Loureiro Engineering Associates, Inc. (LEA) Electrical Energy Management June 2013 Kevin Vidmar, CEM © LEA 20131

Agenda  General Concepts –High level, very condensed  Typical Opportunities – by electrical energy use systems  Questions © LEA

Loureiro Engineering Associates  Started in 1975  Offices in Plainville CT, Manchester NH, Rockland MA, Wakefield RI  Multidiscipline – 100+ emp., 14 PEs –Environmental, Health & Safety, Remediation, Brownfield, SMEP (Structural, Mechanical, Electrical and Plumbing), Energy Services, Construction, WorkWaste  Employee Owned © LEA

Energy Services Background – Kevin Vidmar, Vice President  25 years industrial experience before LEA  Wide Ranging Experience – Pratt & Whitney, The Stanley Works, Cookson Group –Energy Director, Corporate 5S trainer, Lean Manufacturing Team Trainer, TPM Team Member, Kaizen Facilitator, Six Sigma Team Leader, Maintenance Manager, HSE Manager, Process Improvement Manager, Plating Manager (CEF)  Certified Energy Manager (CEM), Certified Energy Auditor (CEA), Carbon Reduction Manager (CRM)  30+ Training sessions a year, AEE & otherwise © LEA

copyright LEA How much coal is needed to run one 100 W light bulb for one full year (8760 hrs)  65 pounds  107 pounds  551 pounds  714 pounds  1020 pounds

Definitions Energy use (KWH) = kW x Hours (eff) (cons)  Conservation –reduced consumption with reduced results  Efficiency –the ratio of output to the input of any system –reduced consumption with same results  There is a difference, and synergy  Thinking about both forces more and better opportunities

So you want to reduce electricity use?  Define “What” – by energy use systems –Data Analysis –Energy Audit – AERO  ASHRAE level 1,2,3 –Kaizen Energy Treasure Hunt –Behavioral Energy Change (BEC)  Then Define “How” –Typical Implementation - Utilities, vendors, site –Energy Support Programs  Energy 5S, BEC, Six Sigma, © LEA

What does your data say?  Look closely  Benchmarks – to yourself and others  View data many different ways  Not just month to month © LEA

Internal Metric - Demand Macro View  KW data by type of day, whole year and December (ECAM) 9 © LEA 2013

Typical Electrical Systems for Conservation and Efficiency  Typical areas, and manufacturing percentages (+/-)  Synergies abound © LEA To Cover Quickly  Lighting  HVAC  Motors  Comp. Air  Plug Load

copyright LEA 11 3 Steps to Lighting Savings 1. Meet Target Light levels 2. Efficiently produce and deliver the light 3. Control lighting - auto or manual  The right amount of light, at the right efficiency, at the right time

Lighting - Conservation  Turning them off! –Sensor study – define value –Sensors – (vandal resistant) –Manual – BEC, 5S © LEA

Lighting – Efficiency  Replace HID with T-5 or T-8 LF, CFL, Inductance, LED  Replace T-12 with T-8, T-5, LED  Replace older T-8 with Super T-8  Replace with half the number of bulbs  Replace 3 bulb T-8, with 2b © LEA

HVAC – from low to high cost  Conservation –Control Exhausts –Setback –Ductwork sealing –Proper operation - occupancy  Efficiency –Rooftop or chiller efficiency changes –Cooling towers © LEA

 From this can calculate fan motor savings AND cooling savings Example of event data logging  Fan cycling stopped when placed in setback copyright LEA 15

Motors  Conservation –Only run when needed  Efficiency –Load changes (belts) –Change motor efficiency – longer run hours –VFD – including stagnant –Energy Saving Motor Controllers © LEA

Compressed Air  Conservation –Leaks – DOE/Others 25%, LEA 50% –Eliminate improper uses  Efficiency –Change compressor – VFD –Compressor Controls  Can be 10% or more of electrical  Have had up to 92% reduction © LEA

copyright LEA Office/plug Load - What does This have to do with This? cccc If every house in America buys one digital picture frame, we would need to add MW power plants Shows the overall importance of plug load, and its growth!

Plug Load  Do an audit, be surprised!  Conservation –Eliminate or remove printers –Power save on computer equipment –Power save strips – for other plugs  Efficiency –Energy Star computers, appliances © LEA

20 Overall Electricity Reduction AERO, Six Sigma, BEC  From 2000 kWh/day to 1200 – with primarily just conservation AERO, BEC, Six Sigma, asking why!  Drop from 1200 to 700 kWh/day with VFDs install  2009 was 50% less than 2008 with conservation and efficiency BEC 7 day rolling average © LEA

21 BEC Example site  Team Training on energy use systems at their site – 4 hours  Outside ID and quantification of opportunities by energy use system  Team ID and quantification as well  BEC program development and rollout  Six Sigma incorporation  One hour conference calls – 10 total  (True) Celebration © LEA 2012 >50% energy use reduction, saving $50K/yr 21

Summary  Evaluate Data – get dissatisfied  Macro and Micro  Conservation and Efficiency –Lighting, HVAC, Motors, Compressed Air, Plug Load, etc.  Systematic, significant reduction can occur even if you have done many equipment changes already – BEC, Kaizen, 5S, Lean © LEA

Loureiro Engineering Associates, Inc. (LEA) Electrical Energy Management June 2013 Kevin Vidmar, CEM © LEA