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Industrial Newsbriefs

September 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

Technical Engineering Assistance

Industrial Plants in Washington State may qualify for technical and project support, including onsite assistance through the Washington State University Extension Energy Program. Experienced engineers and energy specialists can help identify and analyze energy efficiency and renewable energy projects (i.e. costs/savings), and provide technical assistance on process system and equipment efficiency. To learn more about how your plant can reduce energy consumption to help positively affect your bottom line, contact Christine Love at 360-956-2172 or epis@energy.wsu.edu, or visit the Washington State University Extension Energy Program Industrial Services Program web page.

Boilers

Boiler Systems Engineering is a section of articles in the June 2011 issue of HPAC Engineering; a strong emphasis on increasing energy efficiencies runs through the following selection of five articles:

1. "Navigating an Energy Audit," by Steve Connor, Cleaver-Brooks, distinguishes between two kinds of energy audits, the simple system audit and the complete facility audit. How they are conducted, their costs, and how long they can be expected to take are all covered.

2. "Optimizing Efficiency with Multiboiler Systems" was authored by Larry J. Ashton, Raypak, HPAC Engineering. With several boilers onsite, only some will be needed most of the time. The rest can remain unfired until needed.

3. "Modulating Fan-Powered Economizers," by Steen Hagensen, Enervex Inc., shows how these economizers are superior to traditional economizers. Both types are described and compared; performance tables for each are included.

4. "The Quest for Maximum Boiler-System Efficiency," by Ron Rajecki, Senior Editor, is a discussion of the newer boiler technologies and control systems for water flow.

Biomass

2011 U.S. Billion-Ton Update: Biomass Supply for a Bioenergy and Bioproducts Industry was released on August 10, 2011, by the U.S. Department of Energy (DOE). This report examines the nation’s capacity to produce a billion tons of biomass resources for energy uses without impacting other vital U.S. farm and forest products, such as food, feed, and fiber crops. The study provides industry, policymakers, and the agricultural community with county-level data and includes analyses of current U.S. feedstock capacity and the potential for growth in crops and agricultural products for clean energy applications.

Compressed Air

Guidelines for analyzing compressed air energy consumption

"How to Analyze Energy Consumption of Compressed Air Systems," published August 23, 2011, in Sustainable Plant, provides clear step-by-step guidelines for analyzing the energy use of compressed air systems in industrial facilities. Guidelines for estimating leaks and determining system efficiency are provided, and links to further resources are included.

Data Centers/IT

Dennis Brandl, BR+L Consulting, has included the following related articles in his Engineering and IT Insight column for Control Engineering:

1. "Future Is Virtual for Manufacturing IT" was published in April 2011. It is a discussion on how one actual IT server can be made to function as several and how virtual IT servers will impact the systems used in manufacturing plants including those, like controllers, that run manufacturing operations.

2. "Virtualize Manufacturing IT," published in May 2011, shows how virtualized servers need not be located near the shop floor and how they contribute to the financial and operational health of a manufacturing plant.

3. "Virtualize Now, Send the Message to Your Vendors" was published in June 2011 and describes how effective virtualized machines can be in simplifying the process of patch installation. Snapshots of the entire IT system can be used in either of two ways, depending upon whether system downtime is or is not acceptable.

LEED-Platinum data center opens at GE

GE Appliances & Lighting recently opened a data center in Louisville, Kentucky which achieved the highest Platinum level of LEED certification. The certification was achieved by using highly efficient compact servers, an advanced cooling system, low-flow water fixtures, and use of local, recycled, and reclaimed materials. Read more in "GE Unveils Platinum LEED-Certified Data Center," published August 24, 2011, in Sustainable Plant.

Energy Management

A metaphoric take on plant energy management

In "Face Energy Challenges Like a Frontiersman," published August 23, 2011, in Sustainable Plant, Christopher Russel explains how energy management can be approached with one of two attitudes: that of a hunter or that of a farmer. While the farmer observes, keeps records, and strategizes for the long term, the hunter ventures out to find targeted opportunities to meet specific goals. On the frontier of the modern industrial plant, both approaches are needed to achieve and maintain optimal efficiency.

Utilities

Efficiency measures and CHP instead of new power plants

How to Avoid a Train Wreck: Replacing Old Coal Plants with Energy Efficiency is a white paper published by ACEEE in August 2011. The paper outlines how investments in energy efficiency, waste heat recovery, and combined heat and power (CHP) can help utilities to comply with new environmental regulations and increased utility demand, thus avoiding costly upgrades or new power plant construction to replace ageing coal-fired plants.

News

25inTENsity Challenge launched by NEEA

On August 17, 2011, the Northwest Energy Efficiency Alliance (NEEA) announced the launch of a regional initiative, developed by NEAA and regional utilities, to encourage and assist industries to save energy by working toward a unified energy efficiency goal: to reduce energy intensity by 25 percent within 10 years. The 25inTENsity Challenge will provide mentoring, facilitation, and guidance for participating industrial groups and organizations.

ACEE recognizes energy efficiency champions

On July 28, 2011, the American Council for an Energy Efficient Economy (ACEEE) announced four recipients of its annual Champions of Energy Efficiency in Industry award. The award recognizes leadership and accomplishment in industrial energy efficiency programs, policies and initiatives. Among the recipients is the Northwest Energy Efficiency Alliance (NEEA), recognized for forming strong alliances with industrial groups in the Pacific Northwest.

EPA implements mandatory greenhouse gas reporting

On August 22, 2011, large industrial facilities began mandatory greenhouse gas reporting of 2010 emissions via the electronic greenhouse gas reporting tool (e-GGRT). The data collected will be made available to the public by the end of 2011. To learn more, read the EPA press release.

Resources

Industrial Facility Energy Efficiency—Worth a Second Look, published in August 2011 by the Alliance to Save Energy (ASE), discusses opportunities for industrial facilities to increase energy efficiency with code and beyond-code programs such as ASHRAE and LEED. Strategies to increase the efficiency of industrial HVAC, lighting, appliances, and other facility-related applications using these programs are presented and discussed.

Unlock Energy Savings with Waste Heat Recovery is a fact sheet/guidance document published in July 2011 by DOE EERE Industrial Technologies Program. This document provides an overview of waste heat recovery for industrial applications, including the identification of opportunities for use, a process for benefit realization, and a plethora of links to further resources, tools, and studies.

Grants and Funding

National Science Foundation Materials Processing and Manufacturing (MPM)
PD 10-1467
Proposals due: October 1, 2011

The MPM program supports fundamental research on the interrelationship of materials processing, structure, performance and process control. Analytical, experimental, and numerical studies are supported covering processing methods such as molding, forging, casting, welding, hydroforming, composite layup, and other materials processing approaches. Emphasis is placed on environmentally benign manufacturing and virtual manufacturing. Research leading to the development of novel processes and novel hybrid processing techniques to achieve net shape products and complex multi-scale, multi-functional products with superior quality and performance is also supported.

National Science Foundation Manufacturing Enterprise Systems (MES)
PD 10-1786
Proposal window: September 1 – October 1, 2011

The MES program supports research on design, planning, and control of operations in manufacturing enterprises. Research is supported that impacts the analytical and computational techniques relevant to extended enterprise operations and that offer the prospect of implementable solutions. Topics of interest include analytical and computational tools for planning, monitoring, control, and scheduling of manufacturing and distribution operations, and development of methods for optimization of manufacturing enterprises in the presence of a high degree of uncertainty and risk.

Innovative Manufacturing Initiative
DE-FOA-0000560
Proposals due: October 5, 2011

The purpose of this Funding Opportunity Announcement is to solicit applications for funding cost-shared research and development of innovative manufacturing processes and materials technologies to advance the clean energy economy by increasing industrial and manufacturing energy efficiency, deliver the breakthroughs that the nation needs to significantly reduce energy and carbon intensity throughout the economy over the coming decades, and revitalize existing manufacturing industries and support the development of new products in emerging industries.

UPCOMING EVENTS AND TRAININGS

Pacific Northwest

Field Measurements for Industrial Pump Systems
October 5-6, 2011 (register by September 21)
Jerome, Idaho
Registration fee: $199

This course focuses on the measurements that are required for any pumping system performance assessment – flow rate, pressure, and electrical data. Common measurement methods and devices are discussed. A host of application issues associated with test devices are emphasized. Other issues covered include: time coordination of measurements, known sources of error and their potential impact, estimating parameters that can't be measured, and conducting hands-on measurements and converting the measured data.

Adjustable Speed Drive Applications and Energy Efficiency
October 18, 2011 (register by October 4)
Tacoma, Washington
Registration Fee: $139

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 as well as discovering and mitigating harmful electromagnetic interference that can cause motor failure. Additional information on evaluating and specifying VFDs is provided.

Energy Data Analysis: Introduction to KPIs
October 20 (register by October 6)
Eugene, Oregon
Registration Fee: $139

Gain the basic tools that every company needs to manage energy as a controllable cost. Understand energy management as a systematic approach to monitor, control, and conserve energy, and learn how energy management is integral to reducing operating costs. You will leave this training with information that will help you effectively implement an energy management system at your company.

Adjustable Speed Drive Applications and Energy Efficiency
October 27, 2011 (Register by October 27)
Hermiston, Oregon
Registration Fee: $139

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. Additional information on evaluating and specifying VFDs is provided.

Energy Management: Introduction to Best Practices
November 30, 2011 (Register by November 16)
Vancouver, Washington
Registration Fee: $139

Gain the basic tools that every company needs to manage energy as a controllable cost. Understand energy management as a systematic approach to monitor, control, and conserve energy, and learn how energy management is integral to reducing operating costs. You will leave this training with tools and resources that will help you effectively implement an energy management system at your company. This training includes practical exercises and in-class discussion.

PGE Series: Motors and Motor Controls
Wednesdays, Sept. 21 – Nov. 2, 2011, 6:00 – 9:00 PM
Tualatin, Oregon

This seven-week course focuses on how to optimize industrial and commercial system reliability using your motors and motor drive systems. This course will equip participants to better understand the principles of motor fundamentals, improve motor drive systems efficiency, enhance system reliability, and identify system energy savings opportunities.

Efficiency Connections Northwest
November 2 – 3, 2011
Tacoma, Washington

Efficiency Connections Northwest provides an opportunity for participants to tap into the collective knowledge of the efficiency community as national experts join regional innovators to share their success stories. Efficiency Connections Northwest was developed by and for regional utility professionals at both public- and investor-owned utilities and is brought to you by NEEA.

Other Events, Trainings, and Webinars

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.

GHG Permitting Requirements for CHP Systems
September 15, 2011, 11:30-1:00 PST

The requirements of the "Prevention of Significant Deterioration and Title V Greenhouse Gas Tailoring Rule" became effective January 2, 2011. The rule sets thresholds for greenhouse gas (GHG) emissions that define when permits under the New Source Review Prevention of Significant Deterioration (PSD) and Title V Operating Permit programs are required for new and existing industrial facilities. The requirements have elicited considerable interest among CHP system operators and project developers.

Tuesday Webcast for Industry: Securing Financial Incentives for Energy Efficiency Projects: How to Create Corporate Support
September 13, 2011, 11:00-12:00 PM PST

Securing financial incentives for energy efficiency projects is often times a critical barrier to implementation. This makes it increasingly important for corporate energy manager’s to develop strategies that establish energy as a pillar of corporate sustainability principles and generate corporate support for energy efficiency. Walt Brockway, Manager of Global Energy Efficiency for Alcoa, will discuss principles of corporate sustainability and how to creatively overcome common barriers that energy projects face from corporate leadership. The webcast will also discuss how to build a business case for investing energy, justify project payback periods, demonstrate expected ROI, and overcome 'principal-agent’ issues.

Return on Investment – Mechanical Insulation Assessment: A Montana Case Study
September 19, 2011, 10:30 AM -12:00 PM PST

The National Association of State Facilities Administrators (NASFA), the State of Montana and the National Insulation Association (NIA) would like to invite you to a webinar on how the energy efficiency value of the missing or damaged mechanical insulation in your facilities can be qualified and quantified, and actions implemented within a short time horizon, and provide a substantial return on investment. Topics to be discussed include: a review of the State of Montana Case Study, an overview of the state’s assessment program, utilization of ARRA or other funds, and implementation methodology.

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