Rolf Butters Industrial Technologies Program Industrial Buildings Tools and Resources Webinar - June 11, 2009 Michael MacDonald Agenda Introduction to Industrial Buildings Opportunity and Tools EERE Funding, Opportunities, and Resources Next Steps 6/11/2009 2 Facilities Energy ITP has been working for a couple years now to develop tools to address facilities energy use, present in most plants, and about 8% of total sector energy use First tool is a Score Card, implemented both as a stand- alone Excel file and for QuickPEP 3 Score Card has to be simple, so is approximate 3 But it can be a very important tool for scoping facilities energy use at a plant Second tool is an adaptation of the BCHP Screening Tool, originally developed by the Distributed Energy program but now used extensively by FEMP for CHP screenings 3 This tool runs DOE-2.1e simulations to calculate savings Focus Small to medium size plants have a record from the IAC program, FY02-present, of: 3 3,878 assessments, 31,833 recommendations (28,425 were cenergy d), and 8,953 cbuildings energy d recs 3 Of the 8,953 buildings recs, 518 were on envelope, 213 were on ventilation, 6,806 were on lighting, and 1,416 were HVAC Total energy savings for ... more. less.
8,953 recs of 14.7 Trillion Btu/yr Over 2 billion sq ft in 50 states + PR Average plant 500,000+ sq ft, median plant 120,000 sq ft Generic Assessment Actions Obtain utility records / analyze costs Site/Building visit to collect data Energy accounting / Score Card Analyze potential measure savings Report ITP BP Tools website http://www1.eere.energy.gov/industry/bestpractices/software.html IFSAT Listing on same page Example You have completed the generic steps of: 3 Obtained utility data 3 Conducted site visit Now starting to analyze data: 3 Use Score Card to scope buildings energy 3 Use Score Card to scope building energy measure total savings 3 Use other tools, like IFSAT, for further calculations Notes We generally like to analyze utility data before site visit, but keeping flow simpler here for presentation cTypical d plant of 150,000 sq ft, about 4 million kWh/yr, about 40,000 MMBtu/yr gas There is an Excel file available that shows site data needed for an IFSAT analysis Site location here is Allentown, PA IFSAT Field Data Forms, partial Form 1, Forms 1-4 in actual Industrial Facilities Systems Assessment Tool (IFSAT) BUILDING DESCRIPTION DATA FORM Building ID: _______________________ Building Type: ________________ Date: ___________________ Prepared by: ___________________ Building Use: __________________________ e.g., metal fabrication Building location (e.g., city state zip ): _____________________________________ circle circle 1. General Data and Building Envelope NAICS Y or N SIC Y or N Applicable NAICS or SIC codes, as desired to record: _____________________________________ Simple length and width to equal total floor area, ft: Length: _________ Width: _________ Number of floors: _______ Floor-to-floor height(s), ft: _______________ Total Floor area, sq ft: Heated Cooled Unconditioned Above ground Below ground Exposed roof area, sq ft: ____________ Average roof estimated R-value: _______ Roof components, out to in: _______________________ Average estimated opaque wall R-value: __________ Wall components, out to in: ________________ Back to Score Card, we estimate that 50% of total energy is cBuildings d energy, which is not atypical for light industrial with some conditioned space and a lot of exhaust air BUILDINGS Part 2 Energy Estimate and Buildings Energy Buildings Energy Measures Score Card version 1.1 This tool needs an estimate of annual buildings electricity use and fuel/steam use. So this sheet indicates what the estimate will be and allows changes.<br><br> Enter for: TOTAL SITE, all energy, including process ACTUAL or Electricity Fuel/Steam ESTIMATE kWh/yr Million Btu/yr Use a fuel 4,384,525 42,565 calculator, if available, to derive Electricity Fuel/Steam these values $/yr $/yr $306,917 $510,780 CALCULATED Electricity Fuel/Steam BUILDINGS ENERGY kWh/yr Million Btu/yr based on item 'c' on 2,192,263 21,283 PctFac sheet Electricity Fuel/Steam $/yr $/yr $153,458 $255,390 ADJUST BUILDINGS ENERGY if needed Electricity Fuel/Steam Percent of calculated: 100% 100% kWh/yr Million Btu/yr values here will be used: 2,192,263 21,283 Electricity Fuel/Steam Percent of calculated: 100% 100% $/yr $/yr values here will be used: $153,458 $255,390 for total site applicable to buildings being surveyed Energy Use Adjustment Score Card File Score Card Excel file, version 1.1, has How-to instructions, and some documentation Score Card, Parts 1 3 5, are: 1. Percent Buildings Energy based on default Facilities Energy 2. Energy Estimate and Buildings Energy 3.<br><br> Energy End-Use and Maximum Savings Percent Breakouts 4. Scorecard Questions, higher means more savings potential 5. RESULTS Part 3 of Score Card Column 'B' Column 'C' Column 'D' Column 'E' Column 'F' Column 'G' Electricity Fuel/Steam Electricity Fuel/Steam Electricity Fuel/Steam (%) (%) (%) (%) (%) (%) Envelopes 5% 17% 30% 30% 2% 5% Lighting 35% 0% 60% 0% 21% 0% Space Conditioning 15% 50% 50% 50% 8% 25% Ventilation 40% 30% 30% 30% 12% 9% Miscellaneous 5% 3% 0% 100% 0% 3% SUM 100% 100% 42% 42% The sum of columns B and C should be 100% Buildings energy breakout percents by system type (miscellaneous is everything else) Maximum composite percent savings considered achievable if all measures from a range of buildings could be installed (do not change unless you are sure) Max percent Result for Buildings Energy Facility End-Use Part 4, Score Card questions, envelope and lighting, not changed from default E1 Enter percent of total building wall and roof/attic areas of all heated and/or cooled buildings that could have insulation (or additional insulation) added?<br><br> percent 50 25 E2 Could large unsealed openings or broken windows in walls or roofs be sealed or re aired? 1 / 0 for yes/no 1 20 L2 What percent of total floor area is lit by older fluorescent (T12) or incandescent lighting that could be retrofit to T8? percent 75 18.75 L3 What percent of total floor area has lighting left on all the time or most of the time when little or no activity is occurring?<br><br> Or lights cannot be turned off due to lack of switchin ? percent 75 37.5 Part 5, Score Card Results, potential savings for envelope and lighting Buildings Energy System Scorecard Potential out of 100 Electricity Fuel/Steam Electricity Fuel/Steam kWh/yr Million Btu/yr $/yr $/yr Envelopes 45 14,798 488 $1,036 $5,861 Lighting 56 258,961 0 $18,127 $0 IFSAT Beta Facilities Tool Tool has simple spreadsheet-type input, as shown here, for a baseline and a savings case Each case is a simulation run, and savings are based on differences between runs Beta version available from website for testing Extensive results are provided Simulation Output for base case matching to utility data baseline Buildings Energy Estimate Units A 4. Annual Electricity Consumption a.<br><br> Lights kWh 804,460 b. Equipment kWh 102,406 c. Heating kWh d.<br><br> cooling (1) chiller #1 kWh 156,101 (2) chiller #2 kWh 0 (3) desiccant dehumidifier kWh 0 (4) total cooling power kWh 156,101 e. Cooling Tower kWh f. Pump and Misc kWh 21,583 g.<br><br> Ventilation Fans kWh 1,177,686 h. Refrigeration kWh i. Supplemental Heat kWh j.<br><br> Service Water Heat kWh k. Total Power kWh 2,262,237 5. Annual Gas Consumption a.<br><br> Heating MMBtu 24,006 b. Cooling MMBtu c. Supplemental Heat MMBtu d.<br><br> Service Water Heat MMBtu e. Process Thermal MMBtu 557 f. Generator MMBtu j.<br><br> Total 'Plant' and 'System' fuel consumption MMBtu 24,562 Simplified Building Layout Lighting ECM, reduces lighting power from 1 W/sq ft to 0.6 in the Process Space, IFSAT results 90,000 sq ft total Annual Change for Allentown, PA climate Lighting 222,600 kWh reduction HVAC fans 3,700 kWh reduction Heating 397 MMBtu increase Cost @ $0.07/kWh and $12/MMBtu $15,800 - $4,800 = $11,000/yr Roof Insulation ECM, owner plans to re- roof, add R-19, IFSAT results 150,000 sq ft total, existing R-3 Annual Change for Allentown, PA climate Cooling 17,300 kWh reduction HVAC fans 26,500 kWh reduction Heating 2,400 MMBtu reduction Cost @ $0.07/kWh and $12/MMBtu $3,000 + $28,800 = $31,800/yr Reduce Exhaust ECM, assessor finds way to reduce exhaust, IFSAT results Reduce exhaust fan CFM, 15,000 to 10,000 Annual Change for Allentown, PA climate Cooling 7,900 kWh reduction Ventilation and HVAC fans (mainly vent) 375,500 kWh reduction Heating 6,100 MMBtu reduction Cost @ $0.07/kWh and $12/MMBtu $26,800 + $73,200 = $100,000/yr Future Plans IFSAT will be released as version 1 by the Fall, with User Manual, and up to 26 simultaneous scenarios Score Card probably updated to version 1.2 to allow different percentages for electricity and fuel Extended Score Card likely to be developed that allows more ECM calculations and compacts the energy allocation steps, by Fall 2009 Cost-Saving Next Steps 1. Download and use the Industrial Facilities Scorecard spreadsheet and/or tools. http://www1.eere.energy.gov/industry/bestpractices/software.html 2.<br><br> Request an Energy Assessment through: our Info Center (877-337-3463), your Utility, NAESCO, or your preferred Engineering firm. 3. Visit the ITP States page for the Incentives Database http://www1.eere.energy.gov/industry/states 4.<br><br> See the Utilities Management page for Demand Management opportunities http://www1.eere.energy.gov/femp/program/utility/index.html 5. Ask your supplier for a Wireless Sensor demonstration. Project partners include: Johnson Controls, Honeywell, Eaton, GE, Sensicast.<br><br> Imagine what a secure energy awareness scenario might look like in your plant. Download the wireless sensor webcast presentation archive. 6.<br><br> Download previous webcast archives: http://www1.eere.energy.gov/industry/resources/webcasts.html " The American Recovery and Reinvestment Act Act - includes details for current combined heat & power projects, or tax credits " Energy Assessments for industry. 7. Request an Energy Assessment through our Information Center (877-337-3463), your Utility, NAESCO, or a preferred Engineering firm.<br><br> 8. Start Saving Today! Rolf Butters, DOE, 202-586-0984 Rolf.Butters@hq.doe.gov Mike MacDonald, ORNL, 865-574-5187 firstname.lastname@example.org<br><br>