2012 CLEAResult All rights reserved. Industrial Facility

Transcription

1 Industrial Facility

2 Objectives ECM Matrix Power Factor Correction Water & Wastewater Measurement and Verification

3 ECM Matrix Energy Conservation Measures Lighting Lighting Controls Daylight Harvesting HVAC BAS Systems Retro-Commissioning AC Tune-Up Cooling Tower Process Cooling Sys. Motors (High Efficiency) VFD Motors Air Compressor Sys. Injection Mold (High Eff.) Blowers VS. Compressed Air Roofing Piping Insulation Refrigeration Pumps BUILDING TYPES City/Gov. Bldg. X X X X X X X X X X Schools X X X X X X X X X X Colleges/Universities X X X X X X X X X X Hospitals X X X X X X X X X Departments Stores X X X X X X X Small Retail X X X X X X Big Box Retail X X X X X X X Grocery/Supermarkets X X X X X X X X X Office Buildings X X X X X X X X X X Hotels X X X X X X X X X Restaurants X X X X Fast-Food Restaurants X X X Theatres X X X X X Convenience Stores X X X X X X Parking Garages X

4 ECM Matrix (cont d) Energy Conservation Measures Lighting Lighting Controls Daylight Harvesting HVAC BAS Systems Retro-Commissioning AC Tune-Up Cooling Tower Process Cooling Sys. Motors (High Efficiency) VFD Motors Air Compressor Sys. Injection Mold (High Eff.) Blowers VS. Compressed Air Roofing Piping Insulation Refrigeration Pumps INDUSTRIAL Waste Water Treatment X X X X X X Warehouses X X X X Dairy Industry X X X X X Refrigerated Warehouses X X X X X X Metal Fab. X X X X X X X X X Pottery X X X X X X X X X X Distribution Center X X X X X Food Distribution Center X X X X X X Food Mfg X X X X X X X X Plastic Injection Mfg X X X X X X X X X X X Blow Mold Mfg X X X X X X X X X X Bottling Mfg X X X X X X X X X X X Foundry X X X X X X X X X Printing X X X X Corragated Pkging X X X X Cable Mfg X X X X X X X Chemical Processing X X X X X X X X Powder Coating X X X X X X Funiture Fab. X X X X

5 Power Factor Correction

6 Draft Beer: $11 per Glass at the NEW Cowboys Stadium

7 Objectives What is Power Factor? How to correct Power Factor? How does Power Factor effect billing? Issues with correcting Power Factor? Myths of Power Factor Correction

8 What is Power Factor? PF = kvar kw kva kw Real Power (work, HP) kvar Reactive Power (nonworking power kva Apparent Power (what the utility supplies) kva kvar kw kva kw

9 How to Correct Power Factor Add a Capacitive load offset the Inductive load. You can add capacitors at the motor load or connect to the main switch gear.

10 How Does Power Factor Effect Billing.95 ADJ = kw kw PF DC ADJ = Increase to applicable Demand Charge, kw = Monthly Billing Demand, PF = Monthly measured Power Factor, and DC = Demand Charge The billing demand will be the highest of: Large Power Service Rate Customers a) the maximum measured demand (adjusted for primary voltage if applicable), or b) 65% of the highest measured demand established during the twelve (12) month period ending with the current month, or c) 800 kilowatts General Service Rate Customers a) Applies to customers with peak < 799 kw b) the maximum measured demand (adjusted for primary voltage if applicable), or c) 65 percent of the highest measured demand established during the twelve (12) month period ending with the current month, or

11 Issues with Power Factor Correction Secondary Bus Voltage Waveform during Utility Capacitor Switching Harmonic Distortion Harmonics are generated by nonlinear load on your electrical distribution. VFD or VSD are common culprits. Arc welders, DC rectifiers and soft start motors (on start up only) are also contributors.

12 Myth of Power Factor Correction Power Factor will reduce your energy demand. FACT: Adding kvar will decrease the amperage used by the facility, BUT increase the voltage. More kvar is better. FACT: Over-correcting power factor can damage voltage sensitive EQ in the facility. The supply voltage will increase by 10% or more. Recommended: Reduce energy demand first through energy efficiency, before correcting power factor

13 Water & Waste Water Treatment

14 Why WWTP are Important Grade D- assigned by ASCE 1.5% of total US electrical usage Aeration System 10 20M kwh/yr total usage Aeration: 40-70% of plant electrical use Typical electrical savings: 2M kwh/yr 2

15 Aeration Options Surface Sub- Surface 3

16 WWTP Energy Savings VFD for Aerations Blowers Using UV Disinfection versus chemical Biogas capturing and power generation

17 Injection Molding Insulating the barrel heater can reduce the amount energy it takes to melt the plastic pellets prior to injecting the plastic into the mold. VFD controls on cooling tower and chill water pumps Limit switch controls on grinders and granulators

18 Measurement & Verification

19 Objectives Purpose of M&V Two Basic Methods of M&V Whole Facility Retrofit Isolation General M&V Rules of Thumbs

20 Purpose of M&V Increase Energy Savings Document financial transactions Support evaluation of efficiency programs Educate facility users about there energy impacts

21 Two Basics Methods Retrofit Isolation Method: Measures the effect of the retrofit, only Savings are unaffected by changes beyond the measurement boundary Usually needs a new meter (data loggers) Adjustments can be simple Whole Facility Method: Measures all effects in the facility Retrofits AND other changes (intended and unintended) Often uses the utility meter Adjustments can be complex

22 Retrofit Isolation Option A - Key Parameter Measurement Measure only the key parameters Make estimates or assumptions that will significantly affect reported savings Option B - All Parameter Measurement Measure independent variables that affect energy savings Decide the metering system Decide on a baseline period Cooling Tower Chiller Cooling Loads Boundary of Measurement

23 Whole Facility Option C Whole Facility Need both baseline and reporting period data Assess performance of the whole facility, retrofitted and non-retrofitted systems or areas Significant energy savings (10% or more of consumption measured by utility meter) Option D Calibrated Simulations When there is no meter (of facility) in the baseline Baseline data can be manufactured under controlled circumstances. Most expensive method and complicated

24 M&V Rules of Thumb Adhere with International Performance Measurement and Verification Protocol (IPMVP) Define an M&V Plan M&V reports of Savings should be presented as defined in the M&V Plan The cost to M&V should be less than 10% of the annual savings Weigh the cost benefits of M&V accuracy vs. M&V cost

25 QUESTIONS? Presentations Available at