bmj journals media pack 2011 - bmj publishing group

Report to the OREGON PROCESSED VEGETABLE COMMISSION Project: Energy audits to identify opportunities for processed vegetable growers to save electricity, fuel, and fertilizer Prepared: December 21, 2009 Principal Investigator: Joe Junker, Director, OSU Energy/Efficiency Center Assistant Director, OSU Industrial Assessment Center 344B Batcheller Hall, Corvallis, Oregon, USA 97331-2405 Voice: 541/737-5034 Fax: 541/737-5035 Email: [email protected] Project Summary: This project got off to a late start. The Energy Efficiency Center (EEC) did not receive notice that this project was funded until this fall. A University Index for the project was set up November 6th. It was unfortunate that the opportunity to work on the project through summer growing season and greatest center staff availability was missed, but the team has taken the opportunity to focus more on audit tool preparation. With a fall start, the team decided the best strategy would be to begin by preparing an instrument for use in performing efficiency assessments of processed vegetable growing operations. The goal: to develop a comprehensive list of likely efficiency opportunities that might be found in the processed vegetable growing sector, along with templates for analyzing and presenting opportunities. As it is prepared, this content is being put on line for use by EEC staff as well as the general public. It can be found at: http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Sectors/Processed_Vegetables Some of the content that has been developed is included at the end of this report. Plans going forward: With a continuation of this project the EEC plans to

• Continue assessment tool development • Meet with stakeholders to review the tool and solicit feedback on refinements • Perform 1-2 assessments of appropriate operations.

Financial Information: Total granted amount: $9,933.00 Spent to date (12/21/2009): $4,099.25 Attached: Example assessment instrument content (in development)

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(This section is under development

with support from the Oregon

Processed Vegetable Commision.)

This guide serves as an aid for assessing energy efficiency at

farms growing vegetables.

Industry Primer

Vegetable growers, as the name implies, are part of an

agricultural industry that focuses on the growing and

harvesting of vegetables. The grower's harvest or output can be

Sent to processors who might either freeze, can, or dehydrate the vegetables or use

them as an ingrediant in another product

Sold to a distributor

Marketed directly to resturants and local markets and/or at farm stands and farmer's

markets

Common Opportunities

Following is a list of common energy efficiency opportunities found at vegetable growing

operations including background information and tools to make simple and detailed

calculations of energy savings

System Opportunity & Background Information Analysis Tools

Fuel Storage Reduce Fuel Evaporation

Tractor Tractor Operation Tractor Operation.doc

Tractor Maintenance

Soil

AmendmentsGPS Application Control

People MoversUse Less Fuel Intensive People Movers (Gator

Style, Electric, Bicycles)

Electric People

Movers.doc

Irrigation Improve Pump Efficiency

Reduce Line Losses

Low-flow Irrigation Low Pressure

Irrigation.doc

Irrigate Only as Needed (Moisture Sensing)

Refrigeration Improve Refrigeration Efficiency

Improve Refrigeration Insulation

Greenhouses Greenhouse InsulationGreenhouse

Insulation.doc

Section off Idle Space

Heater Efficiency

Ventilation Control

Buildings Furnace Efficiency Boiler Tune.doc

Wall Insulation

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Vegetable Growers - Energy Efficiency Reference http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Sectors/Processed...

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Attic Insulation Attic Insulation.doc

Efficient Windows

Lighting Lighting Efficiency

Lights Off

Electric

GenerationSolar Generation

Wind Generation

Oregon Vegetable Growers

In Oregon, the major processed vegetable crops are green beans, carrots, broccoli,

cauliflower, sweet corn, and table beans. The principal finished products are frozen, canned,

and microwavable mixed vegetables. The Oregon Processed Vegetable Commission includes

eight growers and three processors. The commission provides funds to farmers for product-

oriented projects and hosts an annual meeting for growers at the end of January.

Production of canned vegetables has dropped significantly. Global competition has become a

major issue for Oregon vegetable processors. As a result of this competition, the price of green

beans has fallen sharply from $89 to $110/ton in 2001. Fewer than 10 percent of vegetables

are exported because of a lack of marketing strategies and contacts.

Additional Information

Following are additional resources regarding energy efficiency in the vegetable growing sector.

Websites Reports

Oregon Processed Vegetable Comission "Energy Usage in the Food Industry",

ACEEE

"Understanding the Oregon Fruit

& Vegetable Industry", OPVC

Retrieved from "http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Sectors

/Processed_Vegetables"

Vegetable Growers - Energy Efficiency Reference http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Sectors/Processed...

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Fuel is a major cost on

modern farms, especially

with the continually rising fuel prices. Therefore it is important to find ways to conserve fuel

and reduce associated operating costs. This page provides a number of measures that will

reduce fuel consumption and costs. This page also contains tools to help estimate the amount

savings that may be available.

Tractor Operation

Tractors play a important role in most modern farms,

and are used for a wide variety operations and

procedures. Operators can obtain a number of

speeds by adjusting the transmission gear ratio while

maintaining the same engine RPM. Within each gear

ratio there is further adjustment available with the

governor setting lever (or the idler lever if the

tractor doesn't have a governor). In most cases

tractor field speeds are determined by the implement

and not by the tractor power available. Most

operators run tractors at full throttle using the

transmission gear ratio to vary speed. Significant

increases in fuel efficiency are expected if the

governor speed is reduced and a faster gear ratio is

selected. This is particularly true in cases where the tractor and equipment are not properly

matched and the tractor is operating at less than half load.

Listed below are some useful measures on how to increase fuel efficiency while reducing

associated fuel costs.

The engine speed should be reduced as far as possible while staying in its designed

power range. Check the operators manual to find the engines power range. Generally,

it is save to reduce engine speed by a maximum of 30 percent without getting out of the

power range. Operating a tractor outside side of its designed power range will only

decrease fuel efficiency and increase fuel consumption.

It is important to not overload or lug the tractor. Lugging the tractor causes the engine

to generate more torque at low engine speeds then it was designed for. This can result

in engine overheating and in some extreme cases, engine failure. Key indicators to

overloading is excessive black smoke, or the tractor is sluggish in response when

throttled up to full throttle. The tractor should accelerate quickly when throttled up, if it

doesn't, the engine RPMs should be increased until the engine becomes responsive to

quick throttle change.

Only reduce throttle during non PTO operations unless the tractor is equipped with a

variable speed PTO that can keep its speed with reduced engine RPMs.

To help you easily determine the amount of savings that may be available to your agricultural

operation, we have developed a energy estimator tool located below. Results may not

represent your actual savings but should give a fairly accurate rough estimate. We

recommend you consult a specialist before implementing any actions recommended above to

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Conserving Fuel - Energy Efficiency Reference http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Energy_Efficiency/...

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confirm your savings.

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Horsepower of Tractor : hp

Hours of Operation : hrs/yr

Fuel Cost : $/gal

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Estimated Fuel Savings : 0 gallons

Estimated Annual Savings : 0 dollars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractor Governor Estimator

Calculate Clear

Gadgets powered by Google

For more details refer to the following sample recommendation. It includes a more in depth

approach as well as actual savings and cost calculations. Adobe Acrobat Reader is required to

view these files. You can download the program for free.

Tractor Operation AR (KB)

Listed below are some useful links and documents with more information.

Gear Up and Throttle Down -- Saving Fuel

Gear-up and Throttle Down to Save Fuel

Farmers Can Save Big Money On Fuel

Farm Power and Machinery Management

Tractor Maintenance

Tractors are a key component to most agricultural

operations, yet when it comes to maintaining them,

they are often neglected. This can lead to premature

wear on critical engine components and shorten

there useful life. This can also lead to significant

loses in fuel efficiency particularly on older tractors.

Tractors should be maintained as specified in there

operators manual to get the most out of them. This

will help increase there useful life and fuel efficiency

while decreasing the number of costly breakdowns

that occur during the operating season. This will also

increase the power output while minimizing the

amount of harmful exhaust emissions released into

the atmosphere.

Listed below are some measures that will increase fuel efficiency and keep tractors in top

condition while reducing associated fuel costs.

Check tire pressure weekly - Under inflated tires can not only prematurely wear tires

giving them a shorter life but can also decrease fuel efficiency by 3 percent. Over

inflated tires can cause excessive slip decreasing fuel efficiency by 3 percent. Check tire

pressures weekly as pressure can change when exposed to work intensive tasks. Check

your operators manual for correct inflation pressures.

Check and replace oil and fuel filters seasonally - Clogged or dirty filters can not

only harm the engine but also decrease fuel efficiency by up to 5 percent. Replace filters

as recommended by operators manual.

Check and clean air filters weekly and replace as needed - In some extreme

cases, a dirty air filter can decrease fuel efficiency by up to 20 percent. Check, clean


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and change air filters as recommended by operators manual.

Check ballast weight on implement change - Properly ballast the tractor to reduce

slip, power hop and weight. Excessive weight can increase fuel consumption so it is

important to reduce weight as much possible while still maintaining good traction,

balance and handling characteristics. Tire slippage should be kept to a minimum,

between 5 an 15 percent for work intensive tasks is usually good. Check operators

manual for more details.

Check thermostat is properly functioning - Engines are most efficient when

operating with a water temperature between 165 and 180 degrees F. Fuel efficiency can

decrease by 25 percent when operating at 100 degrees F. Make sure tractors

thermostats are operating correctly and not over or under cooling the engine.

Use engine block heaters before operation - Using engine block heaters that are set

on timers to preheat the engine a couple hours before use can reduce wear on key

engine components. Most engine wear happens on start up when the engine and fluids

are cold. By heating the engine prior to start up, this wear can be avoided extending the

useful life of the engine and keeping failures to minimum.

Check spark plugs - On gas models a fouled spark plug can decrease fuel efficiency

between 10 and 15 percent. It is important to check all plugs regularly for a strong

spark.

Check proper fitting fuel caps - Improper fitting fuel caps can leak fuel. Make sure

the fuel cap is properly tightened after every fill up and replace any broken or worn

seals.

Avoid excessive road use - Excessive road use can prematurely wear tires giving

them a shorter life. Worn tires also get significantly less traction reducing fuel efficiency.

Use correct size tractor for implement - Using an over sized tractor for the

implement can reduce fuel efficiency. If the tractor can be significantly throttled down

while still performing the task it is a good sign that it is over sized and a smaller tractor

should be used.

Upgrade to more efficient models when replacing tractor - When buying a new

tractor it is best to buy an efficient one even if it cost slightly more. The increase in

efficiency will quickly pay for itself.

Avoid quick starts - Engines need to warm up to operating temperatures before

worked excessively to reduce the wear on the engine. This is because the engine oil

needs to be warmed up and circulated throughout the engine to give proper lubrication.

Quick starts don't give the engine enough time to do this causing excessive wear.

Have wheels aligned and balanced - Properly aligned and balanced tires decrease

the overall rolling resistance of the tractor increasing fuel efficiency. Check your

operators manual for more details.







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Horsepower of Tractor : hp


Fuel Cost : $/gal

Check Tire Pressure Weekly : No

Replace Oil/Fuel Filters Seasonally : No

Clean Air Filters Weekly : No

Adjust Ballasting to Implement : No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Tractor Maintenance Schedule Estimator

Calculate Clear





Tractor Maintenance AR (KB)


Let The Air Out! Advantages of Properly Adjusted Radial Tire Pressures

Proper Tractor Setup Can Increase Fuel Efficiency

Conserving Fuel on the Farm

Saving Fuel On The Farm

Saving Fuel In Field Operations

Fuel Storage

Storage tanks are often taken for granted and are

assumed to have no loses, which is simply not true.

And with toady's continually rising fuels costs it has

become more important than ever to pay close

attention to your facilities storage tanks. Storage

tanks can lose a considerable amount of fuel due to

evaporation and unnoticed leaks. In extreme cases

up to 40 percent of a tank’s capacity can be lost per

year through evaporation in above ground tanks

while many leaks continue to go unnoticed in

underground tanks. This is not only wasteful and

costly but also harmful to the surrounding

environment. It is important to recognize that these

problems don't have to occur and that they can be

easily fixed.

Listed below are some measures that will keep storage tank loses to a minimum, reducing

associated fuel costs.

Reflective surface finish - Fuel in tanks slowly evaporates to atmosphere when

exposed to higher temperatures. Darker colors absorb more light/heat then lighter

colors which reflect light/heat. Using aluminum finish or white tanks can significantly

decrease the heat absorbed by the tank lowering its internal temperature. This will help


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reduce the amount of fuel that vaporizes to atmosphere saving fuel.

Protective covering - Tanks should be kept out of direct sunlight to reduce the amount

of fuel that vaporizes. Either burying the tank or putting a protective roof over the tank

can solve this although burying the tank is not recommended because leaks can go

unnoticed increasing fuel lost.

Pressure relief cap - Most older fuel tanks simply vent to atmosphere through a small

vertical pipe. Installing vacuum pressure relief caps on the vents can reduce the amount

of fuel vapors released from the tank while still allowing air to flow into the tank.

Lock unattended fuel tanks - Fuel tanks tanks should be kept locked at all times. It is

not uncommon for workers or neighbors to fill up if tanks are left unlocked.

Regularly inspect tanks - During inspections tighten all fittings and check for leaks and

properly functioning valves. It is important to keep leaks to a minimum to help protect

the environment and your wallet.

Install motion sensor lighting - Sometimes a simple motion sensing light directed at

the tank is enough to deter thief's from trying to steal fuel. It is a simple and effective

way to deter unwanted guests.

Clearly label farm diesel tanks - Labeling tanks "Red Diesel" can further deter thief's

and prevent on farm mix ups. Putting farm diesel in highway vehicles is illegal and can

result in a large fine.






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Fuel Tank Size : gallons

Fuel Cost : $/gal

Type of Finish : Red

Tank Location : Uncovered

Pressure-Relief Cap : No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Fuel Tank Estimator

Calculate Clear





Fuel Storage AR (KB)


Conserving Fuel on the Farm

Retrieved from "http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Energy_Efficiency

/Conserving_Fuel"


5 of 6 12/21/2009 3:17 PM

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Irrigation accounts for a

substantial portion of a

typical farmers electric bills. Therefore it is important to find ways to conserve water and

reduce associated operating costs. This page provides a number of measures that will

increases irrigation efficiencies and reduce associated operating costs. This page also contains

tools to help estimate the amount savings that may be available.

VSD Irrigation Pump

Most irrigation pumps run at full speed no matter the

load on the system. This is very inefficient

particularly when a wide range of flows rates and

pressures are needed through out the season. A

more energy efficient system uses a variable speed

drive (VSD) to slow the motor speed to match the

end use requirements. This will maintain the same

pressure while reducing the flow rate and energy

consumption of the pump. A VSD will also allow

pumps to "soft start", by slowly ramping up the

motor instead of trying to do so instantaneously. This

will ensure the peak demand is never more than the

motors full load operating amps, reducing associated

demand costs. This will also reduce motor wear and

damage caused by hard starting as well as maintenance cost associated with water

surge/hammer and sprinkler head damage.

Listed below are some situations when a VSD controlled irrigation system will be cost effective.

Pumping systems implementing bypass or throttling control valves.

Pumping systems that draw from a well with a depth that varies significantly.

Pivot and linear systems that have a end gun that turns on and off at varying locations in

the field.

Pivot and linear systems located on terrain that has elevation changes.

Pumps that service multiple systems that may not all be on at once.






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Efficient Irrigation - Energy Efficiency Reference http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Energy_Efficiency/E...

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Horsepower of Motor : hp


Energy Cost : $/kWh

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Estimated Energy Savings : 0 kWh


VSD Irrigation Pump Estimator

Calculate Clear





VSD Irrigation Pump AR (KB)


Farmer Finds Efficiency in Drive-Driven Irrigation

Irrigation Energy Efficiency Analysis

Energy Saving Tips for Irrigators

Low Pressure Irrigation

Most irrigation systems utilize a high pressure

sprinkler system to deliver water to the field. These

system typically operate from 70 - 100 psi. This is a

very inefficient method for delivering water to a field.

A more energy efficient system uses low pressure

drop down nozzles that require less pressure to

operate at the same flow rate as conventional

sprinklers. These low pressure systems can operate

at pressures as low as 15 - 20 psi without a reduction

in flow rate. This puts less load on the pump, by

installing a variable speed drive (VSD), the pump is

then able to change how it operates depending on its

current load and pressure reducing energy

consumption.

Listed below are some useful tips on what types of low pressure irrigation system are most

cost effective.

Linear or center pivot irrigation systems are easily retrofitted to run at 15 psi and yield

very quick paybacks. The larger the system the more cost effective it will be.

Hand lines can be converted to semi low pressure (35 psi and sometimes lower) but are

not as cost effective because it reduces the flow rate thus increasing pumping time.

Moving guns can be retrofitted to a moving boom system and can be very cost effective

but will suffer from increased size thus limited mobility and increased chance of operator

caused damage.





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Horsepower of Pump : hp


System Pressure : psi

Energy Cost : $/kWh

Demand Rate : $/kW

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Estimated Demand Savings : 0 kW


Low Pressure Irrigation Estimator

Calculate Clear





Low Pressure Irrigation AR (KB)


Farmer Finds Efficiency in Drive-Driven Irrigation

Irrigation Energy Efficiency Analysis


Irrigation Scheduling

Over irrigation wastes water, energy and labor while

also increasing soil erosion, washing away valuable

nutrients thus reducing crop yields. These nutrients

then have to be replaced in the form of fertilizer

increasing fertilizer costs. Under irrigation stresses

the plant and soil and also causes a reduction in

yield. As a general rule of thumb, irrigation should

begin when soil water content drops below 70

percent. By using moisture sensing devices, flow

rate meters, and tracking the amount of water

applied these problems can be avoided increasing

yield while keeping water and electricity usage to

minimum. On average a farm using irrigation

scheduling will consume 15 to 35 percent less water

than a farm not using it, decreasing pump run times and loads.







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Horsepower of Motor : hp


Energy Cost : $/kWh

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Irrigation Scheduling Estimator

Calculate Clear





Irrigation Scheduling AR (KB)


Irrigation Scheduling to Improve Water - And Energy-Use Efficiencies

Soil Moisture Monitoring: Low-Cost Tools and Methods

Measuring and Conserving Irrigation Water


Irrigation Scheduling

Irrigation Systems

Irrigation accounts for approximately 30 percent of a

farms overall electricity usage. Following the

following tips can help reduce your water

consumption, electricity costs and labor while

improving crop yields and reliability.

Premium Efficiency Motors - When buying

new pumps buy Premium Efficiency (PE), if an

old motor needs rewinding then it may be

economically feasible to buy a new PE motor.

PE motors are between 2 and 10 percent more

efficient than standard efficiency motors.

Test Pumps Efficiency - Testing pumps

efficiency every two to three years can help

make sure that pumps are performing properly and that no significant losses are

occurring. Pumps can feasibly reach efficiencies as high as 70 percent, following are the

recommended actions for given efficiencies.

Efficiencies Above 60% - No action is necessary although efficiency may be

improved by adjusting impeller clearances.

Efficiencies Between 50% and 60% - Adjusting the impeller to housing

clearance is recommend as efficiency may increase by 10-15%

Efficiencies Between 50% and 55% - Damage to the impeller is likely and

repair is recommended as efficiency may increase by 20%

Efficiencies Below 50% - Replacement is recommended in most cases, it may

be caused by a improperly sized motor for the application, consider resizing

components for optimum efficiency.

Pipes - Using the right size pipe for the desired flow rate can significantly reduce energy


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consumption. Using 6 inch mainlines can consume 4 times as much energy as 8 inch

mainlines in some cases. When expanding or replacing your systems pipeline we

recommend consulting a professional to help analyze which sizes may be most cost

effective.

System Setup - Using proper diffusers, fitting, meters, and valves can significantly

increase your overall system efficiency. We recommend looking at the following ATTRA

publications on irrigation energy savings.


Maintaining Irrigation Pumps, Motors, and Engines

Retrieved from "http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Energy_Efficiency

/Efficient_Irrigation"


5 of 5 12/21/2009 3:18 PM

AR No. # Tractor Operation

Recommendation We recommend throttling tractors down while selecting a higher gear ratio during field operations. This will maintain the same speed while increasing fuel efficiency and reducing fuel costs.

Assessment Recommendation Summary Diesel Energy Cost Implementation Payback

(Gallons) (MMBtu)* Savings Cost (years) 1233.4 172.7 $3,071 $0 Immediate

* 1 Gallon Diesel = 0.14 MMbtu. 1,000,000 Btu = 1 MMbtu Background Tractors play an important role in most modern farms, and are used for a wide variety operations and procedures. Operators can obtain a number of speeds by adjusting the transmission gear ratio while maintaining the same engine RPM. Within each gear ratio there is further adjustment available with the governor setting lever (or the idler lever if the tractor doesn't have a governor). In most cases tractor field speeds are determined by the implement and not by the tractor power available. Most operators run tractors at full throttle using the transmission gear ratio to vary speed. Significant increases in fuel efficiency are expected if the governor speed is reduced and a faster gear ratio is selected. This is particularly true in cases where the tractor and equipment are not properly matched and the tractor is operating at less than half load. Engine RPM should not be reduced so far that the tractor is out of its power range. Check your operator’s manual to find the engine’s power range. Generally, it is safe to reduce engine speed by a maximum of 30% without getting out of the power range. Operating a tractor outside of its power range will only decrease fuel efficiency. Proposal During field operations, throttle down your tractors while selecting a higher gear ratio. This will increase fuel efficiency while still maintaining the same speed. It will save an estimated 1,233 gallons of diesel a year, with a cost savings of $3,071. Since it is simply a change in operations there is no implementation cost and therefore an immediate payback.

Courtesy of www.pegtopfarm.co.uk

Tractor Inventory

Tractor Model hp (HP ) hr/yr (OH )

Fuel Savings (Eq.1)

(gallons)

Energy Savings (Eq.2)

(MMBtu)

Cost Savings (Eq.3)

(dollars)

New Holland TC45 45 250 115.9 16.2 288.5New Holland TS110 110 500 566.5 79.3 1,410.6New Holland 4630 55 250 141.6 19.8 352.6New Holland 5640 66 250 170.0 23.8 423.2John Deere 5093E 93 250 239.5 33.5 596.3Total 1,233.4 172.7 $3,071.23

Fuel Costs EquationsDiesel Cost (DC ) $2.49 $/gal Eq. 1) Fuel Savings (F s )

AssumptionsDiesel Consumption Factor (CF 1 ) 0.0515 gal/hp/hr

Throttle Reduction (TR ) 20%Fuel Use Reduction (FR ) 20% Eq. 2) Energy Savings (E s )Diesel/MMBtu Conversion Factor (CF 2 ) 0.14 MMBtu/gal

Energy Saving ResultsTotal Fuel Savings 1,233 gal lons

Total Energy Savings 172.7 MMBtu Eq. 3) Cost Savings (C s )

Economic ResultsTotal Cost Savings $3,071Implementation Costs $0Payback 0.0 years

Tractor Operation

AR No. # Electric People Movers

Recommendation When needed, replace the current on-farm vehicle with an electric vehicle (EV). Due to the increased energy efficiency of electric vehicles, this will reduce your energy use by the equivalent of 506 gallons of gasoline per year.

Assessment Recommendation Summary Energy Cost Implementation Payback

(MMBtu) Savings Cost (years) 64.8 $945 $0 Immediate

Background There are many unknowns and differences in maintenance for electric and gas vehicles, so we make a simplified assumption that purchase costs are equal and over the life of the vehicle the maintenance costs will be too. We therefore make the comparison between a gas vehicle’s fuel cost per mile and an electric vehicle’s fuel cost per mile, along with the annual cost of batteries for the electric vehicle. EV technology is still developing and isn’t appropriate for all applications. We’re used to thinking of a vehicle, like a gas pickup truck, that could move farm personnel to and from the farm on surface streets at high speeds as well as cruise around the farm at low speeds with a load of equipment. EVs would not be able to completely replace the pickup truck because it is not permitted on a section of road where the posted speed limit is above 45 mph. EVs could however replace the pickup truck’s on-farm activities—which are the most inefficient miles of a gas vehicle. Our calculations are based on an exclusively on-farm vehicle and mileage estimates provided by plant personnel of 15,000 miles per year. Proposal When the current on-farm vehicle needs to be replaced, we recommend replacing it with an electric vehicle, saving 54.8 MMBtu per year. Annual cost savings is $945 with no implementation cost and an immediate payback.

Courtesy of www.greencarsite.co.uk

Data Collected EquationsMiles per Gallon of Gas Vehicle (G) 25.0 mpg Eq. 1) Gas Vehicle Fuel Cost (GV)

Cost of Gasoline (Gc) $3.00 /gal

On‐Farm Mileage (FM) 15,000mi/yr

Incremental Energy Data Eq. 2) Electric Vehicle Fuel Cost (EV)

Incremental Energy Cost (Ec) $0.0750 $/kWh

AssumptionsBattery Cost per Year (Bc) $480 Eq. 3) Cost Savings (CS)

Miles per kWh of Electric Vehicle (K) 3.0 mi/kWh

Energy Savings SummaryGas Vehicle Fuel Cost per Mile (GV) 0.12$ $/mi (Eq. 1)

Electric Vehicle Fuel Cost per Mile (EV) 0.025$ $/mi (Eq. 2)

Implementation Costs SummaryImplementation Cost (IC) $0 (Rf. 1)

Economic ResultsCost Savings (CS) $945 (Eq. 3)

Implementation Costs (IC) $0Payback (PB) 0.0 yrs

Electric People Movers

Rf. 1) There is no implementation cost because we recommend that when a current on‐farm gas vehicle needs to be replaced, you buy an electric vehicle.

AR No. # Low Pressure Irrigation

Recommendation Convert your current irrigation system to a low pressure system. This will allow the system to operate at a lower pressure which is more efficient than the current method, and could reduce total pump operating costs by 46%.

Assessment Recommendation Summary Energy Cost Implementation Payback (kWh) Savings Cost (years) 55,950 $4,812 $1,250 0.3

Background Most irrigation systems utilize a high pressure sprinkler system to deliver water to a field. A more energy efficient system uses low pressure nozzles that require less pressure to operate at the same flow rate as conventional sprinklers. These low pressure systems can operate as low as 30 psi without a reduction in flow rate. Energy savings will occur because the Variable Frequency Drive (VFD), that will also be installed, will slow down the pump motor to maintain a lower pressure. As flow will remain the same at a reduced pressure, required pump energy will drop linearly with the required pressure. Proposal Replace your current irrigation system with a low pressure system with a VFD. This will save 55,950 kWh and $4,812 annually. There is an implementation cost of $1,250 with a payback of 0.3 years.

Courtesy of www.fas.org

Data Collected EquationsCurrent Pressure (CP) 90 psi Eq. 1) Proposed Pump Speed Percentage (FS)

Pump Horsepower (HP) 100 hp

Operating Hours (HS) 2,500 hrs/yr

Number of Sprinkler Heads (QU) 500Eq. 2) Loaded Pump Power (LP)

Incremental Energy DataIncremental Energy Cost (Ec) $0.086 $/kWh

Assumptions Eq. 3) Proposed Energy Consumption (PE)

Proposed Pressure (PP) 60 psi

Estimated Load Factor (LF) 0.9Horsepower to kW Conversion (CF) 0.746 kW/hp

Cost per Sprinkler Head (CU) $0.50 $/unit Eq. 4) Current Energy Consumption (CE)

Installation Time per Unit (IT) 0.1 hrs/unit

Cost of Labor (CL) $20 $/hr

Energy Savings Summary Eq. 5) Energy Savings (ES)

Proposed Pump Speed Percentage (FS) 67% (Eq. 1)

Loaded Pump Power (LP) 90 hp (Eq. 2)

Proposed Energy Consumption (PE) 111,900 kWh (Eq. 3)

Current Energy Consumption (CE) 167,850 kWh (Eq. 4) Eq. 6) Material Costs (MC )

Energy Savings (ES) 55,950 kWh (Eq. 5)

Implementation Costs Summary Eq. 7) Labor Costs (LC)Material Costs (MC) $250 (Eq. 6)

Labor Costs (LC) $1,000 (Eq. 7)

Eq. 8) Cost Savings (CS)

Economic ResultsCost Savings (CS) $4,812 (Eq. 8)

Implementation Costs (IC) $1,250 (Eq. 9) Eq. 9) Implementation Costs (IC)

Payback (PB) 0.3 yrs

Low Pressure Irrigation

AR No. # Greenhouse Insulation

Recommendation Install a thermal insulation system on your greenhouse to reduce heat loss during the night. In a greenhouse up to 85% of the heat loss occurs at night. These insulation systems can reduce heat loss by 30%.


(MMBtu) Savings Cost (years) 75.3 $1,045 $2,543 2.4

*1,000,000 Btu = 1 MMbtu Background A large majority of a facility’s energy costs go to greenhouses because they require additional heating during cooler months to maintain necessary conditions for research. When the temperature difference between the greenhouse and the outside air is the greatest, heat loss can be up to 85%. A thermal curtain insulating system can minimize heating costs by reducing the heat loss in the greenhouse. This is especially effective during nights and winter, and can save 30% of the energy lost. Proposal We recommend that you install a thermal curtain insulation system in your greenhouse to reduce heat loss during nights and winter months. This will result in a cost savings of $1,045 and 30% reduction in energy use for the greenhouse. There is an implementation cost of $2,543 resulting in a payback of 2.4 years.

Courtesy of the Virginia Cooperative Extension

Data Collected EquationsNatural Gas Usage of Greenhouse (U ) 251 MMBtu/yr Eq. 1) Energy Savings (ES)

Square Footage of Greenhouse (SF ) 1130 sq. ft.

Incremental Energy DataIncremental Natural Gas Cost (Ec ) $13.88 $/Mmbtu Eq. 2) Cost Savings (CS)

AssumptionsPercentage Reduction (PR ) 30% Eq. 3) Implementation Costs (IC)

Energy Savings SummaryEnergy Savings (ES ) 75.3 MMBtu (Eq. 1)

Implementation Costs SummaryCost of Insulation per sq. ft. (I ) $2.25 $/sq. ft.

Economic ResultsCost Savings (CS ) $1,045 (Eq. 2)

Implementation Costs (IC ) $2,543 (Eq. 3)

Payback (PB ) 2.4 yrs

Greenhouse Insulation

AR No. # Boiler Tune

Recommendation Tune your boiler to 4% excess oxygen so that it will run at a higher efficiency, resulting in an 8% reduction in energy use.


(MMBtu) Savings Cost (years) 835.3 $9,239 $350 0.04

* 1 MMBtu = 1,000,000 Btu Background When a boiler burns fuel, there is a certain amount of excess air that is not used in the combustion process that is then released into the stack and out to the atmosphere. This excess air is being heated, but is not being used by the boiler, which reduces the efficiency of the boiler. We performed a combustion analysis on your boiler and found your boiler to be operating at 9.5% excess air. Ideally, boilers such as yours should operate close to 4% excess air. We also found the combustion efficiency of the boiler to be 73.9%. By having your boiler tuned to 4% excess air, the efficiency of the boiler will increase to 80.8% and save 835 MMBtu annually. By finding the current and proposed efficiencies of the boiler, with the annual energy output of the boiler, we found the annual energy savings and the annual cost savings. Proposal We recommend that you have a boiler specialist tune your boiler to produce 4% excess air to increase combustion efficiency. The annual savings will be $9,239 with an implementation cost of $350. The savings will pay for the implementation cost in 0.04 years. See the following page for more detailed calculations.

Source: www.parkerboiler.com

Data Collected EquationsStack Temperature 537.0 °F Eq. 1) Annual Boiler Output (U )

Room Temperature 63.7 °F

Excess Air 9.5 %

Current Boiler Efficiency (η c ) 73.9 % Eq. 2) Annual Energy Savings (E S )

Incremental Energy DataIncremental Natural Gas Cost (E C ) $11.06 $/MMBtu

Eq. 3) Cost Savings (CS )

AssumptionsAnnual Operating Hours (O ) 2,920 hrs/yr

Boiler Rating (H ) 3.35 MMbtu/hr Eq. 4) Implementation Costs (IC )

Energy Savings SummaryProposed Boiler Efficiency (η p ) 80.8 % (Rf. 1)

Annual Boiler Output (U ) 9,782.0 MMBtu (Eq. 1) ReferencesAnnual Energy Savings (E S ) 835.3 MMbtu (Eq. 2)

Implementation Costs SummaryNumber of Boilers to Tune(B ) 1Labor Cost per Boiler (L ) $350

Economic ResultsCost Savings (CS ) $9,239 (Eq. 3)

Implementation Costs (IC ) $350 (Eq. 4)

Payback (PB ) 0.04 yrs

Boiler Tune

Rf. 1) This was calculated using SteamMaster. The table can be found in Appendix __

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