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Improved Techniques for Saving Energy, Cutting Costs and Simplifying Work

Improved Techniques for Saving Energy, Cutting Costs and Simplifying Work. ISA Norcal TECH 2005 California Maritime Academy May 4-5, 2005 Charlie Middleton, PG&E Senior Chemical Engineer Tel. (415) 973-4008, CEM6@pge.com Don Amuzie, PG&E Supervising Program Manager

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Improved Techniques for Saving Energy, Cutting Costs and Simplifying Work

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  1. Improved Techniques for Saving Energy, Cutting Costs and Simplifying Work ISA Norcal TECH 2005 California Maritime Academy May 4-5, 2005 Charlie Middleton, PG&E Senior Chemical Engineer Tel. (415) 973-4008, CEM6@pge.com Don Amuzie, PG&E Supervising Program Manager Tel. (415) 973-6208, DEA4@pge.com Rachel Diaz, PG&E Speakers’ Bureau Coordinator Tel. (415) 973-1979, RGDE@pge.com

  2. PG&E Energy Monitoring and Analysis Tools • PG&E InterAct Metering, https://inter-act.pge.com/sap/newuser.asp. • PG&E Business Tools, http://www.pge.com/biz/biztools.html. • Pacific Energy Center Tool Lending Library, http://www.pge.com/003_save_energy/003c_edu_train/pec/toolbox/tll/tll_home.shtml.

  3. PG&E InterAct Metering • For qualifying PG&E electric accounts with interval metering. • Tables and graphs of historical “raw” 15-minute interval kW and kVAr data. • Calculated interval kWh and power factor (p.f.) data. • Trending and forecasting of interval kW, kWh and p.f. data for profiling energy loads and troubleshooting system problems.

  4. PG&E Business Tools • For qualifying PG&E nonresidential electric and natural gas accounts. • Tables of historical “billed” monthly electric peak, part-peak & off-peak period kW demand and kWh consumption data. • Tables of historical “billed” monthly gas consumption data.

  5. Pacific Energy CenterTool Lending Library • Measurement tools and test instruments for monitoring and analyzing energy loads; troubleshooting system and equipment problems; and developing and monitoring energy efficiency, demand response and self-generation projects.

  6. PG&E Energy Audits • Business Energy Survey Tool audits of smaller businesses by PG&E account teams. • Integrated Energy Audits of larger businesses with complex equipment or special needs: PG&E engineering consultants assess the no & low-cost and investment opportunities in energy efficiency, demand response and self-generation.

  7. PG&E Energy Efficiency Rebates and Incentives • Express Efficiency rebates for qualifying electric/gas efficiency retrofits in smaller businesses. • Peak 500 Plus rebates and Standard Performance Contract incentives for qualifying electric/gas efficiency retrofits in larger businesses. • Savings by Design incentives for qualifying efficient new-construction. • Multifamily property rebates for qualifying electric/gas efficiency retrofits.

  8. Other PG&E Energy Efficiency Initiatives • Community Energy Efficiency Partnerships and 3rd Party Programs. • Pacific Energy Center in San Francisco, Energy Training Center in Stockton, and Food Service Technology Center in San Ramon. • Codes and Standards, Emerging Technologies and Building Operator Certification Programs. • Energy StarPromotions.

  9. Energy Efficiency, Water Conservation and Environmental Public-Private Partnerships • Association of Bay Area Governments Green Business Programs. • StopWaste.org in Alameda County. • Targeted Opportunities to Prevent Pollution in San Joaquin County. • Dept. of Energy Industrial Assessment Centers in San Francisco State University and Loyola-Marymount Engineering Schools.

  10. Energy Efficiency and Best Technology Opportunities • Consider the customer’s ideas and any safety, vandalism and theft issues. • Turn off any extra equipment at all times. • Perform any scheduled or deferred maintenance, repairs and tuning. • Check the design and performance of the equipment and controls.

  11. Energy Efficiency and Best Technology Opportunities (cont.) • Upgrade or replace any worn, broken, obsolete, incorrectly sized or otherwise inefficient equipment. • Optimize the equipment staging, sequencing, schedules, pressures, temperatures, flowrates and setpoints. • Re commission the facility.

  12. Energy Efficiency and Best Technology Opportunities (cont.) • Optimize the lighting levels, fixtures and controls. • Upgrade or replace any inefficient interior & exterior lights such as incandescent, halogen and mercury vapor lights (and T12/other fluorescent lights with magnetic ballasts) with efficient models. • Install Energy Star compact fluorescent lamps (CFLs) and T5/T8 fluorescent lights with electronic ballasts.

  13. Energy Efficiency and Best Technology Opportunities (cont.) • Install efficient high-intensity discharge (HID) lights such as high-pressure sodium (HPS) lights and pulse-start, metal halide (MH) lights. • Install photocells, timers, dimmers, occupancy sensors and bi-level lighting. • Sweep off the main lights at night and whenever the building is not occupied. • Consider daylighting, light surfaces, shades and overhangs.

  14. Energy Efficiency and Best Technology Opportunities (cont.) • Optimize the refrigeration and building HVAC, shell, fenestration, and cold & hot water equipment including compressors, chillers, packaged HVAC units, air conditioners, economizers, furnaces, cooling towers, evaporative condensers, evaporators, boilers, water heaters, heat exchangers, coolers, freezers, pumps, fans, motors, tanks, piping, ducting, insulation, and instrumentation & controls.

  15. Energy Efficiency and Best Technology Opportunities (cont.) • Insulate or re-insulate the walls, ceiling, cold and hot tanks, piping and ducting. • Install window film. • Replace any inefficient single-pane windows with efficient double-pane windows. • Install premium-efficiency motors. • Install super-efficient, rare-earth, permanent magnet motors.

  16. Energy Efficiency and Best Technology Opportunities (cont.) • Cool the compatible areas or equipment with outside air or cooling tower water when feasible. • Increase the capacity of the economizers, cooling towers and evaporative condensers. • Upgrade the cooling tower fill. • Install side-stream filters on the cooling towers and evaporative condensers.

  17. Energy Efficiency and Best Technology Opportunities (cont.) • Float the head pressure in the refrigeration system. • Upgrade the chemical treatment system. • Optimize the compressed and blown air, pumping, process heating and cooling, pneumatic, hydraulic, vacuum, mixing, aeration, laboratory, warehouse, data center and other facility equipment.

  18. Energy Efficiency and Best Technology Opportunities (cont.) • Identify and repair any compressed air leaks. Minimize the system operating pressure by removing any bottlenecks, staging and sequencing the compressors, and increasing the air storage capacity. Install a new main or secondary air compressor with an adjustable speed drive.

  19. Energy Efficiency and Best Technology Opportunities (cont.) • Install adjustable speed drives on the compatible compressors, pumps and other motorized equipment. • Test the boilers with a stack gas analyzer from the Pacific Energy Center. • Install boiler and water heater controllers to minimize the equipment operating time and optimize the hot water temperature at all times.

  20. Energy Efficiency and Best Technology Opportunities (cont.) • Recover more steam condensate. • Install a waste heat recovery system to preheat the boiler make-up or feed water or the sanitary water. • Upgrade the boilers with efficient low-NOx burners, oxygen trim, selective catalytic reduction, combustion air and flue gas recirculation, and instrumentation & controls.

  21. Energy Efficiency and Best Technology Opportunities (cont.) • Install super-efficient condensing boilers and water heaters. • Optimize the water purification, conservation, recycling and treatment equipment. • Optimize the waste minimization, recycling and treatment equipment. • Replace any inefficient aerators with efficient fine-bubble or brush aerators.

  22. Energy Efficiency and Best Technology Opportunities (cont.) • Optimize the conveyors, loaders, unloaders, packagers, forklifts & battery chargers and other materials handling equipment. • Optimize the office, conference room, break room, business center, library, gym, hallway, stairway, lavatory, laundry, garage, parking lot, yard and other common area equipment.

  23. Energy Efficiency and Best Technology Opportunities (cont.) • Enable the Energy Starsleep mode on the portable computers, printers, FAX machines and other office equipment. • Install Energy Starrefrigerators, clotheswashers, dishwashers and other high-efficiency appliances. • Install Energy Starroof products.

  24. Energy Efficiency Example 1. Install a Dairy Vacuum Pump with an Adjustable Speed Drive. • The new, efficient, dairy vacuum pump has a 25 hp premium-efficiency motor with an adjustable speed drive (ASD). The ASD optimizes the motor speed and vacuum pressure in the milk lines. The new pumping system operates at about 9 kW during the daily milking period (midnight to 10:00 PM) and about 22 kW during sanitization (10:00 PM to midnight).

  25. Energy Efficiency Example 1 (cont.) Install a Dairy Vacuum Pump with an Adjustable Speed Drive. • The old, inefficient, dairy vacuum pump had a 30 hp, standard-efficiency, fixed-speed motor. An inefficient vent valve in the suction header controlled the vacuum pressure in the milk lines. The old pumping system operated continuously at about 26 kW.

  26. Energy Efficiency Example 1 (cont.) Install a Dairy Vacuum Pump with an Adjustable Speed Drive.

  27. Energy Efficiency Example 2. Install LED Traffic Lights and Walk Signs at Five Major Intersections. • The new, efficient, LED traffic lights and “countdown” walk signs at the five major intersections use about ten percent as much electricity as the old, inefficient, incandescent traffic lights and neon walk signs. • Refer to details on Page 32.

  28. Energy Efficiency Example 2 (cont.) Install LED Traffic Lights and Walk Signs at Five Major Intersections.

  29. Energy Efficiency Example 2 (cont.) Install LED Traffic Lights and Walk Signs at Five Major Intersections.

  30. Details for Energy Efficiency Example 2: Install LED Traffic Lights and Walk Signs at Five Major Intersections. (C. Middleton, PG&E) Assume 100,000 kWh/yr savings for this energy efficiency project. Assume a load-following, natural gas power plant on the Northern California electric grid, with a 10,681 Btu/kWh incremental heat rate, per Schedule G-COG – Gas Transportation Service for Cogeneration Facilities, http://www.pge.com/tariffs/pdf/G-COG.pdf. Assume natural gas is pure methane, CH4 = 16 lb/mole. CH4 combustion with air: CH4 + 2O2 = CO2 + 2H2O Assume air has 21% Oxygen, O2 = 32 lb/mole; and 79% Nitrogen, N2 = 28 lb/mole Carbon Dioxide, CO2 = 44 lb/mole; Water, H2O = 18 lb/mole Assume 30 ppmv NOx @ 3% O2 in power plant stack gas. For CH4 combustion with air, assume 0.30 Moles Excess O2 per Mole Natural Gas = 3%*(1+(2*79%/21%))/(1-(3%*(1+79%/21%))) For CH4 combustion with air, assume 8.82 Moles Stack Gas per Mole Natural Gas = 1+(2*79%/21%) + 0.30 Moles Excess O2 per Mole Natural Gas Assume 95% electric transmission & distribution (T&D) system efficiency. Assume 75% heat rejection to power plant cooling tower. Assume 80% H2O evaporation in power plant cooling tower. Estimated Reduction in Natural Gas Consumption in Power Plant = 11,000 therms/yr = (100,000 kWh/yr Savings for Energy Efficiency Project)/(95% T&D System Efficiency)*(10,681 Btu/kWh Incremental Heat Rate) /(100,000 Btu/therm Natural Gas) Estimated Reduction in Cooling Tower Water Consumption in Power Plant = 89,000 gallons/yr = (100,000 kWh/yr Savings for Energy Efficiency Project)*(10,681 Btu/kWh Incremental Heat Rate - 3,412 Btu/kWh Net Power Output) /(95% T&D System Efficiency)*(75% Heat Rejection to Cooling Tower)/(80% H2O Evaporation in Cooling Tower) *(970 Btu/lb H2O Heat of Evaporation)/(8.34 lb/gallon H2O) Estimated Reduction in CO2 Emissions in Power Plant = 62 tons/yr = (100,000 kWh/yr Savings for Energy Efficiency Project)*(10,681 Btu/kWh Heat Rate)/(95% T&D System Efficiency) /(1,030 Btu/scf Natural Gas)/(0.73 scf/mole-deg. R)/(530 deg. R)*(mole CO2/mole Natural Gas)*(44 lb/mole CO2)/(2,000 lb/ton) Estimated Reduction in Oxides-of-Nitrogen (NOx) Emissions in Power Plant = 22 lb/yr = (100,000 kWh/yr Savings for Energy Efficiency Project)*(10,681 Btu/kWh Heat Rate)/(95% T&D System Efficiency) /(1,030 Btu/scf Natural Gas)/(0.73 scf/mole-deg. R)/(530 deg. R)*(8.82 mole Stack Gas/mole Natural Gas)*(30 ppmv NOx @ 3% O2 ) *(mole NO/mole NOx)*(30 lb/mole NO)

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