University of Dayton Industrial Assessment Center Kelly Kissock

University of Dayton Industrial Assessment Center Kelly Kissock, Ph. D. , P. E. Professor and Chair, Mechanical and Aerospace Engineering / Renewable and Clean Energy Director: University of Dayton Industrial Assessment Center

Industrial Assessment Center Program § Sponsored by U. S. Department of Energy – Program began during 1970 s “energy crisis” – 26 centers at universities throughout the U. S. – 20 no-cost assessments per year for mid-sized industries § Goals: – Help industry be more resource-efficient and competitive – Train new engineers in industrial best-practices

Eligibility for No-Cost IAC Assessment § Manufacturing facility SIC: 20 to 39 § Annual energy costs: $100, 000 $2, 500, 000

Other Assistance to Industry from D. O. E. § Save Energy Now program – http: //www 1. eere. energy. gov/industry/saveene rgynow/ § D. O. E. Software Tools – – – Screening: Quick PEP Process heating: PHAST Compressed Air: Air Master Pumps: PSAT Steam: SSAT Motors: Motor Master § General training on D. O. E. software tools – 1 to 3 day seminars on D. O. E. tools § Energy Saving Assessments – 3 -day assessment of specific energy system – Includes training on use of D. O. E. software tool

IAC Assessment § Gather and analyze data before visit § Team of faculty and students visit plant for one day § Work closely with clients to: – Reduce energy – Reduce waste – Improve productivity § Write custom, confidential, independent report with specific savings suggestions § Call back to see what was implemented

UD Industrial Assessment Center § Performed over 800 assessments since 1981 § Check implementation results after one year – Half of recommendations implemented < 2 year

UD-IAC Energy Assessment Approach § Develop Baseline – Billing analysis: how energy is priced – Energy balance: where energy is used – Lean energy analysis: why energy use changes § Identify and Quantify Savings Opportunities – Integrated Systems and Principals Approach to Identifying Savings • • Consider relevant energy systems (elect, lights, motors, fluid flow, compressed air, steam, process heating and cooling, HVAC) Apply principals of energy efficiency (inside out, control efficiency, counter flow, etc. ) – Use engineering fundamentals and fundamental-based software to quantify savings § Measure and Benchmark – Measurement: extend LEA with sliding NAC and EI to measure energy efficiency improvement – Benchmarking: compare NAC and EI for inter-facility benchmarking

Baseline: Utility Bill Analysis § Analyze rate schedule § Verify billing amounts § Check for saving opportunities: – Primary/secondary – Power factor correction – Meter consolidation – Demand reduction potential

Baseline: Calibrated Energy Use Breakdowns

Baseline: Lean Energy Analysis § Model energy use as functions of weather and production – E=a+b. T+c. P – G=a+b. T+c. P § Use models for: – – – Measuring savings Budgeting LEA Breakdown Benchmarking Identifying Savings Opportunities

LEA: High Independent Identifies Operating Opportunities

LEA: High Scatter Identifies Control Opportunities Heating Energy Varies by 3 X at Same Temp!

LEA: Departure From Expected Shape Identifies Malfunctioning Economizers § Air conditioning electricity use should flatten below 50 F § Audit found malfunctioning economizers

Energy Systems – – – Electrical Lighting Motor drive Fluid flow Compressed air Steam and hot water Process heating Process cooling Heating, ventilating and air conditioning Cogeneration Renewable Energy

Principles of Energy Efficiency • • • Inside Out Analysis Understand Control Efficiency Think Counter-flow Avoid Mixing Match Source Energy to End Use Whole-system, Whole-time Frame Analysis

P-1: Think ‘Inside-out’ Result: Significant improvement at minimal cost

P-2: Understand Control Efficiency (Systems sized for peak but operate at part-load)

P-3: Think Counter Flow T Q Parallel Flow T x Q Counter Flow x

P-4: Avoid Mixing • Availability analysis… Useful work destroyed with mixing • Examples – CAV/VAV air handlers – Separate hot and cold wells – Material reuse/recycling

P-5: Match Source Energy to End Use

P-6: Whole System/Timeframe Design • Dopt = 200 mm when Tot Cost = NPV(Energy)+Pipe • Dopt = 250 mm when Cost= NPV(Energy)+Pipe+Pump • Energy 250 = Energy 200 / 2

Integrated Systems + Principles Approach § Effective and Thorough

State of the Art Equipment § Power logging § Ultrasonic flow sensors § Ultrasonic vibration § Combustion analysis § Temperature, light, pressure, air flow, etc.

Lighting § End Use – Turn off blocked light – Occupancy sensors – Maximize day-lighting § Distribution – Add reflectors – Task Lighting – White ceilings / walls § Conversion – Upgrade fixtures

Motor Drive Systems § End Use – Turn off when not in use § Distribution – Smooth to notched VBelts § Conversion – Replace rather than rewind – Right-size motors

Compressed Air Systems § End Use – Eliminate inappropriate uses – Air saver nozzles § Distribution – Fix leaks – Timed to demand control drains § Conversion – – – Reduce Pressure Efficient control Compress outdoor air Properly stage Adequate storage Reclaim heat to space

Fluid Flow § End Use – Decrease head – Pump slower/longer § Distribution – Reduce friction § Conversion – Trim impellor / slow fan – VFDs for variable flow

Process Heating § End Use – – – Insulate hot surfaces Block radiation Minimize infiltration Reduce cooling losses Reduce conveyor losses Reduce batch losses § Distribution – Counter flow heat exchange § Conversion – Reduce excess combustion air – Pre-heat combustion air or load – Cascade waste heat

Boiler / Steam Systems § End Use – Insulate hot surfaces – Cover open tanks § Distribution – Repair failed steam traps § Conversion – Reduce excess combustion air – Pre-heat combustion air or feed -water – Minimize steam pressure – Reduce blow-down – Modulation control – Add O 2 trim control

Process Cooling § End Use – Insulate cold surfaces – Increase HX effectiveness – Pinch analysis § Distribution – Avoid mixing § Conversion – Utilized most efficient cooling process – Properly stage chillers – VFDs on CT fans

Heating Ventilating and Air Conditioning § End Use – Reduce set-points – Reduce infiltration/ventilation – Insulate un-insulated envelope § Distribution – Reduce temp stratification – Radiant heaters § Conversion – Reclaim heat from process – 100% efficient MAU for ventilation – Differential pressure control for MAUs

Measurement and Benchmarking § Measurement – Extend LEA with sliding NAC and EI to measure energy efficiency improvement § Benchmarking – Compare NAC and EI for inter-facility benchmarking

Measure: Extend LEA by Calculating Sliding Normalized Annual Consumption (NAC) • AC up by 10% • NAC down by 12%

Benchmark: Compare NACs of Multiple Facilities DNAC

Institutionalize Knowledge

Free Energy Analysis Software § § § ESim Heat. Sim Cool. Sim Air. Sim Light. Sim ETracker

UD-IAC Alumni § § § § § Mc. Donough-Braungart Johnson Controls Honeywell Energy Resource Solutions 2 RW Consulting Select Energy Services Heapy Go Sustainable Energy And many more…

Awards § U. S. DOE 2003 Center of Excellence § State of Ohio 2006 Governor’s Award for Excellence in Energy § U. S. DOE Energy Champion Awards to UDIAC Clients

Interested? Dr. Kelly Kissock 937 -229 -2852 kkissock@udayton. edu Franc Sever 937 -229 -3343 severfrj@notes. udayton. e du http: //academic. udayton. edu/kissock/http/IA C