Post on 02-Mar-2020
© 2012 CLEAResult │ All rights reserved.© 2012 CLEAResult │ All rights reserved.
Industrial Facility
© 2012 CLEAResult │ All rights reserved.
Objectives
ECM Matrix Power Factor Correction Water & Wastewater Measurement and Verification
© 2012 CLEAResult │ All rights reserved.
ECM MatrixEnergy Conservation Measures
Ligh
ting
Ligh
ting
Cont
rols
Dayl
ight
Har
vest
ing
HVAC
BAS
Syst
ems
Retr
o-Co
mm
issi
onin
g
AC T
une-
Up
Cool
ing
Tow
er
Proc
ess C
oolin
g Sy
s.
Mot
ors (
High
Effi
cien
cy)
VFD
Mot
ors
Air C
ompr
esso
r Sys
.
Inje
ctio
n M
old
(Hig
h Ef
f.)
Blow
ers V
S. C
ompr
esse
d Ai
r
Roof
ing
Pipi
ng In
sula
tion
Refr
iger
atio
n
Pum
ps
BUILDING TYPESCity/Gov. Bldg. X X X X X X X X X X
Schools X X X X X X X X X X
Colleges/Universities X X X X X X X X X X
Hospitals X X X X X X X X X
Departments Stores X X X X X X X
Small Retail X X X X X X
Big Box Retail X X X X X X X
Grocery/Supermarkets X X X X X X X X X
Office Buildings X X X X X X X X X X
Hotels X X X X X X X X X
Restaurants X X X X
Fast-Food Restaurants X X X
Theatres X X X X X
Convenience Stores X X X X X X
Parking Garages X
© 2012 CLEAResult │ All rights reserved.
ECM Matrix (cont’d)Energy Conservation Measures
Ligh
ting
Ligh
ting
Cont
rols
Dayl
ight
Har
vest
ing
HVAC
BAS
Syst
ems
Retr
o-Co
mm
issi
onin
g
AC T
une-
Up
Cool
ing
Tow
er
Proc
ess C
oolin
g Sy
s.
Mot
ors (
High
Effi
cien
cy)
VFD
Mot
ors
Air C
ompr
esso
r Sys
.
Inje
ctio
n M
old
(Hig
h Ef
f.)
Blow
ers V
S. C
ompr
esse
d Ai
r
Roof
ing
Pipi
ng In
sula
tion
Refr
iger
atio
n
Pum
ps
INDUSTRIALWaste Water Treatment X X X X X X
Warehouses X X X X
Dairy Industry X X X X X
Refrigerated Warehouses X X X X X X
Metal Fab. X X X X X X X X X
Pottery X X X X X X X X X X
Distribution Center X X X X X
Food Distribution Center X X X X X X
Food Mfg X X X X X X X X
Plastic Injection Mfg X X X X X X X X X X X
Blow Mold Mfg X X X X X X X X X X
Bottling Mfg X X X X X X X X X X X
Foundry X X X X X X X X X
Printing X X X X
Corragated Pkging X X X X
Cable Mfg X X X X X X X
Chemical Processing X X X X X X X X
Powder Coating X X X X X X
Funiture Fab. X X X X
© 2012 CLEAResult │ All rights reserved.© 2012 CLEAResult │ All rights reserved.
Power Factor Correction
© 2012 CLEAResult │ All rights reserved.
Draft Beer: $11 per Glass at theNEW Cowboys Stadium
© 2012 CLEAResult │ All rights reserved.
Objectives
What is Power Factor? How to correct Power
Factor? How does Power
Factor effect billing? Issues with correcting
Power Factor? Myths of Power Factor
Correction
© 2012 CLEAResult │ All rights reserved.
What is Power Factor?
kW – Real Power (work, HP)
kVAR – Reactive Power (non-working power
kVA – Apparent Power (what the utility supplies)
kW
kVAr
kVA
kW
kVAr
kVA
kVAkWPF =
© 2012 CLEAResult │ All rights reserved.
How to Correct Power Factor
Add a “Capacitive” load offset the “Inductive” load. You can add capacitors at the motor load or connect to the main switch gear.
© 2012 CLEAResult │ All rights reserved.
How Does Power Factor Effect Billing
ADJ = Increase to applicable Demand Charge,kW = Monthly Billing Demand,PF = Monthly measured Power Factor, andDC = Demand Charge
The billing demand will be the highest of:
DCkWPF
kWADJ ×
−
×=
95.
Large Power Service Rate Customersa) the maximum measured demand (adjusted
for primary voltage if applicable), orb) 65% of the highest measured demand
established during the twelve (12) month period ending with the current month, or
c) 800 kilowatts
General Service Rate Customersa) Applies to customers with peak < 799 kWb) the maximum measured demand (adjusted
for primary voltage if applicable), orc) 65 percent of the highest measured demand
established during the twelve (12) month period ending with the current month, or
© 2012 CLEAResult │ All rights reserved.
Issues with Power Factor Correction
Harmonic Distortion Harmonics are
generated by non-linear load on your electrical distribution.
VFD or VSD are common culprits.
Arc welders, DC rectifiers and soft start motors (on start up only) are also contributors.
Secondary Bus Voltage Waveform during Utility Capacitor Switching
© 2012 CLEAResult │ All rights reserved.
Myth of Power Factor Correction
Power Factor will reduce your energy demand. FACT: Adding kVAr will decrease the amperage
used by the facility, BUT increase the voltage. More kVAr is better. FACT: Over-correcting power factor can damage
voltage sensitive EQ in the facility. The supply voltage will increase by 10% or more.
Recommended: Reduce energy demand first through energy efficiency, before correcting power factor
© 2012 CLEAResult │ All rights reserved.© 2012 CLEAResult │ All rights reserved.
Water & Waste Water Treatment
© 2012 CLEAResult │ All rights reserved.
Why WWTP are Important
Grade “D-” assigned by ASCE
1.5% of total US electrical usage
10 – 20M kWh/yr total usage
Aeration: 40-70% of plant electrical use
Typical electrical savings: 2M kWh/yr
2
Aeration System
© 2012 CLEAResult │ All rights reserved.
Aeration Options
3
Surface
Sub-Surface
√
© 2012 CLEAResult │ All rights reserved.
WWTP Energy Savings
VFD for Aerations Blowers Using UV
Disinfection versus chemical Biogas capturing
and power generation
© 2012 CLEAResult │ All rights reserved.
Injection Molding
Insulating the barrel heater can reduce the amount energy it takes to melt the plastic pellets prior to injecting the plastic into the mold.
VFD controls on cooling tower and chill water pumps
Limit switch controls on grinders and granulators
© 2012 CLEAResult │ All rights reserved.© 2012 CLEAResult │ All rights reserved.
Measurement & Verification
© 2012 CLEAResult │ All rights reserved.
Objectives
Purpose of M&V Two Basic Methods of M&V Whole Facility Retrofit Isolation
General M&V Rules of Thumbs
© 2012 CLEAResult │ All rights reserved.
Purpose of M&V
Increase Energy Savings
Document financial transactions
Support evaluation of efficiency programs
Educate facility users about there energy impacts
© 2012 CLEAResult │ All rights reserved.
Two Basics Methods
Retrofit Isolation Method: Measures the effect of the retrofit, only
Savings are unaffected by changes beyond the measurement boundary
Usually needs a new meter (data loggers) Adjustments can be simple
Whole Facility Method: Measures all effects in the facility
Retrofits AND other changes (intended and unintended) Often uses the utility meter Adjustments can be complex
© 2012 CLEAResult │ All rights reserved.
Retrofit Isolation
Option A - Key Parameter Measurement
Measure only the keyparameters
Make estimates or assumptions that will significantly affect reported savings
Option B - All Parameter Measurement
Measure independent variables that affect energy savings
Decide the metering system Decide on a baseline period
Chiller
Cooling Loads
CoolingTower
Boundary of Measurement
© 2012 CLEAResult │ All rights reserved.
Whole Facility
Option C – Whole Facility Need both baseline and reporting period data Assess performance of the whole facility, retrofitted and
non-retrofitted systems or areas Significant energy savings (10% or more of consumption
measured by utility meter)
Option D – Calibrated Simulations When there is no meter (of facility) in the baseline Baseline data can be ‘manufactured’ under controlled
circumstances. Most expensive method and complicated
© 2012 CLEAResult │ All rights reserved.
M&V Rules of Thumb
Adhere with International Performance Measurement and Verification Protocol (IPMVP)
Define an M&V Plan M&V reports of Savings should be presented as
defined in the M&V Plan The cost to M&V should be less than 10% of the
annual savings Weigh the cost benefits of M&V accuracy vs.
M&V cost
© 2012 CLEAResult │ All rights reserved.
QUESTIONS?
Presentations Available at www.elpasoelectric.comwww.epesaver.com