ENERGY MANAGEMENT PLAN - HEADQUARTERS ABC Winery 123 1st Street Franklin, NJ 12345
TABLE OF CONTENTS Executive Summary 3 Background and Site Information 3 Summary 3 Energy Conservation Opportunities 4 Detailed Analysis 5 Conclusions 5 Recommendations for future improvements 6 Allocation of Electrical Use 8 APPENDIX A ABC WINERY SPACE SUMMARY 9 APPENDIX B LIGHTING SUMMARY TABLE 10 APPENDIX C EQUIPMENT SUMMARY TABLE 11 APPENDIX D ABC WINERY AERIAL VIEW 12 APPENDIX E RESOURCES AND REFERENCES 13 LIST OF TABLES Table 1: Summary of Estimated Annual Energy Savings from Efficiency Improvements... 4 Table 2: Energy Savings of Recommendations... 4 Table 3: Measures with Payback Longer than Ten Years... 5 Table 4: Electrical Consumption (2013-14)... 7 Table 5: Gas Consumption (2012-2014)... 7 LIST OF FIGURES Figure 1: Electricity costs (2013) 8 Figure 2: Monthly Electricity Use 8-2 -
ENERGY MANAGEMENT PLAN - HEADQUARTERS ABC Winery Executive Summary ABC Winery is a farming operation that grows grapes and produces wine. The wine production process uses a significant amount of energy, mainly electricity for cooling. Energy is also used for heating and cooling to maintain appropriate temperatures for wine production and in the office and other spaces. The farm grows grapes on approximately 40 acres, and produces 28 different wines with a total production of about 20,000 gallons. Background and Site Information The headquarters operations at ABC Winery are housed in a single building of approximately 4,800 square feet. The building includes a winery which houses processing and storage equipment, an office, a laboratory space and an area for sales which includes rest rooms, storage and additional office space. ABC Winery has been incorporating energy savings in their operations over the last few years, in particular installing more efficient lighting and motors. The producer hopes to reduce energy consumption even further by adding insulation and improving the performance of cooling equipment. By implementing these measures the winery hopes to achieve significant energy savings and improve the wine making process. Summary Energy costs for ABC Winery are more or less evenly divided between propane and electricity. Propane is used primarily for heating; hot water heating is a secondary, much smaller use. The main use of electricity is for cooling. In addition to space cooling for the office, laboratory and tasting areas, a chiller is used to maintain temperatures in the wine vats and the winery. Other electrical uses include mechanical equipment (pumps, motors and processing equipment), lighting, refrigeration and office equipment. The building has uninsulated concrete block walls and wooden roof trusses. In the mezzanine the walls have a framed inner wall with 3-1/2 inch insulation covered with gypsum wallboard. The ceiling has R-19 insulation between the joists. The bar and office have an insulated inner wall of similar construction, and have R-30 insulation between the ceiling joists. The lab and winery have no additional wall insulation and have R-30 insulation in the ceiling. The winery operates year round. Most of the spaces are occupied 7 days a week, at least 8 hours a day. Grapes are harvested in late summer and fall, when they are crushed and pressed. The winery is kept cool during the summer months, and the wine vats are chilled at various times to control the fermentation process Summary Page - 3 -
Recommended Measure Electric Savings (kwh) Propane Savings (Gal) Energy Conservation Opportunities Energy Savings (mbtu) Installed Cost Energy Cost Savings Payback (years) CO 2 N 2 O Estimated 1 3,403 11.6 $650 $851 0.8 2.55 0.03 0.03 9.60 0.02 2 197 0.7 $200 $70 2.9 0.15 0.00 0.00 0.56 0.00 3 5,137 17.5 $3,700 $1,284 2.9 3.85 0.04 0.04 14.49 0.04 4 548 1.9 $500 $137 3.7 0.41 0.00 0.00 1.55 0.00 5 2,069 626 57.1 $14,800 $2,958 5.0 10.04 0.58 0.14 5.90 8.72 6 404 1.4 $800 $101 7.9 0.30 0.00 0.00 1.14 0.00 Totals 11,758 626 90.2 $20,650 $5,380 3.8 17.31 0.66 0.22 33.22 8.78 Table 1: Summary of Estimated Annual Energy Savings from Efficiency Improvements CH 4 SO 2 NO x Recommended Measures: 1. Replace incandescent bulbs in Tasting Room with LED bulbs. 2. Replace T-12 fluorescent fixtures in Lab with T-8 fixtures. 3. Insulate all chilled water pipe. 4. Replace T-12 fluorescent fixtures in Winery with T-8 fixtures. 5. Insulate Winery walls with 4 thick Styrofoam panels. 6. Replace the refrigerator in the front office with an Energy Star rated refrigerator. Fuel Current Usage MBTU Usage Savings Mbtu Savings % Savings Electricity (kwh) 39,582 135 11,758 40.1 29.7% Propane (gal) 1,135 91 626 50.1 55.1% Totals: 226 137 60.9% Table 2: Energy Savings of Recommendations - 4 -
Detailed Analysis Table 1 shows an annual summary of electrical data for ABC Winery. Table 2 is a two-year summary of propane use. Figure 1 shows the annual distribution of electrical use for two years. Figure 2 displays the estimated breakdown of electrical use by application. Electrical use varies during the year, depending to some extent on the weather and also on the various energy needs for processing the grapes and maintaining appropriate conditions in the wine vats. The facility operates year round, seven days a week. Part of the electrical use is attributable to lighting, refrigeration and office equipment, which remains relatively constant from day to day. Propane use varies mostly according to the amount of energy needed for space heating. Hot water, the other use for propane, is a very small portion of the total gas consumed. The most promising energy conservation opportunity is in insulating the exterior walls in the winery. These currently consist of uninsulated concrete blocks. Adding 4 inch thick expanded polystyrene foam panels will increase the R-Value from around 3 to more than 20. There are several opportunities for energy saving in lighting. Because the facility operates 7 days a week, lights are on for many hours a year. Taken together with an electric rate that often exceeds 25 cents a kilowatt hour, payback periods for replacing less efficient lighting are quite short. It is costeffective to replacing incandescent bulbs and T-12 fluorescent fixtures in those areas where they are usually turned on. Illuminated exit signs are on all the time. Replacing signs with incandescent bulbs with new signs with LED lights will typically have less than a 5 year payback period. Conclusions Recommendations for future improvements Install 4 inch thick expanded polystyrene panels inside the wall in the winery. Insulate chilled water piping. Replace incandescent light bulbs with LED bulbs. Replace existing T-12 fluorescent pendant fixtures with T-8 fixtures. Replace aging refrigerators with Energy Star appliances. Other measures evaluated and recommended Measure Electric Savings (kwh) Propane Savings (Gal) Energy Savings (mbtu) Installed Cost Energy Cost Savings Payback (years) CO 2 N 2O Estimated CH 4 SO 2 NO x 7 52 4.2 $2500 $204 12.3 0.71 0.05 0.01 0.01 0.68 8 4,807 16.4 $20,000 $1,202 16.6 3.60 0.04 0.04 13.56 0.03 Table 3: Measures with Payback Longer than Ten Years 7. Replace the hot water heater with a 90% efficient unit. 8. Upgrade the existing chiller system to include a new chiller, new pumps and better controls. Replacing refrigerators and the hot water heater has a relatively long payback period. Consider new energy efficient units when this equipment requires major maintenance or no longer functions properly. - 5 -
Insulating the winery will reduce energy needs for both heating and cooling and will also improve the climate control in the facility. More efficient lighting will reduce the amount of electricity needed for the lights and will also lower the air conditioning needs in the warm months. Despite the relatively long payback period, there are compelling reasons to replace the existing chiller and associated equipment. The existing glycol pump currently runs continuously, independent of the need to provide cooling to specific spaces or equipment. The existing chiller is an older, inefficient unit. A new chiller system can provide the following benefits: Multiple stages to better match loads and provide redundancy and Energy savings through improved glycol pump control Higher operating efficiency Controls to prevent short-cycling In addition to saving energy, a more efficient chiller with more precise control will give ABC Winery better conditions for their fermentation processes and allow them to improve their products. - 6 -
Summary of Energy Use Patterns and Electrical Utilization End Start Days HDD CDD Total $/kwh 6/28/2013 5/29/2013 30 1 211 $568.41 21.41 7/30/2013 6/28/2013 32-463 $1,084.25 22.64 8/29/2013 7/30/2013 30 2 193 $1,019.84 23.04 9/27/2013 8/29/2013 29 87 135 $1,811.27 34.25 10/29/2013 9/27/2013 32 234 41 $911.67 25.57 11/27/2013 10/29/2013 29 555 - $464.46 23.41 12/30/2013 11/27/2013 33 866 - $752.34 28.91 1/30/2014 12/30/2013 31 1,019 - $648.79 22.96 2/26/2014 1/30/2014 27 1,080 - $1,072.76 24.70 3/27/2014 2/26/2014 29 902 - $706.86 24.92 4/28/2014 3/27/2014 32 449 3 $518.22 25.23 5/27/2014 4/28/2014 29 166 24 $387.85 17.54 TOTALS: 363 5,361 1,070 $ 9,946.72 25.13 Table 4: Electrical Consumption (2013-14) Date $ Gal. Therms $/Gal. $/MMBTU 3/8/2012 $389 104 95 3.740 40.88 4/5/2012 $201 54 49 3.722 40.68 10/18/2012 $527 141 129 3.738 40.85 11/15/2012 $799 213 195 3.751 41.00 12/28/2012 $410 109 100 3.761 41.11 1/10/2013 $351 94 86 3.734 40.81 2/25/2013 $787 210 192 3.748 40.96 5/28/2013 $294 79 72 3.722 40.67 11/4/2013 $143 36 33 3.972 43.41 12/4/2013 $1,120 280 256 4.000 43.72 1/14/2014 $1,472 368 337 4.000 43.72 2/12/2014 $1,390 316 289 4.399 48.07 3/12/2014 $1,135 246 225 4.614 50.42 4/30/2014 $713 178 163 4.006 43.78 Average: $9,731 2428 3.922 42.86 Table 5: Gas Consumption (2012-2014) - 7 -
Allocation of Electrical Use 7% Estimated Electric Use by Application 15% 17% 38% Air Conditioning Equipment Chiller Lights Other 22% Figure 1: Electricity costs (2013) 7,000 Electrical Use by Month (2012-2014) (kw-hours) 2013/14 2012/13 6,000 5,000 4,000 3,000 2,000 1,000 Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Figure 2: Monthly Electricity Use - 8 -
APPENDIX A ABC WINERY SPACE SUMMARY # Room Space Function Type Gross Floor Area Weekly Operating Hours Weeks/ Year # Occupants # PCs Principal Lighting Type Hot Water (Y/N?) Principal HVAC Type % of Spaces Heated Tstat ( o F) % of Spaces Cooled A Tasting Rm 56 52 3 Mixed A-1 Mezzanine Sales 555 2 0 CFL N Central 100% 100% A-2 Bar Sales 765 3 2 Incandescent Y Central 100% 100% A-3 Bathroom Employee 48 0 2 CFL Y Central 100% 100% A-4 Closet Storage 20 A-4 Office Office 79 0 1 Incandescent N Central 100% 100% B Office/Lab 84 52 0 0 Fluorescent 100% B-1 Lab Processing 780 0 0 Fluorescent Y Central 100% 100% B-2 Office Office 570 3 4 Fluorescent N Central 100% 100% C Winery Processing 2,000 168 52 2 1 Fluorescent Y Central 100% 50% Total 4,817 10 13-9 -
APPENDIX B LIGHTING SUMMARY TABLE Hrs. CFL/LED Incandescent Other Linear Fluorescent Space Area Watts Qty. kwh Total Watts Qty. kwh Total Watts Qty. kwh Total Type Watts # Bulbs Type kwh Total A 1,467 580 1,672 190 A-1 555 7 17 13 565 56 2 286 15 1 131 Exit A-2 765 7 10 10 256 60 17 2,608 15 2 263 Exit 7-60 9 1,381 120 1 88 120 Rope A-3 48 1 13 3 14 25 1 9 25 Fan A-4 20 0 100 1 - - A-5 79 2 30 4 88 - B 780-820 B-1 570 9 105 2 2 T12 1,381 B-2 210 9 50 4 2 T8 1,315 C 2,000 10 15 2 263 Exit 105 5 2 T12 3,835 1,050 E 12 150 3 164 450 450 1 164 450 HID - 4,247 923 580 4,439 2,122 919 595 6,531 1,870-10 -
APPENDIX C EQUIPMENT SUMMARY TABLE Location Equipment Manufacturer Model Motor Manufacturer Model HP kw RPM V A Ph Hz Eff. P.F. Hrs kw/yr $/year C Winery Pump EP-MINOR 2 1.5 773 220 7.4 3 60 100 147 37 C Winery VFD Pump 1.2 0.9 220 4.38 3 60 500 442 111 C Winery Pump M112A4 5.5 4.0 1740 220 15.2 3 60 77% 50 202 51 C Winery Chiller Pump 2 1.5 8,766 12,904 3,243 C Winery Compressor 2475N 7.5 5.5 230/460 3 60 35 193 49 C Winery Crusher EM3615T 5 3.7 1750 208/230 13.9/13.4 60 90% 78% 75 276 69 C Winery Press IT100 3.6 2.6 1700 220 10 3 60 HFV903 1.5 1.1 1420 230 5 3 50 75% 15 56 14 C Winery Steam Generator LG-20 2 1.5 208 5.6 3 60 150 3,146 791 Total: 17,366 4,364 The steam generator is capable of generating 52 pounds of steam per hour from 60 o F water. It includes three 6.5kW heating elements, for a total of 19.5 kw. Cooling Equipment Heat Pump Performance Serves: Type Manufacturer Model Serial BtuH EER SEER HPSF Winery Chiller CAC120HA Tasting Heat Pump CPLE48-1C 411613624 45,000 9 10 7.5 Office Heat Pump CPKE30-1B D008402309 27,000 9 10 7.0-11 -
APPENDIX D ABC WINERY AERIAL VIEW - 12 -
APPENDIX E RESOURCES AND REFERENCES The following resources provide additional information on ways to save energy at your facility. USEFUL PUBLICATIONS 1. Energy Efficiency in Wineries, Industrial Services Fact Sheet, Washington State University - Extension Energy Program. February 2011. INTERNET RESOURCES 1. New Jersey NRCS Environmental Quality Incentives Program http://www.nj.nrcs.usda.gov/programs/eqip/index.html 2. New Jersey NRCS Energy Conservation Series http://www.nrcs.usda.gov/wps/portal/nrcs/detail/nj/technical/?cid=nrcs141p2_018997 3. New Jersey Agricultural Experiment Station Fact Sheets Assessing Farm Equipment Efficiency http://sustainable-farming.rutgers.edu/assessing-farm-equipment-efficiency/ Understanding On-Farm Utility Costs and Billing http://sustainable-farming.rutgers.edu/understanding-farm-utility-costs-billing/ 1. G&D Chillers 2. PermaTherm Insulated Panels PRODUCT INFORMATION (on following pages) - 13 -
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