Transcript Energy Audit Best Practices 3rd Annual E Source Major Accounts Training Conference and Summit May 9-11, 2007 Boston, Massachusetts Kelly Kissock Ph.D.

Energy Audit Best Practices
3rd Annual E Source Major Accounts
Training Conference and Summit
May 9-11, 2007
Boston, Massachusetts
Kelly Kissock Ph.D. P.E.
Associate Professor
Department of Mechanical Engineering, University of Dayton, Dayton, Ohio
Principal: Go Sustainable Energy
GO
Sustainable
Energy
Energy Assessment Experience
•
Director: University of Dayton Industrial Assessment Center
– 25 no-cost assessments per year for mid-sized industries
– Clients report saving average of $100,000 per year
•
Director: University of Dayton Building Energy Center
– Energy assessments and analysis for residential, commercial, and institutional
buildings
•
Principal: Go Sustainable Energy
– Energy assessments for commercial, industrial, institutional facilities:
– Clients include Ford, Corning, Johns Manville, Cargill, Scotts, Delphi …
•
U.S. D.O.E. Certified Qualified Specialist and Energy Expert
– Compressed air
– Process heating
•
•
Trained
energy
consulting
firms,
utilities,
government agencies in US and abroad.
Awards:
– 2003 U.S. D.O.E Center of Excellence Award
– 2006 Ohio Governors Award for Energy Excellence
industries
and
Purposes of an Energy Audit
• Provide specific advice on current
savings opportunities
• Educate client to help manage energy
costs over long term
• Foster healthy and productive long-term
relationship
Organizing an Audit
1) Preparation
2) Site visit
3) Analysis and reporting
4) Follow up
Preparation: Define Expectations
• Goal to identify and quantify energy
saving opportunities - not final design
• Work together
• Confidentiality
Preparation: Data Request
• Balance value of data versus client time and perceptions
• Typical pre-assessment data:
– Two years of billing data
– Production/sales/occupancy data
– Major energy-using equipment and control systems
– Facility layout/plan
Preparation
• Summarize rate schedule and disaggregate costs
• Calculate avoided cost
• Verify billing amounts
• Graph and analyze trends and relationships
• Identify potential savings opportunities
• Define roles within assessment team
Site Visit
1) Briefing and billing analysis
2) Facility walk-through
3) On-site data collection
4) Debriefing
Initial Briefing: Teamwork
• Include upper management
• Two stories to promote teamwork
– Client’s advantage: you know this facility
– Auditor’s advantage: seen lots of facilities
– Auditor’s job: identify and quantify savings
opportunities
– Client’s job: determine if ideas work within multiple
constraints
• Most productive if work together
Initial Briefing: Utility Analysis
Structure
• Explain rate structure as it relates to client
• Show client how to use rate structure to their
advantage
• Show client how to use billing analysis to
understand their processes and facilities
Purpose
• Develop credibility
• Lead client into discussion of processes and facilities
Explain Rate Structure
As It Relates to Client
Service:
$95 /month
Energy:
$0.00824 /kWh (base)
$0.012 /kWh (approximate fuel adjustment)
$0.00013 /kWh (PIP)
$0.0204 /kWh
Demand:
$13.86 /kW-month
Greatest energy use during any 30 minute period
Greatest of:
100% of on-peak (weekdays: 8 am to 8 pm)
75% of off-peak (all other times)
75% of max in last 11 months
Power Factor: $0.30 /kVAr-month
PF charge = {$0.3 x Tan[ArcCos(PF)]} / kW saved
Disaggregate Costs
Power
Factor
1.0%
Service
0.4%
Energy
33.4%
Demand
65.2%
• Demand/Energy = 50/50
– Typical
• Demand/Energy = 60/40
– One shift operation
– High demand cost
• Demand/Energy = 40/60
– Three shift operation
– High energy cost
Determine Cost of Avoided Energy
• Avoided cost electricity
– Energy:
$0.023 /kWh
– Demand:
$11.23 /kW
– Average:
$0.071 /kWh
• Avoided cost of natural gas
– Winter:
$10.43 /mmBtu
– Summer:
$8.43 /mmBtu
– Annual:
$9.33 /mmBtu
Verify Billing Amounts
Avg Daily
Actual
Billed
Consumption
Power Load
Date
Days
Consumption Demand
Amount
(kWh/period)
Factor Factor
(kWh/day)
(kW)
($/period)
11/20/01 32
1,743,914
54,497
6,731 93%
0.34 $110,757
12/20/01 30
1,526,951
50,898
6,610 93%
0.32 $103,913
1/21/02
32
1,404,734
43,898
6,699 93%
0.27 $102,091
2/20/02
30
1,515,385
50,513
4,131 88%
0.51
$95,426
3/20/02
28
1,325,472
47,338
3,945 87%
0.50
$90,469
4/19/02
30
1,334,098
44,470
3,734 88%
0.50
$90,694
5/20/02
31
1,241,993
40,064
3,548 87%
0.47
$88,291
6/20/02
31
1,335,909
43,094
3,758 86%
0.48
$90,741
7/19/02
29
1,197,403
41,290
3,596 85%
0.48
$87,128
8/20/02
32
1,357,669
42,427
3,467 88%
0.51
$84,359
9/20/02
31
1,248,546
40,276
3,256 86%
0.52
$81,513
10/21/02 31
1,260,806
40,671
3,321 86%
0.51
$81,833
Tot/Avg
367
16,492,880
44,953
4,400 88%
0.43 $1,107,214
Unit Cost
($/kWh)
$0.064
$0.068
$0.073
$0.063
$0.068
$0.068
$0.071
$0.068
$0.073
$0.062
$0.065
$0.065
$0.067
Calculated
Amount
($/period)
$110,758
$103,914
$102,093
$95,427
$90,470
$90,695
$88,293
$90,742
$87,130
$84,361
$81,514
$81,834
$1,107,215
Billing Analysis:
Every Picture Tells a Story…
5,000
4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
500
0
100,000
80,000
60,000
40,000
20,000
0
Demand (kW)
Consumption (kWh /day)
Deamand (kVA)
120,000
1/
31
2/ /0 2
28
3/ /0 2
31
4/ /0 2
30
5/ /0 2
31
6/ /0 2
30
7/ /0 2
31
8/ /0 2
31
9/ /0 2
3
10 0/0
/3 2
11 1/ 0
/3 2
12 0/ 0
/3 2
1/
02
Consumption (kWh/day)
Tell Demand and Energy Story
5,000
4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
500
0
100,000
80,000
60,000
40,000
20,000
0
Deamand (kVA)
120,000
1/
31
2/ /0 2
28
3/ /0 2
31
4/ /0 2
30
5/ /0 2
31
6/ /0 2
30
7/ /0 2
31
8/ /0 2
31
9/ /0 2
3
10 0/0
/3 2
11 1/ 0
/3 2
12 0/ 0
/3 2
1/
02
Consumption (kWh/day)
Quick Electrical Demand Breakdown
Demand (kW)
•
•
•
•
Consumption (kWh /day)
Draw line through winter demand
Below line is “production”, above is “air conditioning”
Ex: Summer = 4,700 kW, Winter = 3,900 kW AC = 800 kW
SEER 10 = 1.2 kW/ton; 800 kW = 670 tons AC
5,000
4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
500
0
100,000
80,000
60,000
40,000
20,000
0
Deamand (kVA)
120,000
1/
31
2/ /0 2
28
3/ /0 2
31
4/ /0 2
30
5/ /0 2
31
6/ /0 2
30
7/ /0 2
31
8/ /0 2
31
9/ /0 2
3
10 0/0
/3 2
11 1/ 0
/3 2
12 0/ 0
/3 2
1/
02
Consumption (kWh/day)
Quick Electricity Use Breakdown
Demand (kW)
•
•
•
•
Consumption (kWh /day)
Draw line through winter energy use
Below line is “production”, above is “air conditioning”
Ex: Winter = 78,000 kWh/day Average = 83,000 kWh/day
Frac Prod = 78,000 / 83,000 = 94%
Frac AC = 6%
Quick Natural Gas Use Breakdown
Consumption (Mcf/day)
700
600
500
400
300
200
100
1/
31
/0
2
2/
28
/0
2
3/
31
/0
2
4/
30
/0
2
5/
31
/0
2
6/
30
/0
2
7/
31
/0
2
8/
31
/0
2
9/
30
/0
2
10
/3
1/
02
11
/3
0/
02
12
/3
1/
02
0
•
•
•
•
Draw line through summer energy use
Below line is “production”, above is “space heating”
Ex: Summer = 310 Mcf/dy
Average = 430 Mcf/dy
Frac Prod = 310 / 430 = 72%
Frac Space Heat = 28%
Energy Breakdowns By Equipment
Equipment
AC #1
Lights
…
Other
Rated Power
50 hp
10 kW
…
Frac Loaded
90%
100%
…
Oper Hours
(hr/yr)
5,000
6,000
…
Utility Bill Total =
Equipment
Boiler 1
Make Up #1
…
Other
Rated Input
(Btu/hr)
1,000,000
500,000
…
Frac Loaded
70%
100%
…
Utility Bill Total =
Oper Hours
(hr/yr)
5,000
2,000
…
Elec Use
(kWh/yr)
187,500
60,000
…
10,000
257,500
Gas Use
(MBtu/yr)
3,500
1,000
…
500
5,000
Other
16%
Compressors
10%
Dynos
8%
CompTech/
Shaffer
21%
Air
Conditioning
1%
CompAir
Machining
Equipment
13%
Fans
4%
Gas Fired Make-up
Air Unit
10%
Space Heaters
(supplied by
boilers)
59%
Lighting
27%
Error due to
change in outdoor
temp.
4%
Parts Washer
9%
Powder Washer
9%
Paint Dryer
9%
Use Energy Breakdowns To…
• Target areas for investigation
– Savings potential is related to load/use
• Screen savings opportunities
– Estimate annual savings
– Imp cost = simple payback x savings
Graph Energy vs Temperature
R2 = 0.92
CV-RMSE = 7.5%
Graph Energy vs Production
R2 = 0.32
CV-RMSE = 9.2%
Use Graphs To Identify:
Departure From Expected Shape
Economizer
malfunctioning!
R2 = 0.70
CV-RMSE = 7.8%
Use Graphs to Identify:
Non-Production Related Energy Use
Equipment Left On!
R2 = 0.01
CV-RMSE = 22.5%
Use Graphs to Identify:
Control Opportunities
Observation
Heating Energy Varies
by 3X at Same Temp!
Discovery
Didn’t close shipping
doors!
R2 = 0.59
CV-RMSE = 67.6%
Or to Identify Well Controlled Facility…
R2 = 0.99
CV-RMSE = 1.1%
Other Savings Opportunities
• Primary/secondary service
– Secondary < 1,000 kVA < Primary
• Power factor correction
– Capacitors cost about $30 /kVAR
• Demand reduction potential
– Demand potential if 2+ shifts per day
with unbalanced demand
Facility Walk Through
• Generate list of possible savings opportunities
– See everything but focus on energy
– Safety
– Stay on task
• Consolidate ideas and plan next steps
– Prioritize savings opportunities
– Pursue all opportunities you believe in
– Write equations for quantifying savings to
guide data collection effort
On-site Data Collection
• Safety
• Make measurements and observations to
quantify opportunities
• Photographs
• Talk to as many levels of personnel as
possible
Debriefing
• Include upper management
• Describe savings opportunities
• Answer questions
• Sell ideas and education throughout site visit
Analysis and Reporting
• Purposes and Format
• Documentation
• Delivery
Final Report: Purposes and Format
• Purposes
– Document current energy using practices
– Identify and quantify saving opportunities
• Format - should support purposes
1) Executive summary
2) Savings summary table
3) Current energy use practices
4) Savings calculations
5) Implementation
Final Report: Savings Opportunities
• Energy savings opportunities
– Calculate savings (most important)
– Implementation cost (ask for client’s help)
• Consider how to handle synergistic effects
Final Report: Writing Style
• Use first person to identify what you did
• Write completely and concisely
– Every number and calculation documented
– No word removed without losing information
• Test
– Client able to read, understand, agree/disagree,
and modify
Final Report: Delivery
• How?
– Deliver report and ask for feedback
– Present report
– Revise report
– Final report
• When?
– As soon as possible
– Helps client
– Reduces errors and omissions
Follow-up
• Initial phone call to answer questions
• Implementation results
– Determine which recommendations
implemented
– Assess overall satisfaction with service
• Savings measurement and continued support
Summary
• Preparation: sets stage for everything that follows
– Set expectations
– Credibility
– Build on your strengths: rate structures and billing analysis
• Site visit
– Create “team” philosophy
– Manage time effectively so you “bring home the bacon”
– Communicate and sell ideas throughout assessment
• Analysis and reporting
– Broad and thorough
• Follow up
– Learn from feedback
Thank you!
questions to
Kelly Kissock
[email protected]
937-229-2852
Site Visit
•
•
Initial briefing
–
–
–
Include upper management
Agree on agenda and deliverables
Roles:
• Your advantage: you know this facility
• My advantage: seen lots of facilities
• Most productive if work together
–
• My role is identify and quantify possible savings opportunities
• Their role is determine if it can work within multiple constraints, much more difficult
Discuss utility analysis
–
–
–
Generate list of possible savings opportunities
Safety
Stay on task
–
–
–
Identify all savings opportunities
Prioritize savings opportunities
Write equations for quantifying savings to guide data collection effort
–
–
Make measurements and observations to quantify opportunities
Talk to as many levels of personnel as possible
–
–
Describe savings opportunities
Sell ideas and education throughout site visit
Facility walk-through
•
Break
•
On-site data collection
•
Debriefing with upper management
Final Report
•
Purposes
•
Format
•
Energy savings opportunities
•
Write completely and concisely
•
Deliver report as soon as possible
– Document current energy using practices
– Identify and quantify energy saving opportunities
–
–
–
–
Executive summary
Savings summary
Energy use practices
Detailed calculations
–
–
–
–
Calculate savings
Estimate implementation cost (ask for help)
Calculate simple payback
Consider synergistic effects
–
–
–
–
Completely, every number and calculation documented
Use first person to identify what you did
Should be able to read each analysis and say yes I agree or no because of this.
Concisely, no word could be removed without changing meaning
Outdoor Air Temperature Data
http://www.engr.udayton.edu/weather