Energy Audit Best Practices 3rd Annual E Source Major Accounts Training Conference and Summit May 9-11, 2007 Boston, Massachusetts Kelly Kissock Ph.D. P.E. Associate Professor Department of Mechanical Engineering, University of Dayton, Dayton, Ohio Principal: Go Sustainable Energy

Energy Assessment Experience Director: University of Dayton Industrial Assessment Center –25 no-cost assessments per year for mid-sized industries –Clients report saving average of $100,000 per year Director: University of Dayton Building Energy Center –Energy assessments and analysis for residential, commercial, and institutional buildings Principal: Go Sustainable Energy –Energy assessments for commercial, industrial, institutional facilities: –Clients include Ford, Corning, Johns Manville, Cargill, Scotts, Delphi … U.S. D.O.E. Certified Qualified Specialist and Energy Expert –Compressed air –Process heating Trained energy consulting firms, utilities, industries and government agencies in US and abroad. Awards: –2003 U.S. D.O.E Center of Excellence Award –2006 Ohio Governors Award for Energy Excellence

Purposes of an Energy Audit Provide specific advice on current savings opportunities Educate client to help manage energy costs over long term Foster healthy and productive long-term relationship

Organizing an Audit 1) Preparation 2) Site visit 3) Analysis and reporting 4) Follow up

Preparation: Define Expectations Goal to identify and quantify energy saving opportunities - not final design Work together Confidentiality

Preparation: Data Request Balance value of data versus client time and perceptions Typical pre-assessment data: –Two years of billing data –Production/sales/occupancy data –Major energy-using equipment and control systems –Facility layout/plan

Preparation Summarize rate schedule and disaggregate costs Calculate avoided cost Verify billing amounts Graph and analyze trends and relationships Identify potential savings opportunities Define roles within assessment team

Site Visit 1) Briefing and billing analysis 2) Facility walk-through 3) On-site data collection 4) Debriefing

Initial Briefing: Teamwork Include upper management Two stories to promote teamwork –Client’s advantage: you know this facility –Auditor’s advantage: seen lots of facilities –Auditor’s job: identify and quantify savings opportunities –Client’s job: determine if ideas work within multiple constraints Most productive if work together

Initial Briefing: Utility Analysis Structure Explain rate structure as it relates to client Show client how to use rate structure to their advantage Show client how to use billing analysis to understand their processes and facilities Purpose Develop credibility Lead client into discussion of processes and facilities

Explain Rate Structure As It Relates to Client Service: $95 /month Energy:$ /kWh (base) $0.012 /kWh (approximate fuel adjustment) $ /kWh (PIP) $ /kWh Demand: $13.86 /kW-month Greatest energy use during any 30 minute period Greatest of: 100% of on-peak (weekdays: 8 am to 8 pm) 75% of off-peak (all other times) 75% of max in last 11 months Power Factor:$0.30 /kVAr-month PF charge = {$0.3 x Tan[ArcCos(PF)]} / kW saved

Disaggregate Costs Demand/Energy = 50/50 –Typical Demand/Energy = 60/40 –One shift operation –High demand cost Demand/Energy = 40/60 –Three shift operation –High energy cost

Determine Cost of Avoided Energy Avoided cost electricity –Energy:$0.023 /kWh –Demand: $11.23 /kW –Average:$0.071 /kWh Avoided cost of natural gas –Winter: $10.43 /mmBtu –Summer: $8.43 /mmBtu –Annual: $9.33 /mmBtu

Verify Billing Amounts

Billing Analysis: Every Picture Tells a Story…

Tell Demand and Energy Story

Quick Electrical Demand Breakdown Draw line through winter demand Below line is “production”, above is “air conditioning” Ex: Summer = 4,700 kW, Winter = 3,900 kW AC = 800 kW SEER 10 = 1.2 kW/ton; 800 kW = 670 tons AC

Quick Electricity Use Breakdown Draw line through winter energy use Below line is “production”, above is “air conditioning” Ex: Winter = 78,000 kWh/day Average = 83,000 kWh/day Frac Prod = 78,000 / 83,000 = 94% Frac AC = 6%

Quick Natural Gas Use Breakdown Draw line through summer energy use Below line is “production”, above is “space heating” Ex: Summer = 310 Mcf/dy Average = 430 Mcf/dy Frac Prod = 310 / 430 = 72% Frac Space Heat = 28%

Energy Breakdowns By Equipment

Use Energy Breakdowns To… Target areas for investigation –Savings potential is related to load/use Screen savings opportunities –Estimate annual savings –Imp cost = simple payback x savings

Graph Energy vs Temperature R2 = 0.92 CV-RMSE = 7.5%

Graph Energy vs Production R2 = 0.32 CV-RMSE = 9.2%

Use Graphs To Identify: Departure From Expected Shape R2 = 0.70 CV-RMSE = 7.8% Economizer malfunctioning!

Use Graphs to Identify: Non-Production Related Energy Use R2 = 0.01 CV-RMSE = 22.5% Equipment Left On!

Use Graphs to Identify: Control Opportunities R2 = 0.59 CV-RMSE = 67.6% Observation Heating Energy Varies by 3X at Same Temp! Discovery Didn’t close shipping doors!

Or to Identify Well Controlled Facility … R2 = 0.99 CV-RMSE = 1.1%

Other Savings Opportunities Primary/secondary service – Secondary < 1,000 kVA < Primary Power factor correction –Capacitors cost about $30 /kVAR Demand reduction potential –Demand potential if 2+ shifts per day with unbalanced demand

Facility Walk Through Generate list of possible savings opportunities –See everything but focus on energy –Safety –Stay on task Consolidate ideas and plan next steps –Prioritize savings opportunities –Pursue all opportunities you believe in –Write equations for quantifying savings to guide data collection effort

On-site Data Collection Safety Make measurements and observations to quantify opportunities Photographs Talk to as many levels of personnel as possible

Debriefing Include upper management Describe savings opportunities Answer questions Sell ideas and education throughout site visit

Analysis and Reporting Purposes and Format Documentation Delivery

Final Report: Purposes and Format Purposes –Document current energy using practices –Identify and quantify saving opportunities Format - should support purposes 1) Executive summary 2) Savings summary table 3) Current energy use practices 4) Savings calculations 5) Implementation

Final Report: Savings Opportunities Energy savings opportunities –Calculate savings (most important) –Implementation cost (ask for client’s help) Consider how to handle synergistic effects

Final Report: Writing Style Use first person to identify what you did Write completely and concisely –Every number and calculation documented –No word removed without losing information Test –Client able to read, understand, agree/disagree, and modify

Final Report: Delivery How? –Deliver report and ask for feedback –Present report –Revise report –Final report When? –As soon as possible –Helps client –Reduces errors and omissions

Follow-up Initial phone call to answer questions Implementation results –Determine which recommendations implemented –Assess overall satisfaction with service Savings measurement and continued support

Summary Preparation: sets stage for everything that follows –Set expectations –Credibility –Build on your strengths: rate structures and billing analysis Site visit –Create “team” philosophy –Manage time effectively so you “bring home the bacon” –Communicate and sell ideas throughout assessment Analysis and reporting –Broad and thorough Follow up –Learn from feedback

Thank you! questions to Kelly Kissock

Site Visit Initial briefing –Include upper management –Agree on agenda and deliverables –Roles: Your advantage: you know this facility My advantage: seen lots of facilities Most productive if work together My role is identify and quantify possible savings opportunities Their role is determine if it can work within multiple constraints, much more difficult –Discuss utility analysis Facility walk-through –Generate list of possible savings opportunities –Safety –Stay on task Break –Identify all savings opportunities –Prioritize savings opportunities –Write equations for quantifying savings to guide data collection effort On-site data collection –Make measurements and observations to quantify opportunities –Talk to as many levels of personnel as possible Debriefing with upper management –Describe savings opportunities –Sell ideas and education throughout site visit

Final Report Purposes –Document current energy using practices –Identify and quantify energy saving opportunities Format –Executive summary –Savings summary –Energy use practices –Detailed calculations Energy savings opportunities –Calculate savings –Estimate implementation cost (ask for help) –Calculate simple payback –Consider synergistic effects Write completely and concisely –Completely, every number and calculation documented –Use first person to identify what you did –Should be able to read each analysis and say yes I agree or no because of this. –Concisely, no word could be removed without changing meaning Deliver report as soon as possible

Outdoor Air Temperature Data