An Equation for Energy Savings?

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1 2 Green ARRA Projects & 1 WWTP: An Equation for Energy Savings? June 22, 2011 Presented By: Ashley G. Elber

Autothermal Thermophilic Aerobic Digestion 8,700 lb/day City of Delphos WWTP OEPA Directors Final Findings and Orders Filed 2004 MBR Technology New Plant Online October 2006 Design Loadings: 12,000

2 Autothermal Thermophilic Aerobic Digestion 8,700 lb/day City of Delphos WWTP OEPA Directors Final Findings and Orders Filed 2004 MBR Technology New Plant Online October 2006 Design Loadings: 12,000 lb/day CBOD 9,000 lb/day TSS Flows and Loadings: Population: 7,000 People Industrial Flow (7x Population) 70% Combined Sewer System Old Peak Flow: 7 MGD New Peak Flow: 18 MGD New Max Day Flow:12 MGD Average Daily Flow: 3.83 MGD Minimum Flow: 0.8 MGD

control projects. Green Projects - $44.5 Mil. Energy/ Water Conservation - $17 Mil.

3 ARRA 2009 Green Projects The Ohio Water Pollution Control Loan Fund was designated to deliver approximately $220 million of the stimulus funds for water pollution control projects. Green Projects - $44.5 Mil. Energy/ Water Conservation - $17 Mil. Green Projects $17 Mil. Innovative Projects - $10.5 Mil. Shovel Ready Buy American Provision

4 Delphos - ARRA Projects Requests 24 Total 5 WWTP All Energy Related

5 Energy Conservation Projects Wind Farm

6 Funding Received

7 Funding Received

8 MBR Blower Replacement

9 Energy Audit Evaluated the different blowers at the plant for potential energy savings Presented Audit to Council and attached with Funding Application Project was justified before starting

10 Blower Power Energy Costs Assume 3,000 SCFM Typically 3 Blowers Operating Peak Events 7 Days Per Month Used $0.0603/kWh Solve For Blower Energy Usage

3,000 SCFM Power Usage 106 kwh 111 kwh 117 kwh 123 kwh 80.7 kwh 84.2 kwh 87.7 kwh 92.

11 3,000 SCFM Power Usage 106 kwh 111 kwh 117 kwh 123 kwh 80.7 kwh 84.2 kwh 87.7 kwh kwh 30 ºF; 70%RH 50 ºF; 70% RH 70 ºF; 60% RH 90 ºF; 60% RH United Blower Kturbo Blower

12 Blower Power Energy Costs Month kwh Per United Blower United Blower Total Energy Cost ($/month) kwh Per Blower KTurbo Total Energy Cost ($/month) January $16, $12,496 February $15, $11,445 March $17, $13,038 April $17, $13,200 May $18, $13,580 June $18, $13,907 July $19, $14,308 August $19, $14,308 September $17, $13,200 October $18, $13,580 November $16, $12,673 December $16, $12,496 $209,923 /Year $158,233 /Year Difference: $51,690

13 Power Consumption Savings $6,000 $5,000 $4,000 $3,000 $2,000 $1,000 $0 Jan Feb March April May June July Aug Sept Oct Nov Dec

14 Estimated Percent Savings Savings on Blower Power Costs = ~ 25% Savings on Total Utility Bill = 10% to 15% Per Month

15 MBR Blower Replacement New Blowers: 6 - Turbo Blowers 200 HP

16 Summary of Project Demo of Existing Blower Demo of Existing VFDs / Soft Starts Six Turbo Blowers Stainless Steel Air Piping Two Louvers Electrical Work Programming Extended Service Agreement

19 4. Operation at Multiple Operating Points

21 Turbo Blowers Manufacturers... and more

22 Basis of Design Type of Blower: Turbo Blower Operating Conditions: 3000 scfm Flow Range Required: 3600 scfm to 1500 scfm Discharge Pressure: 7.15 psig Turndown: 7.15 psi Maximum Temperature: 90 Degrees F; RH 70% Minimum Temperature: 30 Degrees F; RH 60% Motor shall have a service factor of 1.15 that is inverter duty rated

23 Capital Costs New Turbo Blower Complete Package PD Blower United Blower $20, HP Universal Motor $15,000 Sound Enclosure $3,500 Allen Bradley VFD $55,000

24 PD Blower Maintenance Costs Check Oil Level Weekly Change Oil Every 1,500 Hours or Every 6 Months 4 Gallons Per $289/ 5 gal If only every 6 Months: $2,775 per year Regrease Motor Bearings Every 9 Months Check V-Belts Every 500 Hours or Every 9 Months $100 / 6 Belts Per Blower Clean Air Inlet Filters Every 3 Months. Replace with New Every Year $65 / Filter

25 Turbo Blower Maintenance Costs Filters: First Stage Every 8 Weeks at $9/ Filter Second Stage Every 12 Months at $300/Blower VFDs: Checked every 3 Years: $3,000 for trip and all six VFDs Motors: Rebuilt every 10 Years: $5,000 per Blower

26 Turbo Blower Efficiency Blower Efficiency 80 % 70 % 60 % 50 % 40 % 30 % 20 % 10 % 0 % 90 ºF 70 ºF 50 ºF 30 ºF 20% to 30% More Efficient than PD Blowers 3,000 SCFM kw Usage 3,600 SCFM kw Usage 1,500 SCFM kw Usage

27 Not to Exceed Power Requirements Total kw Usage Per Blower 30 ºF 48.6kW 80.7kW 97.1kW 1,500 SCFM kw Usage 3,000 SCFM kw Usage 3,600 SCFM kw Usage 50 ºF 50.5kW 84.2kW 102.0kW 70 ºF 52.4kW 87.7kW 107.3kW 90 ºF 54.7kW 92.4kW 113.9kW

28 Factory Performance Testing March 15, 2010

29 On-Site Performance Testing

30 Using SCADA to Optimize Plant Flow Rates Blower Flow Rates kw Usage Power Costs Instantaneous Daily Weekly Monthly Yearly All Used to Optimize their Plant!!!

31 Actual Blower Data Month Turbo Blower Usage (kwh) Metered Utility Bill Usage MBR Blowers Contribution to Utility Bill Avg. Flow MGD Cost Per MGD September 214, ,400 41% 0.86 $16,501 October 223, ,800 53% 0.91 $17,863 November 248, ,300 45% 1.59 $10,040 December 240, ,000 49% 1.33 $11,745 January 227, ,500 46% 1.22 $13,131 February 276, ,700 54% 2.44 $8,369 March 337, ,900 60% 3.60 $6,771

32 Monthly Percentage Savings Based on Average Flows and Average Power Usage Average Flow Rate with PD Blowers* Average Flow Rate with Turbo Blowers** Average Power with PD Blowers Average Power Usage with Turbo Blowers Avg Power Usage per mgd with PD Blowers Avg Power Usage per mgd with Turbo Blowers Electrical Savings Per Month , , , , % Month Actual Monthly Utility Bill Savings September $34, $7, October $30, $6, November $35, $7, December $31, $6, January $34, $7, February $38, $8, March $40, $8, April $42, $9, Total $61, Average $7, *Data for PD Blowers is from January 2008 to December 2009 ** Data for KTurbo Blowers is from September 2010 to April 2011

33 Solar Module System

34 Site Work Running Ductbank and Wires Stone and Weed Barrier Foundation Racking Installing Solar Panels and Inverters Solar Panel Grounding SCADA Integration

35 N Solar Module System

36 Solar Module Design N Possible Future Expansion ¾ 144

37 Solar Module Racking

Solar Module Design 9 SMA Sunny Boy 8 kw Inverters 77.

38 Solar Module Design 9 SMA Sunny Boy 8 kw Inverters kw Solar Module System (Nominal Peak Output) Power Produced Offsets Entire Plant s Grid Schott 220 W Panels

39 Solar Module Design

40 Solar Array O&M

41 Solar Savings Equation Estimated Power Production = Average Hours of Sunlight x X Days Month x Size of Photovoltaic System x NREL Adjustment Factor Based on Past Data for NW Ohio kw 77%

42 Solar Savings (Past Data) Month Average Hours of Sunlight Per Day Average Hours of Sunlight Per Month Jan Feb March April May June July Aug Sept Oct Nov Dec

43 Estimated Solar Power Production 30,000 kw 25,000 kw 20,000 kw 15,000 kw 10,000 kw 5,000 kw 0 kw Jan Feb March April May June July Aug Sept Oct Nov Dec Total Production = 263,717 kw / Year

44 Estimated Power Savings $1,800 $1,600 $1,400 $1,200 $1,000 $800 $600 $400 $200 $0 Jan Feb March April May June July Aug Sept Oct Nov Dec Total Savings = $15,902 / Year Assuming $0.0603

45 Impact of Alternative Energy on Greenhouse Gases 1 lb = 0.7kWh 1 lb = 77 kwh 1 lb = 49 kwh

47 A web base interface is required to sell SRECs 1,000 kwh = 1 Credit = ~$

49 Estimated Yearly - $51,690 ; 10-15% Savings since September 2010 $60,000 $7,000 monthly average; 18-23% 35,400 kwh Produced = $2,800 Savings 50,500 lb Carbon Dioxide 458 lb Methane 722 lb Nitrous Oxide

self audit energy consumption and energy production Saving Energy and

50 Emerging Technology = More Opportunities for Energy Savings Installing Features to track kw usage provides opportunity to have more control to self audit energy consumption and energy production Saving Energy and Alternative Energy is NEW, EXCITING, PROVIDE COST SAVINGS, and ARE GOOD FOR THE ENVIRONMENT

51 Ashley G. Elber Sterling Court Mentor, OH phone: fax:

Running the Electric Meter Backwards: Real-Life Experience with a Residential Solar Power System

Running the Electric Meter Backwards: Real-Life Experience with a Residential Solar Power System Brooks Martner Lafayette, Colorado University of Toledo Spring 2013 PHYS 4400 - Principles and Varieties