BROAD INITIATIVES/SHARP FOCUS - CUTS ELECTRICITY CONSUMPTION 15% VICTOR GIALANELLA SITE FACILITIES MANAGER EXXON CHEMICAL COMPANY LINDEN, NJ ABSTRACT Analysis of electrical consumption can payout in reduced energy costs. Continuous monitoring of electrical usage coupled with improvements and optimization in system(s) operations can have a favorable impact on annual operating expenditures. Further, participation in local utility rebate programs to reduce electrical consumption will enhance funding of energy efficient programs. OVERVIEW In 1994, Exxon Chemical Company's Linden Technology Center (LTC) formed an Energy Reduction Committee whose charge included the assessment and development of various optimization and energy reduction ideas. The Committee recommended implementing two (2) significant capital projects; namely, the installation of energy efficiency lighting and the shutdown during "oft hours" of electrical consumers which had no impact on base client operations. As a result of these efforts, LTC has reduced its total electrical consumption significantly in recent years. In 1996, electrical usage declined 15% relative to 1995 consumption. Taking into account occupancy consolidations, it has been estimated that electrical usage declined 12% due solely to these two (2) thrusts. LTC SITE BACKGROUND The Linden Technology Center (LTC) is a 75 acre, 45-year old complex located in Linden, Union County, New Jersey, approximately 15 miles WSW of New York City. Today, facilities management operates approximately 540k SF of office, laboratory and pilot plant space. This includes one (1) laboratory/office complex, three (3) office buildings, five (5) pilot plant structures, and one (I) engine testing facility, known as MADS. Figure 1 presents a plan view of the site. Historically, LTC was the primary hub of research development for many operating affiliates of Exxon Corporation. In recent years (since 1993), LTC has been in a consolidation mode due to organizational restructuring and changes in research focus. These developments have provided many challenges in facilities management, especially in the area of operating costs where the focus has been to reduce expenditures in order to remain a competitive site. LTC is a relatively "old" facility (most buildings constructed circa 1950-1965). Automated control flexibility is not inherent in the design of the site's utilities infrastructure nor in the design of air systems servicing the various buildings within the complex... LEGEND: ~ :~~~~~:.nnl 1mB ~-:"~c::~u c=i ~:."-AM' :~~~: CJ :':~DC:~. Figure I. Exxon Chemical Company's Linden Technology Center Site Map 15
Further, capacity changes to original operating systems over the last four (4) decades did not optimize system(s) performance; generally, such changes accounted for incremental requirements ~ only. This "approach" has resulted in overcapacity and energy inefficiencies. AIR CIRCULATION - A SIGNIFICANT PORTION OF LTC'S ELECTRICAL DEMAND Circulating air to the various buildings within the LTC complex utilizes electricity, and this process demands a significant portion of LTC's annual electrical consumption. With the exception of one (1) building, LTC's structures deploy a "oncethrough" air system design, requiring, on average, twelve (12) air changes per hour (typical design standards for laboratory and pilot plant areas). To help put the demand to just circulate air into perspective, the following simplification quantifies the electrical load and cost for a "once through" air process servicing a hypothetical building equal to LTC's net operating area. Let's assume LTC's 540k SF operating area were housed as one (1) structure seven (7) feet high, requiring twelve (12) air changes per hour. The air supply system servicing such a structure would equate to an intake fan capacity of -750k cfm. Assuming the building were "in balance", i.e. no significant internal positive or negative pressure, the exhaust system would exfiltrate 750k cfm as well. Based on an average 3" WG static pressure and a 65% fan efficiency, total system driver capacity would equate to approximately 825 kw. Operating such a system 24 hours per day, 365 days per year, at an average unit rate of 7.5 cents/kwh, electrical consumption would total 7.25M kwh and electricity costs would total approximately $550k. This represents -35% of LTC's electrical consumption and annual electrical bill--just to circulate air. LTC'S ANNUAL ELECTRICAL CONSUMPTION - "CUT' VARIOUS WAYS LTC's 1993-1997 electrical cost profile is shown in Figure 2. Electrical consumption for the same period is shown in Figure 3. Historically, electrical ex-penditures represent approximately 15% of LTC's overall "space" operating budget (rent). Figure 4 presents a pie-ehart of how electricity is consumed within the LTC complex. Figure 5 highlights current "on-hours" vs. "off-hours" consumption ("off-hours" takes into account consumption on weekdays between 6 p.m. through 6 a.m., weekends and holidays). Figures 6 and 7 highlight electrical usage during a "typical" non-summer two (2) week period, and clearly illustrate the progress achieved in reducing electrical consumption at LTC over the course of 1996. Analysis of the "what, when and why" of operations during the non-summer timeframe served as the basis for changes in operations which led to shutting down air supply and exhaust systems during the "off-hours" via a combination of automated and manual shutdowns. The consumption differential shown in Figures 6 and 7 equates to an annual reduction of -3.0M kwh in electrical usage and a savings of $225k in electrical costs. $2,500,000.,------------------ $2,000,000 $1,500,000 $1,000,000 $500,000 so 1993 1994 1995 1996 1997 Figure 2. Ex..xon Chemical Company's Linden Technology Center Historical Electrical Costs 16
35.000.000.,-------------------------- 30.000,000 25.000,000 20,000,000 15,000,000 1993 1994 1995 1996 Figure 3. Exxon Chemical Company's Linden Technology Center Historical Electrical Usage Air Circulation 35 /0 c:::7' '" "I ' Site utlllues mmeralr Intrastrucl1.lre Conditioning Pilot Plant Process 20'''' 15% Consumption 15% Lights, Computers, Daytime Needs 15% Figure 4. How Electricity is Consumed at LTC "On Hours" Demand 40'''' "Off Hours" Usage 60% Figure 5. "Off-Hours" vs."on-hours" Consumption 17
February 4-19, 1996 WeekS 6 and 7 3000,- _ 15001-- _ 1000+-------------------------- 500+-------------------------- H ~ ~ II '1/ '1/ N ~ lis i u! ~ ~! iii ~ ~ iii " iii ;; Figure 6. Daily Electrical Consumption (1996) February 2-10. 1997 WeekS 6 and 7 'ooor--------------------------- 500+-------------------------- li\ li\ li\ 1:: ;: I:: ~ ~ ~ ~ n $ ~ i iii ~ r,;; iii iii iii Figure 7. Daily Electrical Consumption (1997) 18
"OFF-HOURS" SHUTDOWNS Historically, LTC had operated HVAC equipment (i.e. supply fans, exhaust fans, chillers) servicing buildings 24 hours per day, seven (7) days per week. By reducing the air flow within some buildings and by changing the time of day HVAC equipment operated, LTC reduced energy consumption without impacting site operations and its client base. In February 1996, LTC installed metering capabilities which enabled facilities management to monitor power consumption daily. This analytical tool served as the basis for further understanding base and peak loads. The data highlighted that "offhours" electrical consumption was a significant portion of LTC's power usage (-.{j0%). Subsequently, in 2Q96, LTC adopted a more aggressive initiative to revise its operating strategy, and began to manually shutdown non-critical electrical consumers on all weekends and one day during the week. Graphs visually depicted these changes in "off-hour" consumption. This thrust led to capital appropriations totaling $165k which automated the shutdown of certain electrical consumers across the LTC site. ENERGY EFFICIENT LIGHTING In 1994 and 1995, LTC appropriated (capital) $375k to realize savings in electrical consumption via energy efficiency lighting. This effort consisted primarily of evaluating light levels in offices, laboratories, hallways, equipment rooms and other spaces to determine lumen output and color. The project(s) took about one (1) year to complete. During the basis development phase, an inventory of all fluorescent lighting fix1ures (-4500) and light level readings was performed in order to detennine whether replacement or retrofitting fixtures would be required. As part of this energy reduction step, LTC participated in the local utility company's rebate program to achieve a minimum average reduction in consumption of 200 kw per day during the summer peak period. Also, as part of this focus, LTC was instrumental in the development and implementation of the recycling of all mercury-containing bulbs in conjunction with the local utilities authority and chambers of commerce. In fact, LTC hosted the inaugural industrial fluorescent light collection. Figure 8 summarizes energy saved and the project investment return during calendar years 1995 through 1997 for LTC's main laboratory/office complex. 00000,- ----,..._00 71lOOO 00000.." 8." """'" co 40000 0: ~ :JXDl 5.-J,ooo.oo SJO.ooo.oo $20,000.00 """" '0000,...,... 1_kWh Reduced -$ Returned I 110.000..00 "'.00 Figure 8. Ex..xon Chemical Company's Linden Technology Center Lighting Project 1995 through 1997 19
1997 PROGRESS The primary focus in 1997 was to monilor and "tweak" operating conditions and strategies. "OfThour" shutdowns were extended. Air flow measurements were taken for the officellaboratory complex and one (1) office structure deploying "once through" air. Various engineering studies were initiated to recalculate and optimize air supply and exhaust quantities. Field activities included minor changes to fan belts and sheaves to meet reduced air requirements. As a result of these eftorts, electrical usage in 1997 continued to decline. YE97 consumption totaled 19.3 M kwh vs. 19.9 M kwh in 1996, about a 3% reduction. 1997 electrical costs declined S95k relative to 1996 (S1405k vs. S1500k), a 6.7% reduction. Reduction in peak usage during the summer months resulted in lower overall costs when compared to the actual decline in consumption. 1998 GOALS Facilities management intends to further reduce electrical consumption in 1998 by continuing to implement recommended changes in operating strategies. "OfT-hours" shutdowns will be extended to include all weekdays vs. one (1) weekday per week. Optimizing air supply and exhaust requirements servicing the main office/laboratory complex will be completed by lq98. More aggressive monitoring of electrical usage in pilot plant areas will provide additional energy reduction opportunities. From a cost standpoint, LTC facilities management's target is to rcduce electrical expenditures SlOOk relative to 1997's YE bookings (to S1300k). CONCLUSIONS LTC's electrical consumption has declined significantly in 1996 and 1997 relative to 1995 as a result of the thrusts highlighted above. A total reduction of 8.0M kwh in electrical consumption has been realized over the last two (2) years, and electrical costs have decreased S700k relative to 1995 base expendilures. Adoption of the stralegies applied at LTC by olher companies within the chemical industry, especially at technology sites, can payout favorably in reducing electrical consumption and costs. 20