South Lyon Energy Conservation Project

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1 South Lyon Energy Conservation Project By : Robert Martin Superintendent City of South Lyon John Patry Owner UIS Jacob Corvidae Southeast Michigan Regional Energy Office

2 Background South Lyon Wastewater Facility City Population: 11,400 5 Yr Population Change: +5% Ave. Daily Influent: 1.25MGD Maximum Capacity: 6 MGD Description of the Process: Extended Aeration WWTP Picture of overall plant.

3 Background Why do an energy reduction project now? Yearly wastewater Electrical Energy bill: $189,000 in 2011 More than 19% of the operating budget DTE rates going up faster than inflation rate (11% in 2011) South East Michigan Regional Energy Office was offering funding assistance to cut energy costs. DTE and Consumers do as well.

How to Start? EPA Published a Guideline The South Lyon Team simplified the guidelines and created a five step program. I. Perform audits of major energy consumers II.

4 How to Start? EPA Published a Guideline The South Lyon Team simplified the guidelines and created a five step program. I. Perform audits of major energy consumers II. Create a system to track energy usage III. Upgrade equipment or processes IV. to improve efficiency Optimize load profiles by shifting operations where possible V. Develop in-house energy management training for operators

5 Step I - Perform audits of major energy consumers The South Lyon Team proceeded with two Energy Audits Average 2011 KW usage based on DTE bills: 261KW 100% Estimated Major Energy Users were: 1. Aeration Blowers : 4 x 125 HP Blowers, 2 on VFD, 2 Fixed Speed Typical day energy consumption 1 Fixed Speed 100% on - 94 KW 36% 1 VFD Speed 50% on at 50% capacity - 24KW 9% 2. Dewatering and Digester Blowers : 6 x 50 HP Blowers, 6 Fixed Speed Typical day energy consumption 2 Fixed Speed 100% on - 75 KW 29%

6 Step I - Perform audits of major energy consumers Blowers consume 74% of the energy

7 Step I - Perform audits of major energy consumers The South Lyon Team dissected the DTE Energy Invoice On-peak Billing demand = 30% of yearly invoice

8 Step I - Perform audits of major energy consumers The South Lyon Team dissected the DTE Energy Invoice Distribution Demand = 7% of yearly invoice

9 Step I - Perform audits of major energy consumers The South Lyon Team dissected the DTE Energy Invoice Power Factor Costs = 0% of yearly invoice

10 Step I - Perform audits of major energy consumers The South Lyon Team dissected the DTE Energy Invoice On-peak Billing demand = Distribution Demand = Power Factor Costs = 30% of yearly invoice 7% of yearly invoice 0% of yearly invoice Observation:

11 Step I - Perform audits of major energy consumers Conclusions of Step 1 1. Focus energy conservation on: i. Aeration blowers ii. Digester and Dewatering blowers 2. Cut down on peak energy usage

Step II - Create a system to track energy The

12 Step II - Create a system to track energy The South Lyon Team contracted Utilities Instrumentation Service, INC, SCADA team to install a system to track energy. It consisted of: 1. Allen Bradley PM1000 Energy Monitoring System installed in the Switchgear panel board along with PTs and CTs.

13 Step II - Create a system to track energy 2. A new Server with Rockwell FactoryTalk HMI where each of the 7 Wastewater PanelView screens were centralized.

14 Step II - Create a system to track energy 3. Factory Talk software was customized to South Lyon s needs

15 Step II - Create a system to track energy 3. Factory Talk software was customized to South Lyon s needs

16 Step III - Upgrade equipment or processes to improve efficiency 1. Aeration Blowers 45% of total energy With energy monitoring, the South Lyon Team is able to dissect daily energy consumption trends.

17 June 15, 2012 Pre changes both Blowers on VFD Observation: Pre changes data. Actual: Precip: 0.00 Ave KW : 265

18 Jul 9, 2012 Peak demand day What Happenned? Actual: Precip: 0.00 Ave KW : 326

19 Jul 24, 2012 Typical Summer day Observation: Pre changes data. Actual: Precip: 0.00 Ave KW : 251

Jan 8, 2013- Dry & frozen Day Establish lowest energy day with

20 Jan 8, Dry & frozen Day Establish lowest energy day with no I&I and cold water. Actual: Precip: 0.00 Ave KW : 232

21 Feb 11, 2013 Second of winter s two warm days Impact of melting snow raises energy consumption Actual: Precip: 0.00 Ave KW : 271

22 April 3, 2013 Dry day pre diffuser repair Dry spring day performance. About 8% more energy than a dry winter day. Actual: Precip: 0.00 Ave KW : 248

23 April 4, 2013 Dry day when diffusers were repaired DTE called this the On-Peak Power Demand day. Three blowers were working for about 30 minutes. Actual: Precip: 0.00 Ave KW : 243

24 April 5, 2013 Dry day after diffuser repair Diffuser repair helps reduce energy consumption by about 10%. Actual: Precip: 0.00 Ave KW : 223

25 April 11, Year Rain Event Rain events do not increase energy consumption. Pump energy increase is offset by a blower energy decrease. Actual: Precip: 1.35 Ave KW : 231

26 May 14, 2013 Dry day before bucket removal Establish a base. Actual: Precip: 0.00 Ave KW : 230

27 May 16, 2013 Dry Day after bucket was removed. No noticeable change. Actual: Precip: 0.00 Ave KW : 235

28 May 29 th Dry Day with Generator Test Generator test will destabilize the blower program. Actual: Precip: 0.00 Ave KW : 228

29 VFD vs. Fixed Speed on KW Fixed Speed Curve Energy Savings Variable Speed Curve

30 VFD vs. Fixed Speed on the second blower Energy Savings

31 Step III Upgrade equip./process to improve efficiency Aeration Blowers In 2011 before any changes: - Ave. DO reading was between 3 & 4 while target was 1 to 2 - DO probe readings were questionable - Blower speed was proportional to influent flow - DTE Energy peaks were not analyzed Changes: 1. Replaced the DO probe 2. Replaced worn diffusers 3. Changed blower speed program to make speed proportional to DO.

32 Step IV - Optimize load by shifting operations efficiency 2. Dewatering & Digester Blowers 6 x 50 HP Motors 2 on 100% 29% of total energy

33 Step IV - Optimize load by shifting operations efficiency 2. Dewatering and Digester Blowers. Created a simple program to reduce digester and dewatering blower energy consumption project. Observations: i. Water is at risk of freezing in the winter months ii. Water is at risk of becoming toxic in the summer months.

34 Recommendations & Comments Recommendations 1. Upgrade SCADA to get real time data on power trends and each major energy consumer to help identify peak energy events 2. Evaluate the effectiveness of the diffusers at all three locations. 3. Evaluate using VFDs for both aeration blowers using DO as the dependent variable. 4. Evaluate adding a DO driven VFD process on the digester process. 5. Provide a more stable DO program to avoid power peaks during a diffuser repair or generator test. Step V - Develop in-house energy management training for operators 1. Train staff and continue to monitor all peak periods until they are minimized.

35 Recommendations & Comments Comments 1. Analyzing energy trends using your utility company s invoice does not work. Effective power analysis requires more details. Adding main plant energy monitoring and centralizing all major energy consumers status onto one SCADA system pays. 2. South Lyon invested about $35,000 and in the first phase expects to cut costs by about 15% or $30,000/yr. 3. South Lyon was able to finance the project with the help of South Michigan Regional Energy Office.

36 CITY OF SOUTHGATE, SOLAR PV INSTALLATION TO THE POLICE DEPARTMENT local governments & 3 nonprofits

37 CITY OF HAZEL PARK ICE ARENA 1. Ice Arena Waste Heat Use 2. Waste Water Monitoring 3. LED Street Lights 4. Solar Electric 5. Solar Water Heating 6. PACE financing

38 26 Municipal Projects; 4,000 Residential Over $8 Million

39 Energy Toolkit and Case Studies:

Conclusion The program is simple and provides a fast payback. 1.

Create a system to track energy usage 3.

Optimize load profiles by shifting operations where possible 5.

40 Conclusion The program is simple and provides a fast payback. 1. Perform audits of major energy consumers 2. Create a system to track energy usage 3. Upgrade equipment or processes to improve efficiency 4. Optimize load profiles by shifting operations where possible 5. Develop in-house energy management training for operators Save energy, our environment and money! Finally, For those who want a copy of the presentation, please go to: uiscorp.com/white-papers/

41 The End South Lyon Energy Conservation Project By : Robert Martin Superintendent City of South Lyon John Patry Owner UIS Jacob Corvidae Southeast Michigan Regional Energy Office

Aeration System Improvements with a 5-Year Payback. Scott Phipps

Aeration System Improvements with a 5-Year Payback Scott Phipps Wastewater Treatment Aeration Timeline 1970 s Major infrastructure investment Quick and cheap solutions Coarse bubble diffusers & PD/MS blowers