Energy Efficient Manufacturing

Class Project Winter 2008

 

Overview

Write an energy audit report for PECO based on our March 11, 2008 visit.  One savings recommendation, printed out, is due Wednesday April 16, 2008 in class.  The complete report is due at our final exam on Monday April 28, 2008 at 4:30 pm.  The report will be graded on accuracy, completeness, conciseness and clarity.  

Report

The report should have the following sections.

 

Cover Page

Table of Contents

Executive Summary (a paragraph or two which includes the following information)

            “On March 11, 2008 our team visited your facility…”

Current annual electricity and fuel use

Current annual electricity and fuel cost, and total cost

Current annual CO2 emissions

Number of energy saving recommendations

Total cost savings and CO2 emission savings identified

Fraction of total cost savings identified to total energy cost

Fraction of total CO2 emission savings identified to total CO2 emissions

Summary of Recommendations

Table and one-paragraph description of each recommendation.  A sample table

and description are shown below.  The table is in EEM_Project.xls)

 

 

AR 1: Insulate Pipes, Tanks and Pump in Steam System

Much of the steam delivery and condensate return system has little to no insulation.  This uninsulated equipment loses heat during the year, therefore increasing the load on the boiler and creating more natural gas consumption.  Furthermore, insulating these surfaces would create a safer plant environment.  We recommend insulating all steam delivery and condensate return system equipment.  We estimate this would save about $31,350 per year with a 3-month simple payback.

 

Electricity Use Analysis

            Rate Schedule

            Graph of monthly electricity use and demand

            Table of monthly electricity use, demand and cost with annual totals

Lean Energy Analysis of electricity use versus outdoor air temperature with interpretation

Propane Use Analysis

            Table of propane refill amounts and cost with annual totals

Exemplary Practices

Savings Recommendations

            Write savings recommendations for:

                        Replace 400 W MH lights with 6-lamp T8 HBF lights

                        Replace Smooth V-belts with Notched V-belts

                        Install VFD on Chilled Water Pump

                        Fix Compressed Air Leaks

                        Install Ducts and Compress Outside Air

                        Purchase 25-hp Air Compressor

                        Turn Off Paint Booth Ventilation Fan When Not in Use

                        Install Control to Turn Off Hydraulic Motors When Not in Use

                        Install Photosensor to Regulate Compressed Air Blowoff

 

An example savings recommendation is included below.  Each recommendation should start on a new page and include atleast one picture. Write completely and concisely.  ‘Completely’ means that the origins of all numbers and all calculations used in the report are documented.  Carry units in all calculations.  ‘Concisely’ means that that each word in the report is essential to promote understanding.  Eliminate redundancy and seek to convey your ideas with the minimum number of words.

 

 

Pictures

 

Lighting   Blocked light

 

Smooth V-belt     Notched V-belt

 

Chilled water pumps

 

Compressed air tool and leaking fitting

 

50-hp air compressor   Compressed air intake

 

Paint booth    Paint booth exhaust duct

 

Hydraulic motor

 

Conveyor with continuous compressed air blowoff

 

Victorious energy assessment team

 

AR 1: Insulate Pipes, Tanks and Pump in Steam System

 

Annual Savings

Project

Cost

Simple

Payback

Resource

CO2  (tonnes)

Dollars

Natural Gas

4,145 mmBtu

225

$31,350

$8,290

3 months

 

Analysis

Much of the steam delivery and condensate return system has little to no insulation. 

This uninsulated equipment loses heat during the year, therefore increasing the load on the boiler and creating more natural gas consumption.  Furthermore, insulating these surfaces would create a safer plant environment. 

 

Recommendation

We recommend insulating all steam delivery and condensate return system equipment. 

 

Estimated Savings

Calculations are based on standard 2-inch thick fiberglass insulation with white jacketing and thermal conductivity of about 0.15 Btu/(hr-ft2-oF).  The average plant temperature is estimated to be 70 F and the boiler is operated 7,200 hours per year.  

 

The simulations indicate a total energy savings from insulating the steam delivery and condensate return system equipment to be about:

 

(446,777 Btu/hr + 39,518 Btu/hr + 42,258 Btu/hr + 6 x 9,442 Btu/hr)                                    x 1 mmBtu / 1,000,000 Btu = 0.59 mmBtu/hr

 

 0.59 mmBtu/hr x 7,200 hr/yr = 4,248 mmBtu/yr

4,248 mmBtu/yr x $7.38 /mmBtu = $31,350 /yr

 

The total reduction in plant CO2 emissions would be about:

 

4,248 mmBtu/year x 117 lb-CO2/mmBtu / (2,205 lbs/tonne) ≈ 225 tonnes-CO2 /year

 

Estimated Implementation Cost

Based on data from RSMeans Mechanical Costs Data 2002, both pipe and tank insulation costs about $10 per square foot including installation. Thus, the implementation cost would be about:

 

829 ft2 x $10 /ft2 = $8,290

 

Estimated Simple Payback

$8,290 / $31,350 /yr x 12 months/yr = 3 months