Energy Efficiency Programs August 23, 2010

1. Presentation to 406 Class Energy Efficiency Programs August 23, 2010 Presented by: John Rees, PE, CEM Eric Soderberg, PE, CEM Dr. Herb Eckerlin, PE Kevin Martin, MBA

2. Energy Program Technical Staff Stephen D. Terry, PhD, PE Extension Assistant Professor Phone: 919.515.1878 E-mail: sdterry@ncsu.edu Herbert M. Eckerlin, PhD, PE Professor, Director Phone: 919.515.5227 E-mail: eckerlin@eos.ncsu.edu Eric W. Soderberg, PE, CEM Energy Extension Specialist Phone: 919.795.1114 E-mail: eric_soderberg@ncsu.edu Kevin Martin, MBA Strategic Energy Manager Phone: 919.515.0903 Cell: 919.996.9978 E-mail: kevin_martin@ncsu.edu John D. Rees, PE, CEM Energy Extension Specialist Phone: 919.515.9436 E-mail: john_rees@ncsu.edu Energy_Group@ncsu.edu

3. Presentation Outline • MAE Energy Programs • Assessment Process • Energy Systems Analyzed • Survey Procedures and Results • Comments and Questions

4. Two Energy Efficiency Programs Energy Management Program (EMP) Industrial Assessment Center (IAC)

5. Industrial Assessment Center (IAC) • Funded Federally by US Department of Energy (DOE) • Serving Manufacturers • Energy bills typically from $100k to $3 million • Will serve larger as well • Service Territory • North Carolina • Southern Virginia • Northern South Carolina

6. Energy Management Program (EMP) • Funded by NC State Appropriation • Reports to NC Energy Office • Businesses Served • Manufacturers • Commercial • Governmental • Institutional • No size restrictions • Service Territory • State of North Carolina

7. Energy Program Objectives • Save Energy • Reduce Waste • Improve Productivity • Train next generation of “Energy Engineers”

9. Assessment Process

10. Assessment Process ; Preliminary Information & Consultation • Onsite Preliminary Energy Diagnostic Survey (PEDS) • Identification of areas for Potential Savings Targeted System Survey • Survey of Existing Equipment • Measurement & Data Gathering • Interview O&M personnel • Identification of opportunities • Savings and Cost Analysis Report • Client Review of Report

11. Assessment Process ; • Data Analysis & Reporting • ROI, simple payback, life cycle costing • Cost to benefit analysis, NPV, IRR • Full report delivered • Implementation Follow-up & Additional Assistance • Follow-up calls and assistance • Continued assistance as needed

12. Purpose of a Preliminary Energy Diagnostics Survey The purpose of a Preliminary Energy Diagnostics Survey (PEDS) is to evaluate plant operations from an energy perspective, to identify and prioritize energy saving opportunities, and to recommend targeted energy surveys for equipment that offer the greatest potential for energy savings.

13. Systems targeted during a Preliminary Energy Diagnostics Survey • Boilers • Lighting • Compressed Air • HVAC Systems • Chillers and Cooling Towers • Motors & Pumps • Preventative Maintenance • Steam Systems & Steam Traps • Process energy systems

14. Typical Information gathered in a Preliminary Energy Study Air Compressors and Air Dryers There are 3 air compressors. There is one common air dryer. Compressors: Manufacturer: Ingersoll-Rand Model: SSRXFE200-25 Serial: FF1274U97151 Type: Rotary screw Horsepower: 200 hp Rating: 1,100 cfm Operation: 116 – 125 psig

15. Typical Information gathered in a Preliminary Energy Study Chillers There is one water cooled chiller: • Manufacturer: Carrier • Model: 30HXC106R--661KA • Serial: 2307Q07525 • Service: Cooling water for molds • Operation: Setpoint is 48° F

16. Electrical Use and Cost for an Industrial Facility – Data collected for a Preliminary Energy Study

17. Water & Sewer Use and Cost for an Industrial Facility Data collected for a Preliminary Energy Study

18. Water & Sewer Use and Cost for an Industrial Facility

19. Typical Recommendations from a Preliminary Energy Study Summary of Recommendations: The NCSU Energy Management Program (EMP) recommends the following: • Compressed Air Study • Convert T12 task lighting to T8. Explore the possibility of replacing the 8 ft. T12 fixtures with single fixtures containing two 4 ft. T8 lamps. • Consider a Chiller and Cooling Tower Study. • Consider a Motor Study

20. Lighting Surveys

21. Typical Existing Lighting – T12 Fluorescent

22. Typical Lighting in an Industrial Facility – 400 Watt Metal Halide

23. Information Collected during a Lighting Survey Fixture quantities by type Fixture Wattage Lighting level in Footcandles Maintenance issues Electrical Rates

24. Savings and Cost Summary from a Lighting Report Table 1. Savings and Payback for Recommendations 1 & 2 Table 2. Savings and Payback with Utility Incentives

25. Compressed Air Surveys

26. Industrial Air Compressors

27. Industrial Air Compressors

28. Industrial Air Compressors

29. Typical Savings from a Compressed Air Survey

30. Load Monitoring and Recommendations from a Compressed Air Study

31. Boiler Surveys Flue Gas Analysis • O2, CO, CO2 • Stack Efficiency Operating/Maintenance Issues • Dirty Heat Exchange surfaces • Scanner failure • Temperature control

32. Hot Water Boilers in a School

33. Industrial Low Pressure Steam Boilers

34. Boiler Survey Form

36. Data Collected during a Boiler Survey

37. Typical Results of a Boiler Test

38. Typical Recommendations from a Boiler Report • At your next boiler tuneup, discuss the relatively high excess air level on Boiler No. 2 at low fire to determine if the air/fuel ratio can be leaner at low fire. • Boiler No. 1 currently operates more efficiently at low fire than Boiler No. 2 (this may be corrected after burner tune-ups have been performed). Consequently, Boiler No. 1 should be operated when low fire operation is required. • Tune boilers to operate most efficiently at the firing level where they operate most frequently. • Install stack thermometers in the stack to monitor flue gas temeperature. • Use portable flue gas analyzer to measure O2 in flue gas every 6 months (at typical operating loads). • Install gas meters on the individual boilers and track individual boiler fuel usage on a monthly basis. • Consider reducing steam pressure. Lower pressure in 5 psi increments and allow boiler to operate at the reduced level for several days to determine if the system operates acceptably. • Consider installing economizers to heat boiler feedwater.

39. HVAC, Chiller, and Cooling Tower Surveys • Systems Encountered: • Small Commercial • Large Commercial • Small Industrial • Large Industrial

40. Small Commercial HVAC Air Handler

41. Small Commercial HVAC Air Distribution

42. Small Commercial HVAC Heating Source

43. Small Commercial HVAC DX (Direct Expansion Cooling) Units

44. Large Commercial – AHUs at a Community College

45. Air Handling Units at a Community College

46. Air Cooled Chiller at a Community College

47. Previously shown Air Cooled Chiller viewed from Above

48. Large Commercial Air Cooled Chillersfor Office at an Industrial Site

49. Industrial Air Handling System

50. Industrial Water Cooled Chiller