Impact of Control System Technologies on Industrial Energy Savings

Impact of Control System Technologies on Industrial Energy Savings Priyam Parikh Industrial Assessment Center Texas A&M University Bryan P. Rasmussen Industrial Assessment Center Texas A&M University http://farolconsulting.com/?page_id=110

INDUSTRIAL ENERGY CONSUMPTION Improved process efficiencies have reduced the manufacturing sector s energy consumption by 17% from 2002 to 2010 Image: U.S. Energy Information Administration's (EIA) Manufacturing Energy Consumption Survey (MECS)

INDUSTRIAL ENERGY CONSUMPTION However, there s still a need to look for newer energy saving ideas Fresher Worldwide energy consumption saving ideas can. be realized by focusing on the Control System of the equipment Image: U.S. Energy Information Administration's (EIA) http://www.eia.gov/forecasts/ieo/industrial.cfm

CONTROL SYSTEM STRATEGIES Looking beyond a system, instead focusing on how a system operates System

CONTROL SYSTEM STRATEGIES Looking beyond a system, instead focusing on how a system operates Disturbance Setpoint + - Error Control Algorithm Control Action Actuator System Output Feedback Error = Actual Output Desired Output

CONTROL SYSTEM STRATEGIES The working of each element of the control system can be optimized to reduce energy consumption Disturbance Setpoint + - Error Control Algorithm Control Action Actuator System Output Feedback 1. Adjust setpoint for reduced error 2. Improve algorithm for optimized control action 3. Retrofit actuator to improve efficiency 4. Detect and eliminate faults in the system 5. Coordinate systems

Combustion Systems Thermal Systems Compressed Air System Motor Systems Lighting Systems

CONTROL SYSTEM STRATEGIES Exhaust Air Out Exhaust Air Damper Return Air Fan Air from the Room Return Air Damper Cooling Coil Supply Air Fan ROOM Thermostat TB Outside Air In Outside Air Damper CHILLER Air to the Room

CONTROL SYSTEM STRATEGIES Identify the control elements of the system Exhaust Air Damper Return Air Fan FAULTS?? Return Air Damper Cooling Coil ACTUATORS SETPOINT Supply Air Fan ROOM Thermostat TB Outside Air Damper CHILLER BAS CONTROL ALGORITHM

INDUSTRIAL ASSESSMENT CENTER DATABASE - Over 16,000 assessments and 123,000 recommendations - Energy Saved (MMBTU), Cost, Cost Savings, Implementation Rate, Payback

I. SETPOINT ADJUSTMENT Modify temperature and pressure setpoints to meet requirements while optimizing energy use Thermostatic Temperature Setpoint ROOM TB CHILLER Static Pressure Setpoint Reset

I. SETPOINT ADJUSTMENT Low payback, high savings! 1. HVAC: Seasonal Temperature Resets Average Savings: $10,000 per year Image: http://www.ncelectriccooperatives.com/electricity/homeenergy/thermostats_intro.htm

I. SETPOINT ADJUSTMENT 1. HVAC: Seasonal Temperature Resets Low payback, high savings! Condensor Reduce High Pressure 2. Refrigeration: - Increase cold storage temperature setpoints - Reduce refrigeration pressures setpoints Expansion Valve Compressor Average Savings for increasing temperature: $10,300 per year Average Savings for pressure reduction: $19,600 per year Evaporator Increase temperature setpoint

I. SETPOINT ADJUSTMENT Low payback, high savings! 1. HVAC: Seasonal Temperature Resets 2. Refrigeration: - Increase cold storage temperature setpoints - Reduce refrigeration pressures setpoints 3. Steam System: Reduce steam operating pressure setpoint 4. Compressed Air System: Reduce compressed air system pressure setpoint Average Savings: $7,500 per year Average Savings: $3,900 per year Image: http://www.donahuesteam.com/portals/0/rick.gif

II. IMPROVE CONTROL ALGORITHM Alter control algorithm so that it chooses the least energy consuming control action ROOM TB CHILLER 3 CHILLER 2 CHILLER 1 BAS Choosing the most efficient set of chillers

Normalized Frequency Average Payback (Years) II. IMPROVE CONTROL ALGORITHM High savings, but low implementation rate 0.2 2 1. HVAC: Install Building Management System 0.18 0.16 Not Implemented/Pending Implemented Average Payback 1.8 1.6 0.14 1.4 0.12 1.2 0.1 1 0.08 0.8 0.06 0.6 0.04 0.4 Average Savings: $11,350 per year 0.02 0 1981-1985 1986-1990 1991-1995 1996-2000 2001-2005 2006-2012 0.2 0 Image: http://www.matryxs.com/index-4

II. IMPROVE CONTROL ALGORITHM High savings, but low implementation rate 1. HVAC: Install Building Management System 2. Compressed Air System: Use algorithm to select the most efficient set of equipment (compressors) Average Savings: $11,560 per year Image: http://www.izsystems.com/compressedairautomationdataacquisition%20.aspx

II. IMPROVE CONTROL ALGORITHM Newer technologies enhance the operation of the equipment 1. HVAC: Install Building Management System 2. Compressed Air System: Use algorithm to select the most efficient set of equipment (compressors) 3. Furnaces: Use a Furnace Pressure Controller for improved furnace efficiency. Image: Process Heating Tip, Sheet #6 by Industrial Technologies Program Energy Efficiency and Renewable Energy U.S. Department of Energy

3. ACTUATOR RETROFIT Use a more efficient actuator OR variable output actuator Motor Use variable speed motor Motor ROOM TB Use more efficient chiller CHILLER

Normalized Frequency Average Payback (Years) III. ACTUATOR RETROFIT High implementation cost, high cost savings (>$15,000 a year!) 0.2 3 1. HVAC: Use variable speed fans and pumps 0.18 0.16 Average Payback Not Implemented/Pending Implemented 2.7 2.4 0.14 2.1 Average Savings: $18,100 per year 0.12 0.1 1.8 1.5 0.08 1.2 0.06 0.9 0.04 0.6 0.02 0.3 0 1981-1985 1986-1990 1991-1995 1996-2000 2001-2005 2006-2012 0

III. ACTUATOR RETROFIT 1. HVAC: Use variable speed fans and pumps 2. Steam System: Use automatic stack dampers Average Savings: $3,000 per year Image: Honeywell Electromechanical Vent Damper

III. ACTUATOR RETROFIT 1. HVAC: Use variable speed fans and pumps 2. Steam System: Use automatic stack dampers 2. Lighting System: -Use separate switches for perimeter lighting -Use dimmable ballasts with photosensors Average Savings: $3,100 per year 55 to 79% cost savings Image: http://www.todayshomeowner.com/how-to-fix-a-buzzing-or-humming-dimmer-switch/

IV. FAULT DETECTION Sensors and improved algorithms detect faults that increase the energy consumption of the system DDC DDC DDC Use Direct Digital Controlled Dampers to detect faulty dampers ROOM TB BAS CHILLER

IV. FAULT DETECTION Correcting faults results in high cost savings 1. HVAC: Detect faulty dampers and louvers Average Savings: $20,300 per year http://www.techmall.com/air-duct-boost-fans-and-dampers-s/91.htm http://blog.ecofoil.com/2013/11/21/5-ways-reduce-home-electric-bill/

Normalized Frequency Average Payback (Years) IV. FAULT DETECTION Correcting faults results in high cost savings 1. HVAC: Detect faulty dampers and louvers 2. Steam System: Detect incorrect air fuel valve position 0.4 0.35 0.3 0.25 Not Implemented Implemented Average Payback 0.8 0.6 0.2 0.4 Average Savings: $8,900 per year 0.15 0.1 0.2 0.05 0 1981-1985 1986-1990 1991-1995 1996-2000 2001-2005 2006-2012 0

IV. FAULT DETECTION Fault detection can reduce production downtime 1. HVAC: Detect faulty dampers and louvers 2. Steam System: 3. Motors: Detect incorrect air fuel valve position Detect faulty motors 4. Compressed Air System: Detect faults in the lines http://www.maximintegrated.com/app-notes/index.mvp/id/4697

V. SYSTEM COORDINATION Coordinate different systems working on the same space to optimize overall energy use ROOM TB CHILLER Coordinate working of HVAC and Lighting Systems using occupancy sensor data

SUMMARY Identify the control elements and then use- Sepoint Adjustment Improve Algorithm Actuator Retrofit Fault Detection System Coordination Image: http://pmdstudios.com/idea-center/

Thank you for listening! Questions?