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Industrial Newsbriefs

July 2011

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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INDUSTRIAL EFFICIENCY RESOURCE OF THE MONTH

Condensation Control Calculator – Horizontal Pipe

This tool was recently added to a series of Mechanical Insulation Assessment and Design Tools made available by the U.S. DOE Industrial Technologies Program (ITP). The calculator estimates the thickness of insulation required to avoid condensation on the outer surface of an insulated horizontal steel pipe. Input data includes the operating temperature, the ambient conditions (temperature, relative humidity, and wind speed) and details about the insulation system (material and jacketing).

CASE STUDIES

ASE presents case study of Jergen’s plant upgrades

Jergen’s, Inc. underwent a major efficiency overhaul at their main plant in Cleveland, Ohio, following an assessment by West Virginia University’s Industrial Assessment Center. Upgrades were made to the plant’s lighting and compressed air systems, resulting in a 16% reduction in energy consumption and a simultaneous increase in production capacity. Read more in "Machine Tool Manufacturer Achieves Significant Energy Savings to Company Operations," published in March 2011 on the Alliance to Save Energy (ASE) website.

Wind turbine powers manufacturing plant

A millwork manufacturing plant in Newburyport, Massachusetts, currently generates 75% of its operating power with a 600 KW wind turbine system installed at the plant site. Electricity not consumed by the plant is sold back to the grid. The return on investment for the project is expected to be about eight years. To learn more, read "Massachusetts Manufacturer Shifts to Wind Power," published in June 2011 in Distributed Energy.

BAE Systems upgrades achieve major cost, energy savings

By upgrading its HVAC system boilers, chillers and controls, and performing miscellaneous other building system upgrades and retrofits, BAE Systems and Siemens were able to reduce electricity and natural gas consumption by 5 percent and 69 percent, respectively. To learn more, read "Energy Efficiency Upgrade at BAE Systems to Save $305,000 Annually," published June 10, 2011, in Sustainable Plant.

COMPRESSED AIR

New issue of Compressed Air Best Practices

The May/June issue of Compressed Air Best Practices contains several articles related to plant-scale compressed air system efficiency:

"The Benefits of On-site Nitrogen Generation," written by Paul Humphreys of Atlas Copco, discusses the benefits and possibilities of switching from nitrogen delivery to on-site nitrogen production using a nitrogen generator.

"Compressed Air at the Lowest Cost; Energy Management at Ball Corporation," written by Rod Smith, staff, provides an interview with Joseph Gress of Ball Corporation and Chris Gordon of Blackhawk Equipment, the partner company who provides energy assessments for Ball. The interview describes the relationship between Ball Corporation and Blackhawk Equipment, and describes in detail the company’s compressed air management procedures and methods and how they have helped the plant save energy.

"Kellogg's Eggo Factory Saves 675,000 kWh," by Patricia Boyd of Ecos Air, provides a case study of a compressed air retrofit project, describing in detail how the Kellog company was able to reduce compressed air system energy consumption in its Eggo factory by about 26%.

ENERGY MONITORING AND CONTROL

Energy monitoring as catalyst for efficiency upgrades

"How to Justify the Cost of an Energy Monitoring System," by Bill Holmes, P.E., describes how a meatpacking plant was able to save several hundred thousand dollars per year in energy costs by installing an automated energy monitoring system, and by utilizing the resulting data to improve wasteful processes (which in this case, was the refrigeration system). The author goes on to discuss the value of monitoring systems for the justification, planning, and implementation of energy efficiency upgrades in industrial plants. This article appeared on June 20, 2011, in Sustainable Plant.

Control engineers discuss energy efficient manufacturing

In June 2011, a panel of representatives in industrial manufacturing met in Phoenix at the Honeywell Users Group Americas Symposium to discuss plant energy efficiency. The panel, which consisted mainly of systems control engineers and managers from major corporations, discussed the implementation, status, and drivers of energy efficiency in industrial plants today. To learn more, read "Process Control Engineers Say Going Green Is No Longer Optional," published June 20, 2011, in Sustainable Plant.

The following three articles appeared in the April 2011 issue of Control Engineering:

1. "Coordinated Variable-Speed System Drives," by Paul Blaiklock, Marketing Manager, TMEIC GE, describes the difficulty of operating large electric drive systems in web-processing environments such as metals processing, pharmaceutical patch making, and – the focus of this article – paper making. The systems must be capable of high-speeds that can be adjusted by the right controls and drives as determined by the specific web process.

2. "Decreasing the Cost of Control" is a case study written by Javier Gutierrez, Senior Product Manager for Control Design and Simulation at National Instruments. Decreasing the number of variables to be controlled streamlines the process and saves money. The author explains that this can be done through several ways. Employed successfully at Tyco Electronics, advanced process control (APC) eliminates the expense of decoupling controls because it can, with one controller, control a number of variables simultaneously. At Iggesund Workington Mill, imaging technology allows operators to see a current formation image of paperboard to assist in determining accurate measurements when standard sensors cannot. These and more are discussed in detail with helpful diagrams.

3. "Distillery Retains Tradition, but Upgrades Control System" was authored by Ken Keiser, PCS7 Migration Manager, Siemens Industry. This case study describes the migration, at the Four Roses bourbon-making plant, to a new distributed control system that works with the older, but perfectly-working controllers, input/output system, and field wiring. The author explains how this was done and the several important benefits of the upgrade.

GRID POWER

"Selling Energy Efficiency in the Industrial Sector," by John Nicol of SAIC, provides a utility manager’s perspective of marketing utility energy efficiency programs to the industrial sector. The author suggests that managers focus on core processes, such as motors, HVAC, and lighting, and emphasizes the need for those who market energy efficiency programs to be knowledgeable about industrial processes in order to understand their needs, concerns, and motivations. This article appeared in the May 2011 issue of PowerGrid International.

HVAC/R (HEATING, VENTILATION, AIR CONDITIONING, AND REFRIGERATION)

"Ventilation Leads Kerry's Recipe for Success" provides a case study of the HVAC system developed for the LEED-certified and Energy Star-designated Kerry Center in Wisconsin. The challenging three-building complex includes offices, manufacturing facilities, and research labs. This article was written by Rick Hombsch, PE, and Kevin Pope, PE, of HGA Architects and Engineers, and was published in the May 2011 issue of Engineered Systems.

NEWS

ISO 50001 energy management standard now available from ANSI

ISO 50001, a voluntary international energy management standard designed to help business, organizations, and industries voluntarily manage their energy performance, is now available for purchase from the American National Standards Institute (ANSI). To learn more, read the June 15, 2011, news release from the U.S. Council for Energy Efficient Manufacturing, visit the ANSI eStandards Store, or visit the ISO 50001 web page at DOE EERE.

FMA president’s take on the state of green manufacturing

"Green Manufacturing Practices in America Can Help Profits, Will Help Planet" is a well-researched editorial press release by Gerald Shankel, president and CEO of the Fabricators & Manufacturers Association (FMA). Citing statistics and research study results from various sources, the article presents an overview of the state of energy efficient and environmentally sound practices in the U.S. manufacturing sector. A description of the public, corporate, and private drivers behind the accelerating adoption of green manufacturing practices is included, as well as a variety of examples of energy efficiency and waste reduction initiatives in major U.S. manufacturing facilities.

POLICY AND LEGISLATION

DOE recognizes and supports ISO 50001 Energy Management Standard

The U.S. Department of Energy (DOE) is in the process of building a support structure for the international energy management standard ISO 50001, published on June 15, 2011 and available from the American National Standards Institute (ANSI). Tools, training, and other resources related to the new standard will be provided through DOE EERE. For information, see the ISO 50001 web page at DOE EERE.

RESOURCES

Carbon Trust advocates for industrial energy efficiency in the UK

The Carbon Trust is a non-profit company, initiated by the UK government, which helps businesses and industries in the UK reduce their energy use and cut carbon emissions. Henrietta Stock of the Carbon Trust provides targeted assistance specifically to industrial clients. In a 20 minute video presentation of her talk at the Carbon Leaders Summit, Stock describes her work with UK industries, providing specific examples of how she helped an animal feed milling company, an asphalt production company, and a plastics molding facility save energy and reduce their carbon footprint.

GRANTS AND FUNDING

DOE announces funds for Industrial Assessment Centers

On June 16, 2011, Steven Chu announced that over $30 million will be made available to train undergraduate and graduate level engineering students to conduct energy assessments in industrial manufacturing efficiency. The training will be provided through university Industrial Assessment Centers, and will pay for 20 to 30 centers nationwide to train 10 to 15 students each. As part of their training, the students will gain hands-on experience performing assessments, follow-up, tracking, implementation, and management coaching for local manufacturing plants. For more information, read the press release.

DOE to support solar rooftops project for industrial buildings

The U.S. Department of Energy (DOE) has offered a conditional loan of $1.4 billion for the construction of solar panels on the rooftops of industrial buildings across the U.S. managed by the company Prologis. The project, termed Project Amp, has a planned PV capacity almost equal the total amount of PV installed in the U.S. in 2010, and is expected to generate up to one million megawatt hours of electricity annually. For information, read the June 22, 2011, press release.

UPCOMING EVENTS AND TRAININGS

Pacific Northwest

Steam Systems Assessment Training
July 6, 2011, 7:30 AM - 4:30 PM
Port Angeles, Washington
The Steam System Assessment Training covers the operation of typical steam systems and discusses methods of system efficiency improvement. The one-day workshop is designed for end users – at the energy manager, steam system supervisor, engineer, and operations level – who have steam system responsibilities in industrial and institutional plants. The workshop is divided into three major categories: Steam Generation Efficiency, Resource Utilization Effectiveness, and Steam Distribution System Losses. For more information, contact Julie Nurse at nursej@energy.wsu.edu.

Steam Systems Assessment Training
July 20, 2011, 7:30 AM - 4:30 PM
Nampa, Idaho
The Steam System Assessment Training covers the operation of typical steam systems and discusses methods of system efficiency improvement. The one-day workshop is designed for end users – at the energy manager, steam system supervisor, engineer, and operations level – who have steam system responsibilities in industrial and institutional plants. The workshop is divided into three major categories: Steam Generation Efficiency, Resource Utilization Effectiveness, and Steam Distribution System Losses. For more information, contact Julie Nurse at nursej@energy.wsu.edu. This event is co-sponsored by the Idaho Office of Energy Resources, Bonneville Power Administration, the Northwest Energy Efficiency Alliance, the Northwest Food Processor's Association, the Washington State University Extension Energy Program, and the U.S. Department of Energy.

Advanced Management of Compressed Air Systems
July 12-13, 2011
Pocatello, Idaho
This advanced course in compressed air system management teaches you to develop a system profile and address point-of-use issues, including determining actual air quality requirements, investigating and reducing highest point-of-use pressure requirements, and addressing high-volume intermittent applications. In addition, you will learn how to implement a compressed air system maintenance program, determine different compressor control strategies, align the supply-side to demand-side operation, and gain an understanding of the value of heat recovery. Participants will also gain knowledge on how to successfully present project proposals to management.

Industrial Refrigeration Systems Energy Management
July 21, 2011, 7:30 AM-4:30 PM
Yakima, WA
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. Training will focus on technical basics, operation of refrigeration systems, energy efficiency potentials, and case studies of successful energy efficiency projects and imple mentation strategies. Participants will receive a copy of the Industrial Refrigeration Best Practices Guide, which serves as the course’s technical foundation and a roadmap for making industrial refrigeration systems both energy efficient and productive. 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. This training is coordinated by NEEA Industrial Training and sponsored by Pacific Power, Bonneville Power Administration, Washington State University Energy Program, and Northwest Food Processors Association.

Pump Systems Assessment
July 26, 2011
Butte, Montana
Learn more about pump system performance characteristics. This course discusses performance problems encountered in everyday applications. The workshop covers practical issues involved in field measurements of fluid and electrical data and presents the Pump System Assessment Tool (PSAT) used to assess the performance of pump systems. PSAT helps users assess energy savings opportunities in pumping systems, relying on field measurements of flow rate, head, and either motor power or current to perform the assessment. Learn how: 1)The software functions, 2) What data is required, 3) How to use the software when measured data is not available, and 4) What the assessment results mean. This training is offered through a collaboration of Montana Manufacturing Extension Center, Montana Department of Environmental Quality, & Northwest Industrial Partnerships. Meeting space hosted by NorthWestern Energy.

Green Motor Practices for Electric Motors
July 27, 2011
Portland, OR
Attendees will learn how to estimate operating costs for electric motor systems and to identify improvements in motor management practice to increase system reliability and reduce operating costs. Topics include: calculating motor operating costs, continuous motor driven system improvement, a guide to motor operating characteristics, where to get the best motor rewinds and a model repair specification for ensuring quality repair. The presentation format includes interactive group discussions, some fun, and many new innovative practical motor driven system ideas you will use. This course is sponsored by Energy Trust of Oregon, Pacific Power, Portland General Electric, Clark Public Utilities, Bonneville Power Administration, Washington State University Energy Program, and Northwest Food Processors Association.

Other Events, Trainings, and Webinars

Tuesday Webcast for Industry: A Discussion of New ITP Tools and Resources for Industry
July 12, 2011, 11:00 AM – 12:00 PM PST
ITP offers a collection of free software tools to help you identify and analyze energy system savings opportunities in your plant or industrial facility. This Webcast will focus on the variety of new tools and resources for its industrial stakeholders. Craig Cheney of Project Performance Corporation will discuss the updated energy management kit, and the forthcoming ITP/BTP tool suite. The Webcast will also focus on how industry is using ITP’s tools and resources to conduct energy assessments, implement projects, and communicate the importance of energy efficiency in industry.

Webinar: Fundamentals of Pumping System Assessments
August 4, 2011, 11:00 AM – 12:00 PM PST
This free, one hour webinar provides an overview of new ASME EA-2-2009 Standard, which sets the requirements for conducting and reporting the results of pumping system assessments. This webinar is offered by the Hydraulic Institute and Pump Systems Matters.

Tuesday Webcast for Industry: Establishing and Maintaining a Strategic Partnership with the Chief Financial Officer
August 9, 2011, 11:00 AM – 12:00 PM PST
This Webcast will focus on establishing and maintaining a strategic partnership with your company’s CFO. This will include how to build a business case for energy efficiency in corporate sustainability investment plans and how to establish your energy program’s credibility. Neal Elliot, Associate Director for Research of the American Council for an Energy-Efficient Economy, will discuss your ‘pitch’, being transparent in your approach, demonstrating your project’s expected return on investment, and the business impact of sustainability and your energy projects.

Steam Systems Management
August 24, 2011
Downey, California
This 1-day course covers the operation of typical steam systems and discusses methods of system efficiency improvement. The training helps industrial and institutional plant personnel—energy managers, steam system supervisors, engineers, and equipment operators—identify opportunities to improve steam system performance.

Energy Efficiency in Motor-Driven Systems (EEMODS) ‘11
September 12-14, 2011
Alexandra, Virginia
This event provides a forum for discussion of many motor management topics including: developments in motor and system efficiency, energy management, and how to define system efficiency. EEMODS participants include a wide variety of industry stakeholders involved in manufacturing, marketing, and promotion of energy efficient motors and motor-driven systems.

Steam End User Training – E-Learning
Self-paced online workshop
This course covers the operation of typical steam systems and discusses methods of system efficiency improvement. A brief demonstration of the BestPractices Steam System Tool Suite software is highlighted to help identify and quantify savings from selected potential improvement examples. The training is designed for plant personnel, such as energy managers, steam system supervisors, engineers, and equipment operators, who have steam system responsibilities in industrial and institutional plants.

Steam Systems E-Learning
Self-paced online workshop
This training course will provide an overview of the BestPractices Steam Tool Suite. The training course will begin with a navigational tutorial to guide you on how to move through the three modules. Each training module will demonstrate the capability of one tool and its interactions with the other tools. Interactive quizzes will be used to test your basic understanding of the tools after you complete the course.

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.


Past issues available here