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Industrial Newsbriefs

August 2012

Welcome to this edition of Industrial Newsbriefs, produced by the Washington State University Extension Energy Program, and sponsored by the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy (EERE). Please forward this issue to those of your colleagues interested in industrial energy efficiency. View archive 

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Announcements

ASERTTI Fall Meeting: Transformative Innovations in Energy Efficiency and Clean Energy Generation

The Fall meeting of ASERTTI, the Association of State Energy Research & Technology Transfer Institutions, will take place in Seattle on October 10-12, 2012. This year’s meeting brings together ASERTTI members, private sector energy technology leaders, national energy research experts, and others to discuss energy innovation, investment, and deployment. State and private research and technology transfer institutions are changing the way we create, deliver, and use energy, and ASERTTI’s Fall meeting offers a one-of-a-kind venue to access experts in the fields of energy storage, advanced manufacturing, bioenergy, building technology, and combined heat and power. This event is sponsored by the Washington State University Energy Program, and is open to ASERTTI members. If you would like to laern more about becoming an ASERTTI member, please contact Christine Love at 360-956-2172 or lovec@energy.wsu.edu.

Biofuels/Biomass

Port Townsend Paper CHP payback likely

"The $55 million question: Will PT Paper's cogeneration turn a profit?" was published July 18, 2012, at PTLeader.com. This article describes the risks and potential payback of Port Townsend Paper’s cogeneration project, scheduled to begin operation by the end of 2013. As of now, the specific market for the plant’s saleable electricity is unknown, but promising opportunities exist in a favorable regulatory environment.

Compressed Air

Compressed Air Best Practices

The July 2012 edition of Compressed Air Best Practices is now available for download; this issue’s focus is the Woodworking Industry. Article topics include air compressor system upgrades, tri-lobe blowers, airend forensics and pneumatic valves.

Energy Management

Industry in Europe increasingly fueled by electric power

"Understanding the Electrification of Industrial Energy Consumption in Europe," published July 2, 2012, on the Leonardo Energy website, explains why electricity has been steadily picking up watts as the energy source of choice for European industry. Upon examination, the main drivers of this increase are the development of new industrial processes which utilize electricity (such as increased mechanization), and fuel substitution in production processes (electric furnaces, electric steel processes, etc.).

HVAC/R (Heating, Ventilation, Air Conditioning, and Refrigeration)

The following three articles appeared in the June 2012 issue of HPAC Heating/Piping/AirConditioning Engineering

"Accurately Predicting Boiler-Controller Energy Savings," by John D. Sullivan, PE, Alzeta Corp., explains why a common method of testing add-on boiler controllers can suggest more energy savings than are actually going to be realized. His solution to this problem is an alternative, and more accurate, testing method, which he describes. 

"Dancing Deaerator," by Gary Wamsley, PE, CEM, JoGar Energy Services, offers an opportunity to solve a puzzle: why was a boiler tripping offline at certain times? The answer begins in the third paragraph from the top (with the heading Problem Analysis) and continues with a detailed analysis. 

"Maximizing Efficiency with Hydronic Boilers," by Alan Wedal Cleaver-Brooks, makes the case for highly-efficient hydronic boilers.

Policy and Legislation

Announcement: Area Source Boiler Rule No Action Assurance deadline extended

07/18/12 - The EPA is extending the March 13, 2012 No Action Assurance to apply to the deadline for submitting the Notification of Compliance Status regarding initial tune-ups in the final Area Source Boiler rule. The EPA is also amending the expiration date of the No Action Assurance so that it will run until either the final reconsideration rule is issued and becomes effective or to December 31, 2012. For details, please see Area Source NAA EXTENSION MEMO.

AMP report aims to amp up domestic manufacturing

A new report, Capturing Domestic Competitive Advantage in Advanced Manufacturing, was prepared by the American Manufacturing Partnership (AMP) steering committee and released by the President’s Council of Advisors on Science and Technology (PCAST) in July 2012.  The 70-page report outlines recommendations for spurring investment and positioning the U.S. for long-term leadership in advanced manufacturing. It contains recommendations in three categories: enabling innovation, developing and securing talent, and improving the business climate for manufacturing. Included is a call to increase incentives for energy efficiency and conservation (p. 40). A summary fact sheet is available on the whitehouse.gov website.

Targeting Tax Incentives to Maximize Impact and Minimize Cost is a white paper released by ACEEE in July 2012. This paper looks at tax incentives for energy efficiency in the context of tax reform. Recommendations are made, based on past experience, for the application of targeted tax incentives for energy efficiency measures which are likely to provide long term benefit.

Senate to consider bill for industrial efficiency incentives

A bipartisan bill, the Expanding Industrial Energy and Water Efficiency Incentives Act, offers focused, short-term incentives to help the industrial and manufacturing sectors make investments in energy efficiency. The bill, originally co-sponsored by Olympia Snow (R-ME) and Dianne Feinstein (D-CA), creates incentives for water reuse, advanced motors with adjustable speed drives, chillers, and highly efficient thermal biomass, and also enhances existing incentives for CHP systems. The bill was introduced on the Senate floor and referred to committee on June 28, 2012.

Pumps

Pump leaks examined

"Mechanical Seal Failure in Pumps," by Howard W. Penrose, Ph.D., CMRP, was published in the June 2012 issue of Maintenance Technology. This is a quick, but very useful, examination of where pump leakages occur and why. 

Save energy with intelligent pumps

"Intelligent Pump Systems Tap Major Opportunities for Energy Savings," published July 10, 2012, on the Sustainable Plant website, discusses the latest trends in efficient pump system design. A well-designed pump system can reduce energy consumption by incorporating a variable-frequency drive system and a control system which intelligently responds to both internal and plant-wide conditions.

Resources

Energy Resource Center launched by AMO

The Advanced Manufacturing Office Energy Resource Center, a clearinghouse of online tools and resources for the tracking and improvement of energy performance in industrial settings, was released by the U.S. Department of Energy Advanced Manufacturing Office (AMO) in June 2012. The site is a one-stop resource for access to publications, tools, and software for industrial systems assessment, energy management, and performance tracking. Resources include the Plant Energy Profiler (PEP), an eGuide for ISO 50001, and assessment tools and software for steam, CHP, motors, pumps, and more. To learn more, visit the new site, or read the Alliance to Save Energy news release.

ORNL guidance for Boiler MACT Rule

Guidance for Calculating Emission Credits Resulting from Implementation of Energy Conservation Measures was released by Oak Ridge National Laboratory (ORNL) in July 2012. This document provides technical guidance for the implementation of energy conservation measures for boilers covered by the Boiler MACT rule; specifically, it explains how to document efficiency credits for the condensate recovery system, the distribution system, and the end uses of steam.

Reducing leaking energy to a trickle

Slides from a presentation by Dr. Alan Meier, Reducing Leaking Electricity to a Trickle, are available for download from Conduit. The session, presented at the 4th Pacific Coast Collaborative Symposium, focused on three core issues: what is leaking electricity, why it’s not important, and why it IS important.

Thermal Technologies

The following four articles appeared in the June 2012 issue of Industrial Heating:

"Getting the Most out of Your Combustion System" was written by Brian Kelly of Elster Kromschroeder/Hauck Manufacturing Co. Heat treating needs to be energy efficient and product must be produced quickly without compromising quality. In this article, the combustion system is examined in-depth. 

"How to Reduce Energy Requirements for Efficient Vacuum-Furnace Operation" was jointly authored by Nicholas R. Cordisco and Reàl J. Fradette, both of Solar Manufacturing. The authors show how to reduce energy use in several areas of furnace operation: hot-zones, pumps and motors, and water cooling. 

"Revolutionary Backup for Molten-Metal Processes" was co-authored by Brian Bradley of Unifrax I, LLC, U.S. and Luiz Carlos Simao, Unifrax Brazil, Sao Paulo. Suggestions are offered to reduce heat losses in, and to extend the life of, the ladle refractory. The "revolutionary backup" is a Unifrax product.

"Saving Energy with Your All-Metal Hot Zone" was jointly written by Ray O'Neill of Plansee USA LLC and Bernd Kleinpass of Plansee, Reutte, Austria. While most hot zones in use are insulated ones, the authors concentrate on the 20-25% of them that are all metal. They show how to reduce energy with smaller hot-zone mass, by employing a more-efficient shielding, and by adding a Plansee product to the shielding.

UPCOMING EVENTS AND TRAININGS

Note: Trainings and webinars from the NEEA calendar now link to the main NEEA calendar page. To see full description and register, search for the title and/or navigate to the appropriate date.

Pacific Northwest

Adjustable Speed Drive Applications and Energy Efficiency
August 21: Pocatello, ID
August 23: Billings, MT
October 4: Roseburg, OR
November 15: Yakima, WA
This course addresses the choices available and relevant issues regarding the use of adjustable speed drives (ASD) with electric motors, and demonstrates the energy cost savings and other benefits made possible by this technology. In this course we explore how adjustable speed drives work and ways to assess the savings. Variable frequency drives (VFD) are the most common speed control method and is the major focus of the course content which will cover the benefits of pulse width modulation technology and well as discovering and mitigating harmful electromagnetic interference that can cause motor failure. This course is coordinated by the NEEA Industrial Training project.

PGE Series: Motors and Motor Controls
September 19 – November 7, 2012, Wednesdays, 6:00-9:00 PM, Tualatin, Oregon
In this in-depth course, you’ll learn about motor fundamentals, electrical codes, starting, braking, speed control, variable frequency drives, over current protection, overload protection, motor controls and drive system efficiency. Attendees may be eligible to earn up to 21 Continuing Education Units (CEUs) for their Oregon or Washington electrical license, professional development credit hours, and will receive a certificate of completion.

Fan Systems Assessment Tool (FSAT)
September 20, 2012
Developed to highlight the benefits of fan system optimization, this training discusses performance and practical issues, as well as introduces the Fan System Assessment Tool (FSAT). You will learn how the software functions, what data is required, what to do when measured data is not available, and how to interpret the assessment results. After completing this course, you will understand how to use FSAT to actively determine the best configuration for your fan system in order to achieve optimal energy and cost savings. This course is coordinated by the NEEA Industrial Training project and is sponsored by Avista, Inland Power and Light, Bonneville Power Administration, Washington State University Energy Program, and Northwest Food Processors Association.

PGE Series: Power Quality 1-Day Course
September 28, 2012
This one-day Power Quality (PQ) course provides practical information that you can apply to prevent and solve power quality and reliability problems. With over 20 years of experience, the instructor will help you; learn how to eliminate costly downtime due to power quality and grounding issues, and avoid problems through proper specification and purchase of equipment. The information provided will help you avoid equipment damage and improve productivity. Attendees are eligible to earn 8 hours of Continuing Education Units (CEUs) for their Oregon or Washington electrical license renewal. Also qualifies for State of Washington Basic Classroom Credits for Trainees. PGE Special Sponsored Rate: $250 per person, valued at $399.

ASERTTI Fall Meeting: Transformative Innovations in Energy Efficiency and Clean Energy Generation
October 10-12, Seattle, Washington
This year’s Fall Meeting brings together ASERTTI (Association of State Energy Research & Technology Transfer Institutions) members, private sector energy technology leaders, national energy research experts, and others to discuss energy innovation, investment, and deployment. State and private research and technology transfer institutions are changing the way we create, deliver, and use energy, and ASERTTI’s Fall meeting offers a one-of-a-kind venue to access experts in the fields of energy storage, advanced manufacturing, bioenergy, building technology, and combined heat and power. This event is sponsored by the Washington State University Energy Program.

Innovation Engineering Leadership Institute
October 15-17, 2012, Blaine, Washington
This 2 ½ day training, hosted by Impact Washington, is an excellent opportunity for you to learn various innovation tools that will help your organization create, communicate and commercialize new ideas. NIST MEP is focused on increasing manufacturers’ capacity for innovation and ultimately helping them achieve more profitable sales growth.

Industrial Refrigeration Systems Energy Management
October 23: Hermiston, OR
October 24, 2012, Caldwell, Idaho
With a focus on industrial refrigeration systems that use ammonia as the refrigerant, this training will equip attendees with the knowledge and tools to reduce energy usage and operating costs, and improve the reliability of refrigeration systems. With the knowledge and tools gained, past attendees and their customers have implemented low/no cost strategies resulting in annual energy savings greater than $50,000.

PGE Series: Compressed Air Systems
November 11, 2012, Wilsonville, Oregon
This free half-day seminar provides an overview of how compressed air systems work and practical advice about making the most of your compressed air system investment. Compressed air systems can be one of the largest energy consumers in your facility. Learn how to start saving energy and money today.

Webinars and Online Courses

PGE WEBINAR: What is Power Quality and Why it’s Important
September 12, 2012, 8:00 AM-9:00 AM
This 1.5 hour webinar will introduce you to some of the basic fundamentals of Power Quality, and the steps your organization can take to avoid and/or correct Power Quality Issues. The presenter, Gary P. Larkins with Advanced Power Solutions, has over 20 year of experience in power quality consulting, failure analysis and commissioning.

Energy Management Opportunities for Industrial Customers
September 25, 8:00-9:00 AM PST
This webinar on industrial energy efficiency will cover the basics, including kW versus kWh, power factor, and more. We will also discuss end-use technologies such as motors, boiler or furnace heating systems, compressed air, industrial heat pumps, induction heating, and HVAC. You will learn to identify top energy-efficiency opportunities and potential savings for each; valuable information that will help you stay within your energy budget.

Webinar: Adjustable Speed Drives
October 4, 2012, 10:00-11:00 AM PST
In the right applications, adjustable speed drives (ASDs) offer great energy-saving potential from high power factor to improved speed control, soft-start capabilities, and more. This webinar will discuss how they work, the savings potential, best applications, sizing, and how to solve variable frequency drive (VFD) power-quality issues.

Webinar: Introduction to Compressed Air Systems
October 24, 2012: 8:00-9:00 AM PST and 12:00-1:00 PM PST
 At this introduction webinar you will learn highlights from our four-hour seminar of how compressed air systems work and practical advice about making the most of your compressed air system investment. The four-hour seminar on this subject is scheduled November 11 in Wilsonville.

Webinar: Energy Auditing and Troubleshooting
November 6, 2012, 1:00-2:00 PM
This webinar will show you how to estimate energy consumption by end use without the need for submetering. We will focus on refrigeration, compressed air end uses, HVAC, lighting, and office equipment. In addition, you will receive audit checklists for energy conservation. Several third-party auditing tools will also be reviewed.

MORE TRAININGS IN INDUSTRIAL ENERGY EFFICIENCY

For a listing of other upcoming industrial energy efficiency trainings, visit the following websites:

Energy Events Calendar

Northwest Regional Training Calendar

U.S. Department of Energy Industrial Best Practices Training Calendar

Input Requested: Is there something else you would like to see in Industrial Newsbriefs?

If you have thoughts or ideas for what you would like to see in this publication, please email suggestions to Talia Mathews at MathewsT@energy.wsu.edu . We strive to keep this publication as useful and relevant as possible to you, our readers.


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