Fairfax Water Energy Savings Plan Welcome to Fairfax Water s Energy Saving Strategic Plan and Results for Year 2010

Transcription

1 Welcome to Fairfax Water s Energy Saving Strategic Plan and Results for Year 2010 FW Energy Program VA AWWA Energy Webinar 20 April 11 1

2 Fairfax Water Energy Program Fairfax Water Strategic Plan - # 5: The cost of energy exceeds all other expense items except labor for Fairfax Water. The organization desires to improve its cost efficiency and operational effectiveness by the development and implementation of a comprehensive energy management plan. FW Energy Program VA AWWA Energy Webinar 20 April 11 2

3 Fairfax Water s s Energy Approach Selected an Energy Committee at Fairfax Water. Developed an Energy Program. Action Steps that are part of the overall FW Strategic Plan. Created Energy Guidelines. FW Energy Program VA AWWA Energy Webinar 20 April 11 3

4 Energy Action Steps for Fairfax Water s Strategic Financial Plan 1. Review and analysis of regional and national regulatory issues. 2. Develop a comprehensive database to track energy procurement and consumption. 3. Conduct an energy consumption survey to determine Fairfax Water s energy use profile. 4. Identify potential energy savings opportunities. 5. Develop a procurement strategy for energy. 6. Develop energy efficiency design and maintenance standards. FW Energy Program VA AWWA Energy Webinar 20 April 11 4

5 1. Review and analysis of regional and national regulatory issues Member of Virginia Energy Purchasing Governmental Association (VEPGA) Member of Fairfax County s Energy Efficiency and Conservation Coordinating Committee (EECCC) EPA Greenhouse Gas Emissions Dominion 4 to 6 Billion dollar investment over the next 4 years. Governor s Energy Conference FW Energy Program VA AWWA Energy Webinar 20 April 11 5

6 2. Develop comprehensive database to track energy procurement & consumption. Utilized Dominion Power and Washington Gas s key customer web site to track energy consumption and costs of Corbalis and Griffith for targeting high energy usage and costs. Reviewing several software systems for future energy database. FW Energy Program VA AWWA Energy Webinar 20 April 11 6

7 3. Conduct energy consumption survey to determine Fairfax Water s s energy use profile. Utilized the Power Logic system at Griffith to get specific energy patterns by buildings to troubleshoot energy issues and usage problems Developed wire to water energy ratio analysis for tracking energy usage and costs at Corbalis and Griffith Water Treatment Facilities. FW Energy Program VA AWWA Energy Webinar 20 April 11 7

8 Power Logic System improvements at Griffith High demand in summer time causes ratchet demand in one day to be used for 12 months. Added capability for operator to see when Griffith is within 1000kw of peak demand. Added green, yellow, and red color warnings as demand approaches peak from previous year. 1000kw demand savings = Over $100,000 in demand savings on bill for year. FW Energy Program VA AWWA Energy Webinar 20 April 11 8

9 Power Logic System Added Advantages Griffith Capture Transients to track down causes of failures. Documented power usage when primary revenue meter failed. Independent record of large pump operations. Pinpoint disturbances, record times and help electric utility uncover external causes. FW Energy Program VA AWWA Energy Webinar 20 April 11 9

10 Quick Side Trip into Power Quality The same tools used for detailed energy monitoring often monitor power quality. We will have a look at electrical transients in the next few slides to give a taste of power quality. Important power quality issue are: Voltage level sags and swells Harmonics Transients FW Energy Program VA AWWA Energy Webinar 20 April 11 10

11 Example Motor Starting Transient FPS SG01 Side A FW Energy Program VA AWWA Energy Webinar 20 April 11 11

12 Motor Starting Transient Side B after disconnecting PFCC FW Energy Program VA AWWA Energy Webinar 20 April 11 12

13 May 26 Transient FWPS A Side FW Energy Program VA AWWA Energy Webinar 20 April 11 13

14 Fairfax Wire to Water 2009 Jan - Dec Energy Summary 2010 Jan - Dec WTP kwh/mg kwh/mg % change - Energy Corbalis 2,509 2,223-13% Griffith 1,950 1,764-11% Average 2,257 2,039-12% FW Energy Program VA AWWA Energy Webinar 20 April 11 14

15 Kwhr/MG Wire to Water Energy Ratio Corbalis & Griffith Wire to Water Ratio Corbalis Griffith FW Energy Program VA AWWA Energy Webinar 20 April

16 Corbalis and Griffith $/MG Jan Dec 2009 Jan Dec 2010 WTP $/MG $/MG Jan Dec 2009 vs % change - Costs Corbalis $168 $126-33% Griffith $138 $97-42% FW Energy Program VA AWWA Energy Webinar 20 April 11 16

17 Wire to Water Cost Ratio Corbalis & Griffith Cost/MG $180 $160 $140 $120 $100 $80 $60 $40 $20 $0 Wire to Water Cost Ratio Corbalis Griffith FW Energy Program VA AWWA Energy Webinar 20 April

18 Industry Benchmarks Water kwh/mg $/MG Companies *WSSC 1,798 $170 *Columbus, Ohio *Honolulu Water Fairfax Water - Griffith 1,854 $111 1,791 $287 1,759 *$97 FW Energy Program VA AWWA Energy Webinar 20 April 11 18

19 4. Identify potential energy saving opportunities Wire to water efficiency tests were performed on Corbalis and Griffith finished water pumps. Corbalis Wire to Water Efficiency testing finds potential energy saving = $567,030 annually. Corbalis Finished Water Pump #1- valve position change and energy savings of $228,000 annually. FW Energy Program VA AWWA Energy Webinar 20 April 11 19

20 Fox Mill Finished Water Pumping Costs (Valve Throttled) $/MG Pump #1 at 1500hp with the valve open 20% is $65/MG. Pump #2 at 1500hp with the valve open 20% is $66/MG. Pump #3 at 1500hp with the valve open 20% is $61/MG. Pump #4 at 700hp with the valve open 20% is $64/MG. Pump #5 at 700hp with the valve open 20% is $60/MG. FW Energy Program VA AWWA Energy Webinar 20 April 11 20

21 Fox Mill Finished Water Pumping Costs (Valve Wide Open) Pump #1: 1500hp the valve open 100% is $46/MG. Pump #2: 1500hp with the valve open 100% is $44/MG. Pump #3: 1500hp with the valve open 100% is $41/MG. Pump #4: 700hp with the valve open 100% is $48/MG. Pump #5: 700 hp with the valve open 100% is $46/MG $/MG FW Energy Program VA AWWA Energy Webinar 20 April 11 21

22 Tyson s II Finished Pumping Costs Pump #1 at 1250hp with the valve open 100% is $60/MG. Pump #2 at 1250hp with the valve open 100% is $63/MG. Pump #3 at 1250hp with the valve open 100% is $54/MG $/MG FW Energy Program VA AWWA Energy Webinar 20 April

23 Fox Mill & Tyson s comparison Fox Mill $/MG in consistent range between $41 and $48/MG Tyson s $/MG pumping costs higher at $54/MG to $63/MG Foxmill Tysons FW Energy Program VA AWWA Energy Webinar 20 April 11 23

24 Griffith Raw Water Pumping Energy Costs Pump #1 at 1750hp is $48/MG Pump #2 at 1750hp is $48/MG Pump #3 at 1250hp is $40/MG Pump #4 at 1750hp is $48/MG Pump #4 at full load is $49/MG Pump #4 at full load running with #7 is $39/MG Pump #4 Normal with #7 wide open is $44/MG Pump #7 at 700hp is $52/MG Pump #7 wide open with #4 normal is $42/MG $/MG FW Energy Program VA AWWA Energy Webinar 20 April 11 24

25 Griffith Raw Water Wire to Water efficiency improvements Discovered that running the raw water pumps past the pump curve increased efficiency Due to high suction pressure available All pumps now running past curve results in better kwh/mg efficiency and costs savings. Caveat Emptor (this might not work in your situation) FW Energy Program VA AWWA Energy Webinar 20 April 11 25

26 GTP Raw Water Pumping Stn. FW Energy Program VA AWWA Energy Webinar 20 April 11 26

27 RWPS Lower Hydraulic profile RW Pumps Located 55 feet below dam crest FW Energy Program VA AWWA Energy Webinar 20 April 11 27

28 Upper Hydraulic Profile into GTP Splitter box HGL ft above dam 165 ft above pumps Flash Mix Control Flow Split to FS Basins FW Energy Program VA AWWA Energy Webinar 20 April 11 28

29 Griffith Raw Water Pump Combinations (2) Pump Combinations Pump # 1 (2,4) & 3 (5) Pump # 3 & 5 Pump # 1 (2,4) & 7 55 MGD BEP P1: DP= 117 psi; VP=74% P7: DP= 120 psi; VP=66% 760 kwh/mg $ 46 /MG 51 MGD BEP P3: DP= 105 psi; VP=89% P7: DP= 120 psi; VP=66% 74 MGD BEP P1: DP= 117 psi; VP=74% P3: DP= 104 psi; VP=100% MGD Full Load P3: DP= 103 psi; VP=100% P5: DP= 104 psi; VP=100% 67 MGD Full Load P1: DP= 103 psi; VP=100% P7: DP= 102 psi; VP=100% 651 kwh/mg $ 39 /MG Less than "BEP" Operating Range 712 kwh/mg $ 43 /MG 647 kwh/mg $ 39 /MG 81 MGD Full Load P1: DP= 103 psi; VP=100% P3: DP= 104 psi; VP=100% 662 kwh/mg $ 40 /MG Pump # 3 (5) & 7 57 MGD Full Load P3: DP= 103 psi; VP=100% P7: DP= 102 psi; VP=100% 686 kwh/mg $ 41 /MG 634 kwh/mg $ 38 /MG Flow expressed as MGD FW Energy Program VA AWWA Energy Webinar 20 April 11 29

30 Overview Scheme (2) Pump Combinations Griffith Raw Water Pump Combinations Pump # 1, 2 & 4 Pump # 1 (2,4) & 3 (5) Pump # 3 & 5 Pump # 1 (2,4) & 7 Less than "BEP" Operating Range Two Large One Large + Medium Two Medium One Large + Small Pump # 3 (5) & 7 One Medium + Small Flow expressed as M GD FW Energy Program VA AWWA Energy Webinar 20 April 11 30

31 Pump # 1 (2,4) & 7 Pump # 3 (5) & 7 55 MGD BEP P1: DP= 117 psi; VP=74% P7: DP= 120 psi; VP=66% 760 kwh/mg $ 46 /MG 67 MGD Full Load P1: DP= 103 psi; VP=100% P7: DP= 102 psi; VP=100% 651 kwh/mg $ 39 /MG KEY DP=Discharge Pressure VP=Valve Position Flow expressed as M GD FW Energy Program VA AWWA Energy Webinar 20 April 11 31

32 Griffith Finished Water Pumping Costs Pump #2 at 1800hp is $63/MG Pump #3 at 1800hp is $53/MG Pump #4 at 1800hp is $73/MG Pump #6 at 500hp is $20/MG Pump #7 at 500hp is $18/MG Pump #8 at 500hp is $19/MG $/MG FW Energy Program VA AWWA Energy Webinar 20 April 11 32

33 Corbalis Finished Pumping Costs Pump #1 at 1750hp is $65/MG Pump #2 at 1500hp is $54/MG Pump #3 at 1500hp is $55/MG Pump #4 at 1500hp is $53/MG Pump #5 at 1500hp is $54/MG Pump #6 at 1500hp is $55/MG Pump #7 at 1500hp is $45/MG Pump #8 at 1500hp is $42/MG Pump #9 at 1000hp is $62/MG $/MG FW Energy Program VA AWWA Energy Webinar 20 April 11 33

34 Corbalis Wire to Water Efficiency testing projected potential energy saving = $567,030 annually. Finished water pump #1 -best test pump efficiency at 86.5% For initial snapshot, finished water pumps #2 - # 8 were more than 10% below their BEP. Closer examination warranted. Total energy savings annually for optimizing the pumping operation and running the finished water pumps at their BEP is estimated at $567,030 annually. Additional benefit of not throttling pumps = longer life and less cavitation. FW Energy Program VA AWWA Energy Webinar 20 April 11 34

35 Corbalis Finished Water Pump #1- valve position change and energy savings of $228,000 annually. Worked with Distribution to perform a 5 day test on the Corbalis Finished Water Pump #1 with the spill valve open and closed in A savings can be achieved totaling $dollars when the spill valve closed. When the spill valve was closed the running amps were 146 with 133 psi. When the spill valve was open the running amps were 164 at 120 psi. Both tested when the flows were the same with a total system load of 55 MGD. The test continued to show the increased energy usage when the spill valves is open. A substantial energy efficiency improvement and cost savings of an estimated $228,000 annually when the operation of the spill valve changed from open to closed position. FW Energy Program VA AWWA Energy Webinar 20 April 11 35

36 Impeller adjustments at Griffith Finished Water Griffith Finished Water pump # 2 Annual Savings $3,150 $1.08/MG Annual Savings. 365MG more production per year. Life of Pump increased $$$$ Impeller Change Pump Eff (%) Annual Cost Savings Wire to Water (kwh/ mg) Before 80.7% $732, After 83.6% $735, Total Annual Savings (24/7) 3% $3, FW Energy Program VA AWWA Energy Webinar 20 April 11 36

37 Why operate near pump s BEP? Smooth pump operation Minimum internal circulation Reduced bearing and mechanical seal failure Reduced risk of cavitation damage Minimal vibration Reduced noise Reduced discharge pulsation Best Efficiency Point FW Energy Program VA AWWA Energy Webinar 20 April 11 37

38 Wasted Energy Costs Pumping costs are lower when the flows are higher than BEP Maintenance Costs are higher when the flows are below BEP Carbon dioxide emissions $8,000 $6,000 $4,000 $2,000 $0 ($2,000) ($4,000) Wasted Energy Costs Flow as a % of BEP Cost to Pump BEP Volume FW Energy Program VA AWWA Energy Webinar 20 April 11 38

39 Reliability Effects Related to BEP FW Energy Program VA AWWA Energy Webinar 20 April 11 39

40 Total Failure, Maintenance, and Energy Costs off BEP Operation ANSI Horizontal Pump 1750 rpm. Total estimated benefit from pump optimization. Annual Costs, $ Total Costs of BEP Operations $140,000 $120,000 $100,000 $80,000 $60,000 $40,000 $20,000 $ Flow as % of BEP Maintenance Energy Failure FW Energy Program VA AWWA Energy Webinar 20 April 11 40

41 Griffith Raw Water Pump #1 FW Energy Program VA AWWA Energy Webinar 20 April 11 41

42 Griffith Raw Water Pump #1 FW Energy Program VA AWWA Energy Webinar 20 April 11 42

43 Internal Wear as a Factor in Reduced Pump Efficiency Operation away from BEP is not the only reason for reduced efficiency in pumps. Significant impact on pump system efficiency. Wear of internal components; through erosion, cavitation, corrosion, etc. Opportunities to save energy by replacing or repairing system components cannot be overlooked. FW Energy Program VA AWWA Energy Webinar 20 April 11 43

44 Monroe County Water Authority Discovered many pumps 20% below OEM specifications. One pump had an OEM rated efficiency of 88% and after 6 years of service it dropped to 77.8%. Mechanical refurbishments plus sand blasting and coating increased the pump efficiency at BEP to 88.5% The annual savings was equal to $17,000 a year at $0.085/kwh. The causes of reduces efficiency were mechanical wear and tuberculation on wetted internal surfaces. FW Energy Program VA AWWA Energy Webinar 20 April 11 44

45 Morin and P&E Energy Upgrades Summer to 74 degrees which surprisingly created only a handful of complaints. Outdoor pole lights changing to LED. Upgraded the 100 watt sodium bulbs and fixtures to 15 watt LED fixtures - under the canopy and in a few wall lights. Replaced most of the 24 hour emergency lights in the Morin Building with LED tubes and reduced the number of bulbs in the stairway by half. Replaced most of the decorative lights Bulbs with 3 watt LED bulbs maintain aesthetics. FW Energy Program VA AWWA Energy Webinar 20 April 11 45

46 5. Develop a procurement strategy for energy Renegotiated the Natural Gas contract with Pepco Energy Services. Fairfax Water will save annually $121,000 starting December 1, VEPGA s fuel rate charge saved Fairfax Water over $2,000,000 dollars at Corbalis and Griffith annually starting July 1, Moved six electric accounts to a new rate structures that saved an estimated $100,000 annually to Fairfax Water. Analysis of Foxmill s bill found that Dominion had a high contract demand. New Foxmill demand contract will produce an estimated savings of $12,000 annually by reducing the contract demand from 3200kw to 1700kw. FW Energy Program VA AWWA Energy Webinar 20 April 11 46

47 Example of factors outside energy Manager s Control FW Energy Program VA AWWA Energy Webinar 20 April 11 47

48 VEPGA Updates 2009/2010 Fuel Rate Summary Jan 1/09-6/30/ cents per kwh July 1/09-10/31/ cents per kwh Nov 1/09-12/31/ cents per kwh Jan 1/10-6/30/10 - July 1/10-6/30/ cents per kwh cents per kwh FW Energy Program VA AWWA Energy Webinar 20 April 11 48

49 First 6 months $1,335,500 Fairfax Water Fuel Charge Total Costs 2 nd 6 months $1,889,210 Increase of $553,710 July-Dec % Jan-June % FW Energy Program VA AWWA Energy Webinar 20 April 11 49

50 6. Develop energy efficiency design and maintenance standards. Developed Energy Guidelines for Fairfax Water with the FW Energy Committee. Trust Engineer Tour Found unoccupied space at 75F to 80F. Need for Energy Guidelines. Unoccupied Buildings 55F Winter and 85F summer. Pump Rooms 55F Winter and 95F Summer. New energy-saving fixtures, lamps and ballasts will be used to replace existing less efficient types, whenever economically feasible and appropriate. Exterior lighting will be LED when feasible. FW Energy Program VA AWWA Energy Webinar 20 April 11 50

51 Total Dynamic Head in Feet Example Pump Curve with throttling compared to same pump with reduced speed operation Operating Point KEY Dark Blue shows baseline pump curve head v flow; Flow in GPM Pink shows effect of throttling discharge Valve at different flows. Yellow Shows pump curve at a reduced speed. Lt Blue Cv*Q^2 curve. Pump Affinity Characteristic FW Energy Program VA AWWA Energy Webinar 20 April 11 51

52 Future improvements = sustainable energy savings. Add ability for operators to see $/mg, kwh/mg, and kw demand for each pump to scada system. Show operators key energy efficiency indicators in control room. Allow operators to pick and choose most efficient and lowest cost consuming pumps to run real time. Allow operators to operate clearwell with less water during off peak times (less risk) of year to increase energy savings. Special Merit Award for Energy Savings Ideas and Results FW Energy Program VA AWWA Energy Webinar 20 April 11 52

53 Any questions? FW Energy Program VA AWWA Energy Webinar 20 April 11 53