery industries before ending up in his present role in the production of automotive internal engine parts. Throughout his career his varied roles have always center primarily on safety and environmental compliance with other roles as needed. His current role in EHS at American Fine Sinter centers primarily on overall safety and environmental compliance secondary roles include ISO and guiding AFS s future energy strategies. Jeff is a graduate of Bowling Green State University. Robert Moots, Senior Cost Planning / Purchasing, Weastec, Inc N. High St., Hillsboro, OH robert.moots@weastec.com Robert has spent over 30 years at Weastec, Inc. in Hillsboro and among his responsibilities are: global strategic sourcing, VA/VE improvements, purchasing management, lean management & efficiency, risk management/analysis, quality metrics & improvements, TS16949-Certified, contract management, cost control, continuous improvement of operations, asset management and control and ISO Certifications.

3 American Fine Sinter Tiffin, Ohio * Over $87,000 in Incentives *

4 AFS Background Tier 1 supplier for Toyota internal engine parts 2003 >Started production 2013 >Added 23,000 sq.ft. addition 2015 >Added 109,000 sq.ft. Plant 2 With the expansions came new equipment, including 5 new furnaces, presses, air compressors and team members

5 AFS Background Tier 1 supplier for Toyota internal engine parts Parts start off as powdered metal and are formed onto shape using a press

6 AFS Background Tier 1 supplier for Toyota internal engine parts Parts start off as powdered metal and formed onto shape of parts then hardened (sintered)

7 AFS Background Tier 1 supplier for Toyota internal engine parts Parts start off as powdered metal and are formed onto shape using a press Sintering process (hardening) uses a hydrogen/nitrogen atmosphere in an electric furnace to heat parts to over 1,100C

8 AFS Background

9 AFS Background Tier 1 supplier for Toyota internal engine parts Parts start off as powdered metal and are formed onto shape using a press Sintering process (hardening) uses a hydrogen/nitrogen atmosphere in an electric furnace to heat parts to over 1,100C Machined, inspected and shipped

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11 AFS Background SINTERING requires quartz resistance heating gasses are used for atmospheric conditioning 2018 power consumption over 14,000,000 kwh

12 CAPITAL PROJECT 2010 Lighting Project 458W Metal Halide lights removed from the high bays and replaced with 225W T-5 HO 6-fluorescent light fixtures 190K+ kwh reduction/ $6,580 Incentive

13 CAPITAL PROJECT

14 CAPITAL PROJECT 2013/14 new expansion- 33k sq. ft. Lighting Plant 1 36K+ kwh reduction/ $1,591 Incentive VFD Chilled water pump 13K+ kwh reduction/ $1,350 Incentive VFD Air compressor 173K+ kwh reduction/ $10,000 Incentive

15 CAPITAL PROJECT 2015 new plant expansion- 100k+ sq. ft. Interior/ Exterior Lighting Plant 2 547K+ kwh reduction/ $23,394 Incentive VFD Air compressor 173K+ kwh reduction/ $9,000 Incentive

16 CAPITAL PROJECT 2016 VFD Process motor 105K+ kwh reduction/ $4,800 Incentive VFD Chilled water pump 13K+ kwh reduction/ $1,800 Incentive

17 CAPITAL PROJECT 2017 Custom AC units 173K+ kwh reduction/ $12,153 Incentive VFD Process motor 105K+ kwh reduction/ $4,800 Incentive VFD Chilled water pump 13K+ kwh reduction/ $1,800 Incentive

18 CAPITAL PROJECT 2018 HVAC unit replacement, 3 units -only incentivized on single smaller unit 171 kwh reduction/ $105 Custom Servo Press 285K+ kwh reduction/ $15,012 Incentive Another Servo Press in process under different program

19 BACKGROUND PROJECTS No loss condensate drain 4.7K+ kwh reduction/ $50 Incentive LED Lighting- exit, emergency 1.9K+ kwh reduction/ $86 Incentive

20 BACKGROUND PROJECTS

21 BACKGROUND PROJECTS No loss condensate drain 4.7K+ kwh reduction/ $50 Incentive LED Lighting- exit, emergency 1.9K+ kwh reduction/ $86 Incentive Glass door Refig./ Freezers 16K+ kwh reduction/ $1,475 Incentive HVAC unit 171+ kwh reduction/ $105 Incentive

22 Summary Capital projects 1,707,155 kwh reduction $86,167 Incentive Background Projects 19,615 kwh reduction $1,716 Incentive Year Over Year $avings

23 METHODS TO ACHIEVE Know what projects are on the horizon Get AEP involved early Eligibility o What is o What program

24 METHODS TO ACHIEVE Get AEP involved early Your Requirements/ documentation o Invoices o Spec. Sheets o Schedules Contractors - especially capital projects Think Outside the Box- look at everything

25 Weastec Weastec Environmental /Energy Savings Project Results w/ AEP Support Boilers, HVAC, LED, Water and Air Compressor Improvements Cost Planning / Purchasing Sr. Mgr Robert Moots

26 Weastec Over View Weastec Inc. is a Distribution Facility Located in Hillsboro, Ohio Our facility consists of: Plant Area of ~ 100,000 sq/ft Office Area of ~ 25,000 sq/ft Total Space of ~ 125,000 sq/ft In 2014 Weastec needed to reduce our overall Electrical Expenses, as well as other costs of our building being 25 yrs old, because it was becoming a Major Factor in our Overhead Cost. Weastec laid out a 3-yr plan for Building Improvements and Upgrades to our Existing Systems that were either outdated, and/or were Non-efficient within our operations. The following is a History of what was changed, and the results of those changes that have occurred with the help of AEP Ohio and their Business Incentive Program, that helped Weastec make the Decision to do the necessary changes.

27 Weastec Over View Computerized Controls of HVAC System - Better Control of Air Environments

28 for better Control of Air Environments By adding HVAC Software, and VAV Boxes to our HVAC System, Wtec can control Temperatures better in all areas of the Facility, and program our System for Daily use as well as Shutdowns, Weekends, and Holidays. FY Cost Down Attribution: -$24,310

29 Weastec Over View Summer Mo. Timing

30 Weastec Over View Efficiency Improvement

31 Weastec Over View Robert Current Heating / Boilers Configuration 1,125,000 BTU (330 KW) #1 #2 #3 675,000 BTU's (198 Kw) 1,125,000 BTU (330 KW) #4 #5 #6 675,000 BTU's (198 Kw) Input: 6 375,000 Btu's (110 Kw) Total: 2,250,000 BTU's (660 Kw) Current Efficiency: BTU In > Out = 60% Output: 2,250,000 = 1,350,000 BTU (396 Kw) Yearly Natural Gas Usage = 3,935,000 cf (111,427 Cu Mtr) Yearly Natural Gas Cost = $30,845 2,714,360

32 Weastec Over View Better efficiency of Heating

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38 Weastec Over View Air Compressor Project - >25 yr old Overhead Airlines - Unaware Lines were Plugged and Leaking: - Only 40% Efficient

39 Weastec Over View 2017 CY Project Completion Target

40 Weastec Over View Forklift Battery - Timer Project - Added Timers to Forklift Charging to reduce Peak hours usage

41 Weastec Over View Forklift Battery Charging Timers Weastec added Timers on the Forklift Battery Charging Stations, programmed to Activate after the Peak hours of 6:00 pm to reduce our PJM factor, reducing Electrical Cost from the Peak-Demand Costing from Electric Companies. Timer Program Panel Timer connected to Fuse Panel Battery Chargers connected to Panel

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45 Weastec Over View - Awards Weastec Awarded AEP Energy Efficiency Champion 1 of only 20 Companies in Ohio to Receive AEP Business Incentives Multi Year Participation Award Achieved ISO 14001:2015 August 2018 SHARP Award - 1 of only 28 Companies in Ohio to be Awarded to this Prestige Weastec was featured in a 2018 Major Magazine Article written and published by AEP Distribution ~ 50,000 Weastec goes 100% LED Facility AEP Energy Check Awarded

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48 Weastec Over View OSHA Impact

49 Weastec Over View Environmental Management System

50 Weastec Over View Additional Benefits Seen from Weastec s Energy and Environmental Improvements - Corporate Insurance Reductions - Corporate Tax Reductions - GHG Reductions

51 Weastec Over View - Commercial Insurance

52 Weastec Over View Dept of Energy Tax Incentives

53 Weastec Over View Greenhouse Gas Reductions

54 Weastec Over View Add l (Energy Reduction) Tax Deductible Totals

55 Weastec Over View Thank you for your time in reviewing this Presentation, and allowing me to brag on Weastec and it s Projects! Robert Moots Sr. Mgr Cost Planning/Purchasing