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Effective Energy Management

Effective Energy Management. Effective Energy Management. Develop baseline Plant energy balance Lean energy analysis (LEA) Take action Identify and quantify energy saving opportunities Prioritize energy saving opportunities Implement energy saving opportunities

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Effective Energy Management

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  1. Effective Energy Management

  2. Effective Energy Management • Develop baseline • Plant energy balance • Lean energy analysis (LEA) • Take action • Identify and quantify energy saving opportunities • Prioritize energy saving opportunities • Implement energy saving opportunities • Measure and benchmark to sustain efforts • Develop metrics for system energy efficiency • Measure energy efficiency improvement with sliding NAC and EI • Compare energy efficiency between facilities with NAC and EI

  3. Energy Use Baseline Plant energy balance Map energy use throughout the plant Statistical analysis (Lean Energy Analysis) Understand drivers of energy use

  4. Estimate Equipment Electricity and Fuel Use • 1) Estimate energy use from: • rated power • frac loaded • operating hours • 2) Calibrate sum against measured total energy use

  5. Electricity And Fuel Energy Balances

  6. Map Energy From Supply to Conversion To Process

  7. Plant Energy Balances • Use plant energy balances to: • Identify biggest energy users • Prioritize action plans • Calibrate savings estimates

  8. Lean Energy Analysis

  9. Statistical ‘Lean Energy Analysis’ • Quantifying relationship between: • Energy • Production • Weather by developing simple statistical models • Deriving actionable information from models

  10. Source Data

  11. Actual Temperature Data http://www.engr.udayton.edu/weather

  12. Time Trends: Electricity and Outdoor Temperature

  13. Time Trends: Electricity and Production

  14. Electricity vs Toa: 3PC R2 = 0.67 CV-RMSE = 6.4%

  15. Electricity vs Production: 2P R2 = 0.32 CV-RMSE = 9.2%

  16. Electricity vs Toa: 3PC-MVR R2 = 0.82 CV-RMSE = 5.1%

  17. Elec = Ind + Wea-dep + Prod-dep E (kWh/dy) = 41,589 (kWh/dy) + 361.159 (kWh/dy-F) x [Toa (F) – 30.7093 (F)]+ + 2.4665 (kWh/dy-unit) x P (units) Independent = 41,589 (kWh/dy) Wea-dep = 361.16 (kWh/dy-F) x [Toa (F) – 30.71 (F)]+ Prod-dep = 2.4665 (kWh/dy-unit) x P (units)

  18. Disaggregate Electricity Use Electricity Weather = 10% Production = 39% Independent = 51% Temperature

  19. Time Trends: Fuel Use and Outdoor Temperature

  20. Time Trends: Fuel Use and Production

  21. Fuel Use vs Toa: 3PH R2 = 0.92 CV-RMSE = 7.5%

  22. Fuel Use vs Toa: 3PH-MVR R2 = 0.97 CV-RMSE = 5.1%

  23. Fuel Use = Ind + Wea-dep + Prod-dep Fuel Use (mcf/dy) = 59.58 (mcf/dy) + 9.372 (mcf/dy-F) x [62.06 (F) - Toa (F)]+ + 0.0199 (mcf/dy-unit) x P (units) Independent = 59.58 (mcf/dy) Wea-dep = 9.372 (mcf/dy-F) x [62.06 (F) - Toa (F)]+ Prod-dep = 0.0199 (mcf/dy-unit) x P (units)

  24. Disaggregate Fuel Use Fuel Weather = 28% Production = 58% Independent = 14% Temperature

  25. ‘Lean Energy Analysis’ Called “lean energy” analysis because of its synergy with the principles of “lean manufacturing”. In lean manufacturing, “any activity that does not add value to the product is waste”. Similarly, “any energy that does not add value to a product or the facility is also waste”.

  26. Quantified “Leaness” of Electricity Use Electricity “Independent” is energy not added to product. Perfectly “lean” when Ind = 0 Weather = 10% Production = 39% Independent = 51% Temperature

  27. Quantified “Leaness” of Fuel Use Fuel “Independent” is energy not added to product. Perfectly “lean” when Ind = 0 Weather = 28% Production = 58% Independent = 14% Temperature

  28. How ‘Lean’ is Your Electricity Use?

  29. How ‘Lean’ is Your Fuel Use?

  30. Using ‘Lean Energy Analysis’ To Discover Savings Opportunities LEA Indicators of Savings Opportunities High “Independent” indicates waste Departure from expected shape High scatter indicates poor control

  31. Large Independent Fuel Use Identifies Insulation Opportunities • 50% of fuel use by holding furnaces • Insulate furnaces and switch to coreless furnaces

  32. Departure From Expected Shape Identifies Malfunctioning Economizers Air conditioning electricity use should flatten below 50 F Audit found malfunctioning economizers

  33. High Data ScatterIdentifies Control Opportunities • Observation:heating energy varies by 3x at same temp • Discovery: didn’t close shipping doors

  34. High Heating Slope Identifies Excess Ventilation • Turn off excess exhaust air fans reduces vent by 13,000 cfm • Lowers heating slope, balance temperature, and fuel use

  35. Lean Energy Analysis Quick, accurate disaggregation of energy use: Quantifies non-value added energy Helps identify savings opportunities Provides an accurate baseline for measuring the effectiveness of energy management efforts over time.

  36. Take Action • Identify and quantify saving opportunities • Prioritize saving opportunities • Implement saving opportunities

  37. Identify and Quantify Saving Opportunities • Identifying energy saving opportunities • Use “Integrated Systems + Principles Approach (ISPA) • Quantifying energy savings: may consider • Equipment vendors (compressed air, boiler, etc.) • Energy savings performance contractor (ESPC) • Independent energy audit

  38. Prioritize Saving Opportunities • Multiple filters • Financial return on investment • Rank versus other energy saving opportunities • Rank versus other requests for capital • Risk • Consistent with other priorities • Available and knowledgeable staff to manage project

  39. Implement Savings Opportunities • Management commitment • Maintenance commitment • Operator commitment

  40. Measurement and Benchmarking • Sustaining energy efficiency efforts requires that effectiveness of past efforts be accurately evaluated. • Verify the performance of past energy-efficiency efforts • Inform the selection of future energy-efficiency initiatives • Help develop energy-efficiency targets • Measurement • Use LEA model to measure savings • Benchmarking • Use LEA model to compare facilities benchmarking

  41. Measure Weather-Normalized and Production-Normalized Energy Savings Savings Pre-retrofit Post-retrofit

  42. Track Weather-Normalized and Production-Normalized Energy Use (NAC) Solid Line: NAC Annual Consumption increased 17%. NAC increased 6% Plant energy efficiency decreased 6%. Dashed Line: Actual Consumption

  43. Track Weather-Normalized and Production-Normalized Energy Intensity (NEI) Normalized Energy Intensity decreased 5.4%.

  44. Benchmarking Comparing energy performance across multiple sites Benchmark best/worst NAC and change in NAC Benchmark best/worst coefficients and change in coefficients

  45. The Big Picture: Electricity NAC and DNAC for 14 Facilities DNAC NAC

  46. More Detail: Ei and DEi Best candidates for lighting retrofits DEi Ei

  47. More Detail: Tb and DTb DTB Best candidates for controls retrofits TB

  48. More Detail: CS and DCS Best candidates for HVAC retrofits DCS CS

  49. Effective Energy Management: Summary Develop baseline Plant energy balance (breakdown) Lean energy analysis (drivers) Take action Identify and quantify energy saving opportunities Prioritize and implement energy saving opportunities Implement energy saving opportunities Measure and benchmark to sustain efforts Use LEA models to measure energy efficiency improvement Compare energy efficiency between facilities

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