Basic Industrial and Commercial Electrical Energy Audit Training for Utility Personnel Draft

1. Basic Industrial and Commercial Electrical Energy Audit Training for Utility Personnel Draft Robert Scott Frazier, Ph.D., CEM. Assistant Professor, Renewable Energy Extension Engineer Biosystems & Agricultural Engineering Oklahoma State University (405) 612-3641

2. What We Will Cover Today • Utility Background Data • QuickPEP® Software • Motors • Lighting • Compressed Air • HVAC • Process Heat

3. What You Should Come Away With Ability to produce general recommendations for the facility Ability to generate a nice cover report with graphics for the customer regarding energy use Ability to spot some of the more common energy areas for opportunity

4. ENERGY AUDIT WORKSHOP Before we begin … There are two ways to look at a facility's energy conservation (savings) potential: (1) A general view – without much effort – how much might we save and in what general areas? (2) A detailed view – with more effort – at what specific points in the plant can we place improvement efforts and how much can we expect to gain from these efforts?

5. Eight (Typical) Key Energy Issues in Auditing Facilities • Current situation -- getting a grip. • Process heating and cooling. • Steam and steam delivery. • Compressed air and air delivery. • Building and HVAC. • Lighting. • Electrical motors and systems. • System x system interactions (not specifically discussed, but very important in overall assessment).

6. Eight Key Questions for Commercial and Industrial Systems • What function(s) does this system serve? • How does this system serve its function? • What is the energy consumption of this system? • What are the indications that this system is properly functioning? • If system is not working properly, how can it be restored to proper operation? • How can the energy cost of this system be reduced? • How should this system be maintained? • Who has direct responsibility for maintaining and improving the operation and energy efficiency of this system?

7. What Equipment is Needed for Basic Energy Auditing? • Inexpensive IR Thermometer • Digital Camera • Data Loggers (Onset, etc.) • Steel toe boots/shoes • Side shields for glasses (get your own) • Ear plugs (get your own) • Good notebook and multiple pens • Business cards

8. What Else Should You Know? • What Federal Incentives are there? • What State Incentives? • Visit http://www.dsireusa.org • Stay on top of it – it constantly changes with the whims of Washington and state government

9. Current Situation – Getting a Grip • Facility Background • Personalities • Rate Schedule • Billing Analysis • Energy Profiles – As a whole • Energy Profiles – By systems/processes (if you can)

10. Start a File (Hard and Softcopy) • Everything goes in… • “Google®” company • Photos • Hand notes • Emails (Print if important) • Correspondence • Newspaper articles • Napkins with notes • Anything at all that has to do with this customer

11. Pre-Visit Phone Information I • Primary Contact Name: • Street Address of the plant we will be visiting: • Principal products Produced: • # of Employees: • Annual Sales ($): • Annual Energy Expenses ($): • # of Building we will be looking at: • Plant Area (square feet): • Production/yr (lbs, pcs…../yr): • Number of Shifts per day per week (and hours): • Primary Energy Users: Boilers ….How Many, approx capacity (MMBtu, lbs steam, etc.)…Fuel type Chillers….How Many, approx capacity………Size Furnaces…How Many Air Compressors…..How Many……What HP? • Type Of HVAC in Plant/Offices: • Type of Lighting in “ “ : • Other Energy Users of Interest (Blow Molders, etc.) ……..Energy Size (kW, Btu, etc.): • Other: (Things you would like us to look at) Do we need to bring safety Equipment? Don’t show up in open toe shoes or 3-piece suit. Leave jewelry at home.

12. Pre-Visit Phone Information II You may need to get copies of originals bills.  You are the utility so you may have this in-house… • Energy bills (gas also possibly) for the past 12 consecutive months. • Water and sewer bills for the past 12 consecutive months. • Simple plant layout (8.5x11) (if they have it) • Process flow chart (if they have one) • List of primary energy consumers (e.g. motor list with horse powers's, etc. if they have it) ** Part of this is to show the client – this is stuff they should have and be aware of!

13. Personalities • Who is your main contact? • How important are they? • Are they threatened by this visit? • Plant manager knows the plant… • CEO can make sure projects get implemented… • Closing meeting – who is responsible for any possible recommendations? • Implementation and progress calls (let’em know you will be calling)

14. Rate Schedule • You are the utility person • If you know nothing else, you should be able to explain their rate schedule and bills • Make sure you know if they are on a “special” internal schedule • If it’s a big customer, ask (internally) if there is anything special you should know about these folks • Ask engineering if there is something unusual about their service or metering before you go out to the plant (look like the company speaks as one)

15. Billing Analysis • One of our most important tools. • Get data for all meters at general location. • Assemble data into spreadsheet (next slide). • Break into columns showing: kW, kWh, Fuel charges, taxes, PPCA, etc.

16. Billing Analysis (cont.)

17. Client* Billing Analysis (cont.) What's going on here? *Confidential

18. Client Billing Analysis (cont.)

19. Billing Analysis (cont.)

20. Billing Analysis (cont.) • Know the definitions and relationships of kW and kWh. • Understand what tariff the customer is on and determine if it is the correct one (they will ask). • Understand the “fine print” items on the tariff and how they work (e.g. power factor adjustment, ratchet clauses, etc.)

21. Electrical Energy Management • Electrical energy management is unique due to the nature of electrical power. • Almost impossible to store significant quantities of this energy source (Maybe hydrogen in the near future). • Must have sufficient capacity to meet instantaneous demands (kW). • Odd characteristics such as power factor. • Issues such as power quality.

22. Electrical Demand Control • Partially because demand (kW) is a separate portion of the bill, we can look at specific methods toward reducing this charge (and impact on electrical system). • Try to keep in mind however that demand (kW) and consumption (kWh) are closely related.

23. Electrical Demand • The thing to keep in mind is that demand is a kind of “snap-shot” of the maximum electrical draw – at any particular time of the month from your facility. • Recall also that this snap shot is not really instantaneous but usually averaged over some interval like 15 minutes • That’s good for the customer – shorter intervals are worse. Try to imagine why that is…. • Still, “Demand” is a reflection of how much electrical equipment was on at a particular time in the facility.

24. Electrical Demand & Load Factor • There is a “Load Factor” column in the billing analysis spreadsheet • Load Factor = Total Month’s kWh divided by 720 x measured monthly max demand • If load factor is <<0.30 for a one shift operation or <<0.6 for a three shift operation, there may be demand control opportunities • Load factor indicates how even/uneven the electrical usage is during the billing period (demand peaks), LF=1 is a perfectly consistent load

25. Demand Control (cont.) • Many demand reduction strategies will be aimed at moving some of the load to different times of the day so we don’t get a coincident peak. • Other strategies might include going to different types of equipment. • Lets look at some of these demand control methods.

26. Demand Control (cont.) • Demand Shedding: In simplified form, the facility operator will identify the high electrical draw pieces of equipment that can have their operations rescheduled to other times of the day. • The operator (or software) will be monitoring the facility or sub-area total demand (kW). • At some agreed-upon kW point, the operator, or software, will reschedule the previously identified equipment to avoid a demand peak. • Various automated systems available (web search for “electrical demand control”)

27. Demand Shedding (cont.) • In a simpler scenario, schedules of the equipment, or processes, are adjusted so that the peaks are avoided ahead of time. • The problem is: Get it wrong once during the month and a high demand charge may be set.

28. Demand Shedding (cont.) • Examples of equipment that can be Demand-Shed: • Chillers. • Air handlers. • Large pumps. • Large Grinders. • Recharging Stations (fork trucks, etc.). • Large unnecessarily illuminated areas. • Any large electrical load is a candidate…

29. Demand Control (cont.) • Duty Cycling (different than demand shedding) • Long uninterrupted equipment run times lead to a higher probability that coincident loads will produce a “peak” demand. • Imagine what types of equipment this sounds like (hint – Air Handling Units) • Duty cycling uses a signal (time, temperature or other controlled parameter) for the on/off operation.

30. Demand Control (cont.) • Other demand and energy control methods • Optimum start/stop. • Night setback. • Hot water reset. • Chilled water reset. • Boiler and chiller optimization. • Chiller demand limiting controls. • Free cooling.

31. Power Factor Improvement • This is an area that you (as a utility person) need to be somewhat familiar with. • The reason is that your customers may be billed for Power Factor and you are the utility rep, therefore … • You will still defer most technical problems to engineering but lets be able to “talk-the-talk” a bit

32. Power Factor • Basics: • Induction loads (big electric motors) cause current to lag behind voltage so more kVA is needed to get the same kW. Yet, we are paying for kW. (???) – Bottom line…Power Factor – BAD! • Charge is applied when PF exceeds the minimum level usually around 80 or 90% (95% for you folks!). • Power factor is kW/kVA. See power triangle next page. • Correction is (usually) made by adding capacitor banks

33. Power Factor • Power triangle (kV) x (I) x (√3) kVAR kVA kW Motor load example: (kVA) x (PF) or (HP load) x (.746 kW/HP) x (1/η)

34. Power Factor Example • A plant has 2,000 kW demand and a power factor of 80%. How much capacitance is needed to correct this to 95%? (Why did I use 95%?) ΔkVAR = 2000 (.421) = 842 kVAR ΔkVAR 2500kVA Table Next Page 2000/.8 = 2500 kVA 2000 kW

35. Power Factor Table

36. THE GENERAL VIEW • QuickPEP® • http://www1.eere.energy.gov/industry/quickpep/(wu24wh55es44h1550shxdjby)/default.aspx • Plant Energy Profiler • Quick “Expert System” that gives: • Estimated Breakdown of Energy Use • Estimated Savings Potential • Suggested Areas for Improvement • Graphics in a report type template

37. QuickPEP Screens and Sample Case (“TCC-1”)

39. We will talk about where this data comes from in a bit… Must use blended kWh & kW Cost