Energy Saving Opportunities Utilities and Facilities

Transcription

1 Energy Saving Opportunities Utilities and Facilities

2 Energy Saving Opportunities Where is the energy going??

3 Opportunities Energy Bills Analysis Energy Performance Indicators Energy Bills Analysis Energy Performance Indicators Compressed air system Cooling system Heating Ventilation and Air Conditioning (HVAC) Lighting New Projects

4 Energy Saving Questions - Do we need to use energy? - Can we use a cheaper form? - What are its minimum operating conditions? - Are we operating it to this operating conditions? - Then and only then - Are we distributing it efficiently? - Are we generating it efficiently?

5 Energy Bills Analysis Management of bills MIC adjustment Power Factor Correction Penalties on bills

6 Energy Bills Analysis All major suppliers have an on line system for Bills Analysis Consumption Analysis Comparison of Costs / Consumption Very useful to study trends in consumption Weekends Holiday Periods Non production periods

7 Energy Bills Analysis Annualised Gas Utilisation 40,000,000 35,000,000 Energy (kwh) 30,000,000 25,000,000 20,000,000 15,000,000 10,000,000 5,000,000 0 Apr-01 Apr-02 Apr-03 Apr-04 Date Apr-05 Apr-06

8 Energy Performance Indicators Site Energy Usage (kwh/kg) Significant Energy users Individual line performance (kwh/kg) Refrigeration (COP) Compressed air (kwh/m3) Boiler efficiency (%) etc

9 Energy Performance Indicators (6 sigma) Electricity Main Incomer EPI Analysis Electricity Load [kw] MIC 1,900 UCL - EPI 1,700 LCL - EPI 1,500 1,300 1, Nov-03 Jun-04 Dec-04 Jul-05 Date [-] Feb-06 Aug-06

10 Compressed Air

11 Compressed Air Compressor Cost over a ten-year life 2% 7% Installation Maintenance Capital Cost Energy Cost 18% 73%

12 Compressed Air 90% of energy consumed by a compressor is rejected as low grade heat. A 40 C drop in intake temperature can increase compressor efficiency by 1%. A compressor running unloaded utilises 30% of the full load power (VSD option) A 25mb intake pressure drop due to clogged filters reduces efficiency by 2%.

13 Compressed Air

14 Compressed Air Energy saving opportunities include: End use requirements (alternatives) Raising awareness (C.A. not free) Leak report and repair program Implement maintenance program Compressor drive and system control measures Recover waste heat for space heating Install no loss moisture drain traps

15 Cooling Systems

16 Cooling Systems End use energy requirements Is there an alternative What is the max cooling temperature 10C rise in temp 3% reduction in energy use Reduce the compressor discharge pressure Isolate users when not required Minimise pumping (2 way V/V systems)

17 HVAC Systems

18 HVAC Systems Typical AHU Opportunity

19 HVAC Systems End use energy requirements Use Natural ventilation where possible Minimise Air Change Rates Check for simultaneous Heating and Cooling Dampers Excessive duct leakage Enthalpy control Turn it off!!

20 Lighting Systems

21 Lighting Systems The energy consumption associated with lighting can be a significant part of the annual energy bill. Opportunities: Installing electronic ballasts Upgrading to Compact Fluorescents T5 V T8 Automatic switching (PIR s Photo Cells etc.) Energy Efficient Lighting LED s One size doesn t fit all

22 Lighting Systems No cost improvements can be very effective: Cleaning skylights and luminaries Check light levels against tasks in that area Label switches and motivate staff to save energy by switching off when not in use. (Security cleaners etc)

23 New Projects

24 New Projects Carry Out a Design Review of new projects Ask The following: Do we need to use energy? Can we use a cheaper form? What are its minimum operating conditions? Are we operating it to this operating conditions? Then and only then Are we distributing it efficiently? Are we generating it efficiently?

25 New Projects Minimise Clean Room area Locate machine melt-feed barrel, heaters and rams external to cleanroom Consequents: Maximised use of space Significant reduction in HVAC system Heating and cooling system reductions Reduced cleanroom heating load Ease of maintenance (Gowning requirements)

26 New Projects Challenge all energy requirements Compressed air Pressure Heating Hot water Temperature Cooling system circulating Temperature Cooling system generation plant selection Cooling tower V Chiller system Lighting Requirements Task Lighting Access Lighting

27 Energy Saving Projects Don t accept: Its Like that in the existing plant Its always been like that We tried that 10 years ago but. I don t think that we would be doing it this way without a good reason!!!!!

28 Questions????????