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Five Common Energy Conversion Projects in Small and Medium-Sized Industrial Plants

Britton, A. J.; Heffington, W. M.; Nutter, D. W. (Energy Systems Laboratory, Department of Mechanical Engineering, March 1993)

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Abstract:	A Department of Energy funded Energy Analysis and Diagnostic Center (EADC) has operated at Texas A&M University for six years. During the first five years of the center's operation, 135 audits were conducted and projects were recommended which would save $4 million annually (about 9 % of utility costs) for Texas manufacturers. Five projects discussed in this paper—repair air compressor leaks, install heat recovery equipment, correct power factor, install skylights, and tune-up boilers—recur often and have applicability to many plants in many industries. A simple method of measuring air compressor leak rates is covered. Decisions about power factor correction based on utility billing data can be made and those are discussed. The use of simple electronic analyzers to measure boiler combustion efficiency and tune boilers is possible, and higher cost projects such as use of skylights and recovery of heat from exhaust gases are also covered.
Description:	The Department of Energy assists small and medium-sized industrial plants with no-cost energy surveys provided by twenty-three Energy Analysis and Diagnostic Centers (EADCs) around the U. S. The Texas A&M University EADC began in late 1986. During the first five years of operation, 135 audits were conducted and projects were recommended which would save $4 million annually (about 9 % of utility costs) for Texas manufacturers. Projects actually implemented realize just over half of the recommended earnings and the overall payback for implemented projects is slightly less than one year. Audits by the EADC are performed by students and staff of the Energy Systems Laboratory and Mechanical Engineering Department of Texas A&M University. Five important energy conservation opportunities (ECOs) are discussed in this paper with descriptions and at least one example. All five opportunities are common recommendations with significant energy and dollar savings, and simple paybacks less than four years.
URI:	http://handle.tamu.edu/1969.1/2474

Files in this item: 1

ESL-PA-93-03-03.pdf (4.075Mb)

EModel: A New Tool for Analyzing Building Energy Use Data

Haberl, J. S.; Claridge, D. E.; Kissock, J. K.; Reddy, T. A. (Energy Systems Laboratory, Department of Mechanical Engineering, March 1993)

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Abstract:

While computer technology has vastly increased the quantity and quality of measured building energy use data, our ability to analyze the data has not kept step. As a result, building energy use data that could be used to identify operational and maintenance problems, determine retrofit savings, or point to new and innovative ways to reduce energy costs are routinely discarded. In this paper, we draw upon information system and data analysis theory to introduce EModel, a new tool for the analysis of building energy use data. EModel simplifies the previously laborious tasks of data browsing, reformatting and modeling through a user-friendly, Windows-based interface. Graphical, statistical, and residual analysis are performed with simple mouse clicks. Currently, EModel is used by the Texas LoanSTAR program to model pre and post-retrofit energy use so that retrofit savings can be determined. Its use to identify energy use models at a large institutional building is demonstrated.

URI:

http://handle.tamu.edu/1969.1/2475

Files in this item: 1

ESL-PA-93-03-04.pdf (3.030Mb)

Exploring New Data Displays for Facility Energy Data

Sparks, R. J.; Campbell, S.; Kissock, J. K.; Haberl, J. S.; Belur, R. (Energy Systems Laboratory, Department of Mechanical Engineering, March 1993)

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Abstract:

This paper explores some techniques which may help facility operators better understand complex hourly energy data by enhancing the display of data with animation (or timesequencing). Animated displays such as the ones presented in this paper enhance the usefulness of the graphic display because time and temperature dependent trends can be more easily seen. There is an increasing need for new display paradigms that can help facility operators efficiently scan and detect problems within the river of incoming data from control systems. This need becomes even more important during times of a shrinking labor pool. In this paper the use of animated displays are described as they apply to the measurement of chilled water where the animated display makes a faulty flow meter easier to diagnose.

URI:

http://handle.tamu.edu/1969.1/2472

Files in this item: 1

ESL-PA-93-03-01.pdf (3.452Mb)

Instrumenting Buildings to Determine Retrofit Savings: Murphy's Law Revisited

Boecker, C. L.; Bohmer, C.; O'Neal, D. L.; Bryant, J. (Energy Systems Laboratory, Department of Mechanical Engineering, March 1993)

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Abstract:	Experiences with instrumentation, installation and maintenance of building energy metering systems are presented. The building energy metering is installed to support the Texas LoanSTAR program in sites throughout the State of Texas. Metering typically includes monitoring the whole building electric load, building thermal loads and selected submetered loads. The emphasis of the lessons learned is on the instrumentation used and installation problems encountered during this project.
Description:	This paper is not meant to be only a discussion of instrumentation failures or problems. There are a number of "real world" problems that involve the installation of the instrumentation and maintenance. Other problems focus on proper communication between the installer and instrumentation manufacturer or between the installer and those who have to analyze the data. The presentation of the material is divided into three categories: (1) Equipment, (2) Installation, and (3) Maintenance.
URI:	http://handle.tamu.edu/1969.1/2473

Files in this item: 1

ESL-PA-93-03-02.pdf (4.660Mb)

Flow Measurement with Tangential Paddlewheel Flow Meters: Analysis of Experimental Results and in-situ Diagnostics

Watt, J. B.; Haberl, J. S. (Energy Systems Laboratory, Department of Mechanical Engineering, April 1994)

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Abstract:	Flow measurement is an important part of the analysis of building energy use whenever thermal energy use is being investigated. In a building flow measurements are typically required for the analysis of chilled water, hot water and steam condensate use. In applications where the accumulated or totalized energy use is needed microprocessor-based thermal energy meters, or Btu meters are often used to integrate and display flow and energy data or generate a totalized signal for input into a data acquisition system. In this paper new results from calibration efforts in the LoanSTAR program are presented, including the premature drop-out of magnetic-type tangential paddlewheel sensors, as well as several in-situ diagnostic measures for ascertaining whether or not a flow meter is experiencing turbulent conditions or if a flow sensor's output signal is suffering a degraded signal due to shaft wear.
Description:	Flow measurement is an important part of the analysis of building energy use whenever thermal energy use is being investigated. In a building accurate liquid flow measurements are required for the analysis of chilled water, hot water and steam condensate use. Currently, in applications where the accumulated or totalized energy use is needed microprocessor-based thermal energy meters, or Btu meters are often used to integrate and display flow and energy data or generate a totalized signal that can be recorded by data acquisition system. The accuracy of totalized flow and energy measurements is directly effected by the quality of thermal and flow measurement devices.
URI:	http://handle.tamu.edu/1969.1/2476

Files in this item: 1

ESL-PA-94-04-02.pdf (3.882Mb)

Electrical Energy Monitoring in an Industrial Plant

Dorhofer, F. J.; Heffington, W. M. (Energy Systems Laboratory, Department of Mechanical Engineering, April 1994)

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Abstract:

The Energy Systems Laboratory (ESL) at Texas A&M University is currently monitoring the electrical energy use of a metal fabrication facility in Houston, Texas. This paper deals with the installation of the data acquisition system and subsequent analysis of 15-minute data. The data acquisition system has been used to justify energy conservation retrofits, increase productivity, and monitor plant activities. Projected future uses include quantifying savings from retrofits. Uses of the data and the resolution of early problems in dealing with the large amount of data generated each month will be discussed.

URI:

http://handle.tamu.edu/1969.1/2478

Files in this item: 1

ESL-PA-94-04-04.pdf (2.659Mb)

Maintaining Space Temperature and Humidity in the Digital Switch Environment

Saman, N. F.; Johnson, H. (Energy Systems Laboratory, Department of Mechanical Engineering, April 1994)

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Abstract:	A methodology for a psychrometric analysis of the problem of maintaining space temperature and humidity in the digital switch environment is presented. Such spaces produce minimum or no humidity generation. Several different humidification schemes, including isothermal (steam generation) and adiabatic (evaporative cooling) were analyzed. In some cases, the addition of a steam humidifier to an air handling system with an outside air economizer cycle was seen to require more energy than running the same system on minimal outside air with mechanical refrigeration and substantially lower moisture load. Because individual locations will have different operational parameters, this sort of analysis is done by the design engineer as a tool in selection and design of an appropriate humidification system.
Description:	The intent of this paper is to outline a simple methodology to compute cooling and humidification loads at any location, using a variety of techniques for space conditioning. Application of the methodology for a given location will yield a comparative estimate for the amount of energy used for different space conditioning strategies. Although there are numerous building energy calculation methods ranging from simple degree-day procedures to comprehensive and computerized procedures which simulate building heat transfer and system/equipment performance, the Bin Method was chosen for this analysis. With this method, simplified manual calculations that account for the significant parameters affecting the energy usage in buildings are possible. Bin data is given in tabular form as the number of hours per year in which the ambient temperature falls in a given 5 degree window. Inasmuch as coincident wet bulb and specific humidity are given for each dry bulb window, the Bin Method further provides means of evaluating annual humidification loads. Using this technique, different cooling and humidification strategies for the space can be evaluated.
URI:	http://handle.tamu.edu/1969.1/2479

Files in this item: 1

ESL-PA-94-04-05.pdf (2.792Mb)

Energy Conservation Through Improved Industrial Ventilation in Small and Medium-Sized Industrial Plants

Saman, N. F.; Nutter, D. W. (Energy Systems Laboratory, Department of Mechanical Engineering, April 1994)

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Abstract:	This paper discusses energy conservation projects in the area of industrial ventilation that have been recommended by the Texas A&M University Energy Analysis and Diagnostic Center (EADQ to small and medium-sized industries in Texas. The projects recommended include reducing blower operating time/speed and static pressure for dust collectors, installing radiation shield on ovens, and using outside air for cooling. The projects were recommended to different kinds of industries including wood fabrication, frozen food, primary metals, plastics and insulation products. These projects are predicted to save up to 8% of the plants' utility bills with average simple payback periods of less than three years. Projects that involved blowers (fans) speed/operation time reduction resulted in most savings.
Description:	Industrial ventilation is key to providing a suitable working environment for employees and it assists in maintaining safety operation of different processes in an industrial facility. Usually, the emphasis is on designing a ventilation system that works properly. However, due to present and future increases in the costs of equipment and energy, it has become necessary to provide properly operating ventilation systems at reduced initial and running costs. In this paper three types of energy reduction projects that are related to industrial ventilation are discussed. They include reducing blower power, operating time/speed or filter pressure drop for dust collectors; using radiation shields on ovens; and using outside air for cooling process.
URI:	http://handle.tamu.edu/1969.1/2477

Files in this item: 1

ESL-PA-94-04-03.pdf (2.249Mb)

Marginal Cost of Steam and Power from Cogeneration Systems Using a Rational Value-Allocation Procedure

Kumana, J. D.; Al-Gwaiz, M. M. (Texas A&M University (http://www.tamu.edu)Energy Systems Laboratory (http://esl.tamu.edu), 2004)

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Abstract:	The problem of pricing steam and power from cogeneration systems has confounded engineers, economists, and accountants for a very long time. Normal industry practice is to fix the cost of one (usually power) at its local market price, and calculate the “n
URI:	http://handle.tamu.edu/1969.1/6042

Files in this item: 1

ESL-IE-04-04-31.pdf (610.9Kb)

Conserving Energy in Blast Freezers Using Variable Frequency Drives

Kolbe, E.; Ling, Q.; Wheeler, G. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	A stationary blast freezer processing 22-lb cartons of sardines in 19,000 pound lots was modified to improve efficiency and to conserve energy. Baffles were first added to produce uniform air flow. Maximum measured freeze times of 12.6 hours fell to 10.5
URI:	http://handle.tamu.edu/1969.1/6052

Files in this item: 1

ESL-IE-04-04-08.pdf (657.5Kb)

Rule Based Energy Management and Reporting System (EMRS) Applied to a Large Utility Power Station Complex

Bamber, D.; Childress, R.; Robinson, J. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	Deregulation of electricity and rising fuel costs are causing renewed interest in Energy Management Systems (EMS) to service both the utility and private sectors. This paper details a case study of the successful integration of a new class of rule-based E
URI:	http://handle.tamu.edu/1969.1/6051

Files in this item: 1

ESL-IE-04-04-07.pdf (1.191Mb)

Advanced Powerhouse Controls Save Pulp Mill $500 in Purchased Energy in First Month

Morrison, R.; Hilder, S. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	This case study describes the application of advanced regulatory and supervisory controls to powerhouse operations at a large pulp mill in central British Columbia. Substantial reductions in mill operating costs were achieved by actively managing boiler a
URI:	http://handle.tamu.edu/1969.1/6050

Files in this item: 1

ESL-IE-04-04-06.pdf (643.0Kb)

Real-Time Utility System Optimization

Fernandez-Polanco, D.; Eastwood, A.; Knight, N. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	At the 2002 IETC, we described the benefits of a site-wide utility system simulation model that can translate all in-plant process modifications to the resulting changes in fuel, water and electricity at the factory fence to ensure that process BTUs are a
URI:	http://handle.tamu.edu/1969.1/6049

Files in this item: 1

ESL-IE-04-04-05.pdf (793.2Kb)

Steam System Optimization

Aegerter, R. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	Refinery and chemical plant steam systems are complex and the fuel required to produce the steam represents a major expense. The incremental cost for generating a 1,000 lb./hr. of steam is typically $45,000 - $60,000/year. Most plants have numerous low/
URI:	http://handle.tamu.edu/1969.1/6048

Files in this item: 1

ESL-IE-04-04-04.pdf (641.3Kb)

Identifying Steam Opportunity "Impact" Inputs for the Steam System Assessment Tool (SSAT)

Harrell, G.; Jendrucko, R.; Wright, A. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	The U.S. DOE BestPractices Steam "Steam System Assessment Tool" (SSAT) is a powerful tool for quantifying potential steam improvement opportunities in steam systems. However, all assessment tools are only as good as the validity of the modeling inputs.
URI:	http://handle.tamu.edu/1969.1/6047

Files in this item: 1

ESL-IE-04-04-03.pdf (449.9Kb)

Energy & Environmental Benefits from Steam & Electricity Cogeneration

Ratheal, R. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	Eastman's Texas Operations (TEX) occupies a 6,000 acre site where it manufactures more than 60 major products and employs 1,800 persons in a complex of more than 200 buildings. TEX is Eastman's largest single consumer of energy; its processes require lar
URI:	http://handle.tamu.edu/1969.1/6046

Files in this item: 1

ESL-IE-04-04-35.pdf (452.2Kb)

Morris Plant Energy Efficiency Program

Betczynski, M. T. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	Competing in an increasingly global industry, U.S. chemical facilities have intensified their efforts to improve energy utilization. Increases in energy efficiency can offset age, scale, or other disadvantages of a chemical plant when compared with its in
URI:	http://handle.tamu.edu/1969.1/6045

Files in this item: 1

ESL-IE-04-04-34.pdf (527.4Kb)

DTT Energy Reduction Project

Heinrich, C. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	DuPont Titanium Technologies has developed a sustainable growth strategy that includes an initiative focused on improving energy efficiency. The energy efficiency initiative is a disciplined approach that began with creation of an Energy and Greenhouse G
URI:	http://handle.tamu.edu/1969.1/6044

Files in this item: 1

ESL-IE-04-04-33.pdf (451.2Kb)

State Opportunities for Action: Review of States' Combined Heat and Power Activities

Brown, E.; Elliott, N. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	Combined heat and power (CHP) has been the focus of federal attention since the mid-1990s. However, many of the market barriers to CHP are at the state level. As a sign of the maturing CHP market, a number of states are now undertaking activities to addre
URI:	http://handle.tamu.edu/1969.1/6043

Files in this item: 1

ESL-IE-04-04-32.pdf (896.5Kb)

Reduction in Unit Steam Production

Gombos, R. (Energy Systems Laboratory (http://esl.tamu.edu)Texas A&M University (http://www.tamu.edu), 2004)

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Abstract:	In 2001 the company's Arch-Brandenburg facility faced increased steam costs due to high natural gas prices and decreased production due to shutdown of a process. The facility was challenged to reduce unit steam consumption to minimize the effects of thes
URI:	http://handle.tamu.edu/1969.1/6041

Files in this item: 1

ESL-IE-04-04-30.pdf (451.6Kb)

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