Energy Saving Opportunities in Water & Wastewater Infrastructure

Transcription

1 Energy Saving Opportunities in Water & Wastewater Infrastructure Energy / Facilities Connections 2011 May 12, 2011 Layne McWilliams Water/Wastewater Sector Specialist Energy Smart Industrial Slide 1

2 Roadmap The ESI Program Why do conservation incentive programs exist? What s in it for me and why should I care? Ok, now that I care, how do I proceed? Getting Started & Energy Audits Typical Savings Opportunities Hint: It s not just VFD s... Slide 2

3 Why does conservation matter? Water/Wastewater sourcing, treatment, distribution, collection, conveyance, treatment, and disposal accounts for about 3% of the nation s energy consumption. BPA capacity is becoming constrained, and conservation is the lowest cost resource. Tiered rate structures start FY2012 so local utilities (BPA s customers) want to keep their base allocation open to keep rates low, attract new customers, and allow for growth. Slide 3

4 Why should you care? Your electric rates are going to go up. (Have they ever gone down?) Electrical costs associated with pumping and treatment is often the highest non-labor cost for a municipality and one of the few costs that can be reduced without impacting water quality. The lifetime costs of most equipment is incredibly dependent on its efficiency. Systems are designed for 20 year predicted flows and built by low bid project delivery methods. Chances are you re running at less than best efficient point on much of your equipment. Often that means equipment is working harder than it needs to. The SRF grants and loans have green requirements now, and energy projects qualify. Slide 4

5 What s in it for you? Depending on utility, up to 25 cents per kwh saved based on first year s energy consumption. This is about $1600 per horsepower on a 24/7 basis. So, if we can take an aeration system pulling on average 45 hp down to 35 hp, there is a potential incentive of roughly $16,000 available. The incentive is capped at 70% of the project cost. Assistance from the program with identifying opportunities, handling paperwork and approvals, post-project M&V, and shepherding projects. Slide 5

6 But wait... There s More! Slide 6

7 You ll also get: Ongoing energy savings for life of the measure. Often reduced maintenance cost from turning off or turning down equipment. Aesthetic and comfort improvements e.g. better lighting, better HVAC. Conservation: The gift that keeps on giving! Slide 7

8 How do I get started? Do you buy electricity from a public or an investor owned utility? If an IOU, call them and ask to talk with a conservation specialist. If it s a public utility, they are probably in the program, so... Call or me, and I can get the process started. layne.mcwilliams@energysmartindustrial.com Or call your local utility representative and let them know you are interested. Slide 8

9 ESI Utilities Within Washington WASHINGTON (WEST) Blaine, City of Centralia City Light Clallam County PUD Clark Public Utilities Cowlitz County PUD Eatonville, Town of Grays Harbor PUD Klickitat PUD Lakeview Light & Power Lewis County PUD Mason County PUD #1 Mason County PUD #3 McCleary, City of Orcas Power & Light Cooperative Pacific County PUD #2 Peninsula Light Port Angeles, City of Seattle City Light Skamania County PUD #1 Snohomish County PUD Sumas, City of Tacoma Power Tanner Electric Coop Wahkiakum PUD Whatcom County PUD #1 WASHINGTON (EAST) Asotin County PUD Benton PUD Benton REA Big Bend Electric Coop City of Cheney Light & Public Works City of Chewelah Electric Dept. Columbia REA Consolidated Irrigation District Coulee Dam, Town of Ellensburg, City of Ferry County PUD #1 Franklin PUD Grant County PUD Inland Power & Light Kittitas County PUD Modern Electric Water Co. Nespelem Valley Electric Cooperative Okanogan Co PUD #1 Pend Oreille County PUD Richland, City of Vera Water & Power District Slide 9

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11 Energy Smart Industrial Program Components Energy Smart Industrial Partner (ESIP) Face of the program Energy Management - Pilot Trade Ally Driven Custom Projects Energy Project Manager (EPM) Track and Tune (T&T) High Performance Energy Mngt. (HPEM) Small Industrial (SI) NW Trade Ally Network (NW TAN) Green Motors Initiative Traditional Capital Projects Addresses End User Staffing Addresses O&M Savings Addresses Corporate Management And Culture Addresses Small Projects Addresses Lighting Projects Motor Rewinds Technical Service Proposal (TSP) Consultants Provides Technical Consulting Slide 11

12 Custom Projects - Incentives for traditional capital projects. Pumps Fans Compressed Air Refrigeration Lighting Motors Variable Frequency Drives Control Upgrades Process Upgrades Slide 12

13 -Depending upon utility, but up to $0.25 per kwh saved in first year. -Capped at 70% of project cost -You get the lesser of 25 cents / kwh OR 70% of project cost. -Project cost can include design fees, and can be incremental cost between baseline and efficient equipment for new construction -Paid based on Measured and Verified (M&V) savings. -The payment comes after the project is complete, so capital funds still needed upfront to cover the project. Slide 13

14 Energy Smart Industrial Program Components Energy Smart Industrial Partner (ESIP) Face of the program Energy Management - Pilot Trade Ally Driven Custom Projects Energy Project Manager (EPM) Track and Tune (T&T) High Performance Energy Mngt. (HPEM) Small Industrial (SI) NW Trade Ally Network (NW TAN) Green Motors Initiative Traditional Capital Projects Addresses End User Staffing Addresses O&M Savings Addresses Corporate Management And Culture Addresses Small Projects Addresses Lighting Projects Motor Rewinds Technical Service Proposal (TSP) Consultants Provides Technical Consulting Slide 14

15 What is Small Industrial? Addresses small industrial projects Independent of facility or sub-system size Utilizes simplified analysis tools Ex. Compressed Air 75 hp Additional tools in development (refrigeration, VFDs) Rapid review and approval process Leverages trade allies Treated as custom projects for incentives No M&V is required There will be spot checks to fine-tune process Slide 15

16 Energy Smart Industrial Program Components Energy Smart Industrial Partner (ESIP) Face of the program Energy Management - Pilot Trade Ally Driven Custom Projects Energy Project Manager (EPM) Track and Tune (T&T) High Performance Energy Mngt. (HPEM) Small Industrial (SI) NW Trade Ally Network (NW TAN) Green Motors Initiative Traditional Capital Projects Addresses End User Staffing Addresses O&M Savings Addresses Corporate Management And Culture Addresses Small Projects Addresses Lighting Projects Motor Rewinds Technical Service Proposal (TSP) Consultants Provides Technical Consulting Slide 16

17 What is NW TAN? Existing TAN program currently provides high level support to utilities and trade allies The goal of the KAMs is to increase the number and magnitude of industrial lighting projects for BPA utility customers Project specific support on industrial lighting projects Industrial lighting is often extremely low hanging fruit with quick paybacks. Slide 17

18 Energy Smart Industrial Program Components Energy Smart Industrial Partner (ESIP) Face of the program Energy Management - Pilot Trade Ally Driven Custom Projects Energy Project Manager (EPM) Track and Tune (T&T) High Performance Energy Mngt. (HPEM) Small Industrial (SI) NW Trade Ally Network (NW TAN) Green Motors Initiative Traditional Capital Projects Addresses End User Staffing Addresses O&M Savings Addresses Corporate Management And Culture Addresses Small Projects Addresses Lighting Projects Motor Rewinds Technical Service Proposal (TSP) Consultants Provides Technical Consulting Slide 18

19 What is the Green Motors Initiative? Participating utilities are offering incentives for rewinds identified by Green Motors Practices Group members as process compliant Thereby retaining original nominal efficiency values Standard NEMA ratings from 15 hp - 5,000 hp with no core damages are eligible Incentive amount of $1.00 per hp per motor will be credited instantly on the rewind invoice Go to for list of shops Saves up to 40% (or more) of the cost of buying new motors Recycles 98% of motor materials Slide 19

20 Do you know the muffin man? Slide 20

21 Where have I been? Do you know your local power and gas account rep? Your rep can provide a printout of historical usage and associated charges. Is there a trend? Any step changes e.g. switching from chlorine disinfection to UV...? Slide 21

22 Where have I been? Other issues associated with billing: Who reviews and pays your monthly power bill? What percentage of your operating costs goes towards energy? How much am I paying for demand vs. consumption? Where am I using energy? Slide 22

23 Where have I been? Has your facility ever performed or received an energy study or audit? Dust off those old energy studies. Similar or same equipment still in use? Probably! Ideas that were good then are usually still good now. Slide 23

24 Where am I now? The Basics Your Power Bill What rate are you paying? How is power measured? What is a demand charge and how can I control it? What is power factor and does it matter? Slide 24

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27 Billing Terminology kwh = kilowatt hour = 1000 W for 1 hour (or 45 hp for 1 minute!) 1 hp = kw; 10 hp motor consumes 7.5 kw at full load That means a 15 kw unit heater is like a 20 hp motor Demand Charge The highest minute average operating load during the billing month Utilities have to have capacity to provide that amount of power, so it helps pay for the infrastructure. In-rush current at motor start does not typically impact demand charge. Power Factor Think of pulling a rail car. Slide 27

28 Power Factor = Real Power / Apparent Power - the closer this is to 1.0, the happier your utility will be... Slide 28

29 Meter Reading Slide 29

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31 Where am I now? Benchmarks can be used for your Energy Dashboard Slide 31

32 EPA Portfolio Manager Real Time kw Reading Monthly kwh to date kwh / Million Gallons Treated kwh / 1000 lbs. BOD Removed Load Factor = kwh X 100 Peak kw x 24 x days in billing period Slide 32

33 Where am I now? - Benchmarking Slide 33

34 Where am I now? - Benchmarking Some lessons learned: Benchmarks are great for tracking your facility s performance over time. They are of limited value in comparing your facility to another. You will need to include the energy you produce on-site as well as the energy you buy to obtain a true picture of your facility s efficiency. Complicated benchmarks can be useful simply as a tool that forces you to gather data in a regimented manner. Benchmarks are powerful marketing and communication tools. Be Consistent! They are only useful if they are developed using the same methods during each reading. Slide 34

35 Where am I headed? Audits can help you identify opportunities and focus efforts. Slide 35

36 Where am I headed? Types of audits: Plant-wide scoping Typically, a walk-through where an energy specialist will look for and identify common inefficiencies essentially help tag the low-hanging fruit. Often available without charge from your power company. System audit Often performed by specialist, e.g. air compressor or pump vendor. Focused on one portion of the plant, and will usually involve data logging or other power monitoring over a period of time. Comprehensive audit / tune-up Can include workshop / teaching opportunities Generally identifies several O&M opportunities as well as capital projects Slide 36

37 You don t need to wait for an audit, and you can often find truly great opportunities because of your knowledge of the plant! Slide 37

38 Guidelines for finding conservation opportunities Find loads that run continuously or nearly continuous Look at your electrical diagram and pick out big motors Look at equipment more than 10 years old Systems that are run on simple (or no) control Seasonal loading / permit changes Slide 38

39 O&M Opportunities Four easy ideas for immediate O&M savings within your facilities. Engage your O&M staff to help identify more opportunities e.g. scavenger hunts for inefficient motors; awards & recognition for good ideas and practices Slide 39

40 O&M Opportunities #1: Reduce operating pressure and flow of plant wide fluid and air systems. E.g. compressed air, reclaimed water, plant water systems On a +/- 100 psig air system, 2 psig reduction saves 1% in energy costs Reclaimed water isn t free! Lewiston, Idaho: Reduced plant water pressure from 106 psig to around 60 psig, and performed an intentional analysis of where it was used. Will save about $6000 annually on power bill. Slide 40

41 O&M Opportunities #2: Use your efficient equipment first and most often. Identical equipment in a line-up isn t identical in operation! Manufacturing tolerances Wear Installation differences You may have multiple resources available. Multiple wells Surface water vs. ground water Portland Water Bureau cut 6% from booster station consumption. Slide 41

42 O&M Opportunities #3: Optimize control set points. A 0.5 mg/l reduction in D.O. level represents 6 7% energy savings 2.0 is nominal, many run lower than that. Running above 3 mg/l? Or 5? How about 8?!?! Lift station or other low-head pumps can benefit from small adjustments in wet well level E.g.: RAS pump with 20 feet TDH at normal operating point Setting wet well pump on elevation 6-inches higher reduces head (and power requirements) by 2.5% Slide 42

43 O&M Opportunities #4: Now that spring is finally here SPRING CLEANING! Sensors for temperature, dissolved oxygen, ph and water chemistry, ambient and occupancy lighting sensors Filters on air, water, and hydraulic systems Diffusers, air knives, distribution nozzles anyplace where the flow is supposed to be distributed Large impact of small losses in low pressure systems Moving a 10 psig aeration system to 9.8 psig results in 1.8% energy savings Slide 43

44 A few capital project ideas to consider... Slide 44

45 Project ideas Main idea: Pumping power equation: BHP (water hp) = (GPM * TDH ) / (3960 * pump eff.) Electrical hp = water hp / motor efficiency Similar equations for fans and blowers Power can be reduced by: Reduce flow rate Operate at lower differential pressure Higher efficiency equipment Slide 45

46 Project ideas cont. Match power (& flow) to load VFD s in lieu of control valves VFD s in lieu of dampers on odor control or foul air systems Install an additional, smaller pump in lieu of internal recycle flows Use efficient equipment Swap out old motors rather than rebuilding If you are rewinding, utilize Green Motors program Check that your pump impellers are correct for actual conditions Use your most efficient equipment first and most often Slide 46

47 Project ideas cont. Reduce line pressure or pump lift Upsize sewer force main or water main size. Question: Why does the system pressure need to be XX psig? Identify specific demand locations and address them separately Run a lower pressure normally, and bump it up only when needed Compressed air systems generally present excellent opportunities Most process pumps are fairly low head, so 2 or 3 feet of pressure difference can be a good percentage of total head. Slide 47

48 Project ideas cont. A project doesn t have to touch an electrical panel to be an energy project Water conservation strategies Leak detection and repair programs Backwash / filter operational changes to reduce off-spec water Conservation rate structures(?) Wastewater reduction strategies Inflow / Infiltration reduction programs (?) Gray water reuse Industrial pretreatment (?) Slide 48

49 Project ideas cont. Eliminating electrical consumption completely Replace lift station with gravity sewer Situate the treatment plant to take advantage of gravity Using control valves to control gravity flow is a great use of control valves, since it doesn t cost anything for the head you re burning Possible to select groundwater source points to reduce or eliminate pumping energy? Or Use electricity instead of gravity Use VFD s in lieu of reservoirs to avoid pumping up the hill and then burning that hard earned elevation through a PRV. Slide 49

50 Nice ideas but I want to know.. Does this stuff really work? Slide 50

51 ESI Track and Tune Case Study Sysco (first 44 months) Total Distribution Center Energy Intensity kwh/day/1000 ft Refrigerated Warehouses Building Tune Ups Energy Management Some Capital Upgrades Some Efficient New Construction Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Slide 51

52 kw B O N N E V I L L E P O W E R A D M I N I S T R A T I O N ESI Track and Tune Case Study Example of Immediate Improvement at Single Site 1,200 Plantwide Impact of Commissioning: Before & After 1,100 1, Commissioning Changes on 10/ /05 10/10 10/15 10/20 10/25 10/30 11/04 11/09 11/14 Date Slide 52

53 Making Efficiency Part of Your Operating Strategy DOES Work! Actual facility history from a Corporate Energy Management client Lighting Project 44% savings (Dec 10 vs. Dec 07) Lighting Project Oct 2008 Facility Tune Almost 2 times the projected savings from facility tune-up so far Implemented NO capital projects after tune up Slide 53

54 Whether you think you can, or think you can t, you re right. -Henry Ford Thanks! Slide 54