Michael R. Muller USA Rutgers University, Center for Advanced Energy Systems

1. Michael R. Muller USA Rutgers University, Center for Advanced Energy Systems Software Tools and Information Resources U.S.- Brazil Industrial Energy Efficiency Workshop Rio de Janeiro , Brazil August, 2011

2. Information • Lois Horowitz, author of “Knowing Where to Look: The Ultimate Guide to Research” “Not having the information you need when you need it leaves you wanting. Not knowing where to look for that information leaves you powerless. In a society where information is king, none of us can afford that.”

3. Energy Software Tools Where to Obtain Software Tools and Information • PURCHASE commercial tools • Not our focus today • FIND free publicly available tools • There are plenty and more every day • DEVELOP tools – great for local knowledge

4. Categories • Developing an energy management plan • Identifying good projects • Initial Ideas • Quantifying Energy/Cost Savings • Implementation Cost Estimating • Administrative Hurdles • Permitting and other paperwork • Knowing rebates and tax incentives • Design/Build • ensuring value • ensuring performance Today’s Focus

5. Energy Management

6. Energy Management - EPA • EnergyStar • Well known brand • Spreadsheet based • Not quantitative

7. Energy Management Standards • Several new standards have recently appeared • Recognizing that many good projects don’t get done • An energy management plan can increase activity • Talked about elsewhere at this workshop The Management System for Energy  (ANSI/MSE 2000-2008)

8. Energy Management - USDOE • New focus from USDOE –Supported the development of ISO 50001 • USDOE is moving one step beyond ISO 50001 by supporting the development of Superior Energy Performance (SEP) certification…and Global Superior Energy Performance (GSEP) • USDOE is developing an energy management tool suite to support ISO 50001 and SEP activities by industry. • USDOE has existing technical tools for identifying energy savings opportunities in energy-intensive systems.

9. Overall Energy Management Toolkit Structure Under Development Currently Available 3

10. Energy Management Toolkit • Will consist of: • Corporate, Facility and Project analysis tools (also source of metrics) • Full and Lite versions of Self-Paced Module (LEADER Company, non-LEADER Company) • System area tools, calculators and scorecards (simple, expert) • User will be able to access resources: • Systematically, self-paced • Individually (go straight to tools they want to use) • Site index will be provided • Example- User will be able to access simple calculators individually via the system area pages or view and all at once via the site index • Example- User will able to access all analysis tools via the self-paced process or individually via the site index • Example- Recommendations Portfolio, Project Prioritization Tool, and Project Tracker Tool will be available as part of the facility-plant-corporate analysis tools and also as the “Implementation Portfolio” 4

11. Beyond Planning • First steps are to understand the energy use by the plant • It is surprising how many plants don’t have a good picture • Great tool from DOE – a “plant energy profiler” Old Management Adage: You can’t control what you don’t measure

12. Quick Plant Energy ProfilerQuickPEP • Web-based plant energy profiling • and evaluation tool • The profile includes: • Plant energy and resources usage and costs • Production types and levels • Maintenance procedures • Identifies potential energy saving opportunities for further investigation • More detailed analyses can be conducted with the system tools • Future upgrades to include multiple languages

13. QuickPEP Tool Website

14. Plant Energy Profiler (QuickPEP 2.0) Energy-Carbon Footprint and Energy Baseline Calculators

15. QuickPEP Tool Results Establish Baselines SSST/SSAT 3E+ NXEAT PHAST Identify Energy Savings Opportunities By System PSAT FSAT CHP Tool AirMaster+ MotorMaster+ Help/References CWSAT QuickPEP Tool

16. Specialized Case • OUTPUTS • Overall picture of energy use and efficiency • End-use breakout • Potential areas for energy efficiency improvement • Overall energy use reduction potential • INPUTS • Description • Utility bill data • System information • IT • Cooling • Power • On-site gen Data Center Profiler (DC Pro)

17. Generating Ideas

18. IAC Program • Provides two easy tools iac.rutgers.edu/database

19. Top Ten Lists

20. ARC Manual is an “Idea List”

21. DOE ITPSoftware Tools • The DOE provides an extensive set of industrial assessment software tools • These tools are both high quality and fully supported • The latest versions are always available online • Primary Tool Categories • Plant-wide • Steam • Process Heating • Motor-Driven • Data Centers

22. Energy Use and Potential Energy Savings Process Heating/ Steam Systems Typical Energy Consumption Rates 60 – 80% Electric MotorSystems Pumping Systems 8-15% CompressedAir Systems 7-15% Other* 2-7% < 2% * Other ancillary energy usages such as lighting represent less than 2% of energy consumption 10% to 30% 5% to 10% 10% to 20% 10% to 20% 5% to 10% Potential Energy Saving Opportunities

23. DOE ITPSoftware Tools DOE ITP Software Tools and Resources can be found at http://www.eere.energy.gov/industry/

24. DOE ITPSoftware Tools Notes Developed and supported by energy assessment experts Designed to meet the specific needs of an industrial energy assessment Used to identify energy savings opportunities across the United States Well documented with manuals and case studies DOE provides training in tool use Continually developed and improved Free to the public Available in English and Metric Units, and different currencies

25. DOE ITPSoftware Tools Plant-wide • Industrial Facilities Tool Suite • Quick Plant Energy Profiler/Integrated Tool Suite (QuickPEP) Process Heating • Combined Heat and Power (CHP) Application Tool • NOx and Energy Assessment Tool (NxEAT) • Process Heating and Survey Assessment Tool (PHAST) Data Centers • DC Pro Software Tool Suite Steam • Steam System Scoping Tool (SSST) • Steam System Assessment Tool (SSAT) • 3E Plus Motor-Driven • AirMaster+ • Fan System Assessment Tool • MotorMaster+ • MotorMaster+ International • Chilled Water System Analysis Tool (CWSAT) • Pumping System Assessment Tool (PSAT)

26. Quick PEP Helps plants assess plant-wide operation to identify savings and efficiency opportunities. PHAST Helps assess energy use in furnaces and identifies ways to improve performance. SSAT Assists in assessing potential benefits for specific steam-system improvements. CHP Application Tool Enables users to evaluate the feasibility of CHP for heating systems. 3EPlus Insulation Tool Calculates most economical thickness of insulation for various operating conditions. NxEAT Assesses NOx emissions and applications of energy efficiency improvements at petroleum refiningand chemical plants. DOE ITPSoftware Tools • Motor Master+ International Aids in energy-efficient motor selection and management. • PSAT Assesses efficiency of pumping system operations and quantifies benefits of system optimization. • Air Master+ & LogTool Provides comprehensive information on assessing compressed air systems. • FSAT Assesses efficiency of fan system operations and quantifies benefits of system optimization. • CWSAT Determines chilled water system energy requirements and evaluates energy and costs savings opportunities.

27. DOE ITP Software Tools • Time does not permit us to give details about all the tools • Look at 2 • Steam • MotorMaster+ • Compressed air and process heating are discussed in other presentations

28. Steam System Tool Suite • Steam Tools are bundled into the Steam System Tool Suite (SSTS) • These tools include: • Steam System Scoping Tool • Steam System Assessment Tool • 3E Plus – An insulation energy savings calculator

29. Steam System Scoping Tool • Quickly evaluates overall qualityof steam system operation • Consists of 26 qualitative questions based on all major components of a steam system • The questions are separated into these primary areas: • Steam System Profile • Steam System Operating Practices • Boiler Plant Operating Practices • Steam Distribution, End Use, Recovery Practices • The score is out 340 points and also given as a %

30. Sample Page Steam System Scoping Tool

31. Steam System Assessment Tool • Steam System Assessment Tool • Steam system modeling software • Common energy recovery projects can be added into an alternate model • This allows “what if” evaluations based on the addition or removal of various projects • Steam system model requires the balancing of: • Mass • Energy • Economic • based on fuel and water costs

32. Major Equipment Simulated: Boiler Back pressure turbines Condensing turbine Deaerator Steam traps, leaks, insulation losses Letdowns Flash vessels Feedwater preheat exchangers Choice of 1, 2, or 3 header pressure models Schematics of model steam systems Estimates of site environmental emissions Steam System Assessment Tool

33. Steam System Assessment Tool • Modifications can be simulated on an alternate model generated from the original • Savingsestimates can be determined for individual and combinations of the various energy projects • The “Results Summary” page details the cost and energy usage of both the original and alternate models

34. 3E Plus: Insulation Energy Savings Calculator • Provides simple tabulated information for heat loss (or gain) and surface temperatures • Provides simple tabulated information for energy costs and savings • Can provide an Economic Insulation Thickness for a particular application

35. Motor-Driven Equipment Tools Pumping System Assessment Tool (PSAT) AirMaster+ & LogTool (Compressed Air Systems) Fan System Assessment Tool (FSAT) Motor System Management Tool (MotorMaster+) Chilled Water System Assessment Tool (CWSAT)

36. MotorMaster+ International Assists in the development of a decision based motor management plan. MotorMaster+ International has multi-language capability (with the current release supporting Spanish, French and English)

37. Includes Important Motor Data • The current version of the software contains manufacturer’s databases for over 25,000 NEMA motors and over 7,200 IEC motors. • Full- and part-load efficiency values • Technical data to help optimize drive systems, (power factor, full-load speed, etc.) • Motor purchasing information, including list prices and motor weights

38. New Motor Selection • Analysis includes selection of the “best available” motor for a given application giving: • energy savings, • demand reductions, • dollar savings, • GHG emission reductions, • simple payback, • cash flows, • ROI

39. Repair or Replace? • Motors don’t live forever • Since motors are involved in the process, the fastest way to get them back into service is rewinding • This reduces efficiency! • MotorMaster+ helps plants decide which motors can tolerate rewinding or which need to be replaced • Plants should then stock backup motors for critical systems

40. A Necessary Caution • Software tool results are only as good as the tool and the data input. • Tools should be used in support of engineering analysis, not as a replacement. • Using a software tool without understanding how it works (using a “Black Box” recommendation”) increases risk • Misuse and user-error are always possible • Common sense and “sniff” tests of results are needed

41. Um Novo Dia!!!

42. Contact Information Michael R Muller Center for Advanced Energy Systems (CAES) Rutgers, The State University Of New Jersey 73 Brett Road Piscataway, NJ 08854 United States of America phone: 732.445.5540 fax: 732.445.0730