energy saving opportunities in water & wastewater infrastructure

B O N N E V I L L E P O W E R A D M I N I S T R A T I O N

Energy / Facilities Connections 2011

May 12, 2011

Layne McWilliams

Water/Wastewater Sector Specialist

Energy Smart Industrial

Energy Saving Opportunities in

Water & Wastewater

Infrastructure


Roadmap

• The ESI Program

– Why do conservation incentive programs exist?

– What’s in it for me and why should I care?

– Ok, now that I care, how do I proceed?

• Getting Started & Energy Audits

• Typical Savings Opportunities

– Hint: It’s not just VFD’s . . .


Why does conservation matter?

• Water/Wastewater sourcing, treatment, distribution,

collection, conveyance, treatment, and disposal

accounts for about 3% of the nation’s energy

consumption.

• BPA capacity is becoming constrained, and

conservation is the lowest cost resource.

• ―Tiered‖ rate structures start FY2012– so local utilities

(BPA’s customers) want to keep their base allocation

open to keep rates low, attract new customers, and

allow for growth.


Why should you care?

• Your electric rates are going to go up. (Have they ever gone down?)

• Electrical costs associated with pumping and treatment is often the

highest non-labor cost for a municipality– and one of the few costs

that can be reduced without impacting water quality.

• The lifetime costs of most equipment is incredibly dependent on its

efficiency.

• Systems are designed for 20 year predicted flows and built by low

bid project delivery methods.

– Chances are you’re running at less than best efficient point on much of

your equipment.

– Often that means equipment is working harder than it needs to.

• The SRF grants and loans have ―green‖ requirements now, and

energy projects qualify.


What’s in it for you?

• Depending on utility, up to 25 cents per kWh saved based on first year’s energy consumption.

– This is about $1600 per horsepower on a 24/7 basis.

• So, if we can take an aeration system pulling on average 45 hp down to 35 hp, there is a potential incentive of roughly $16,000 available.

– The incentive is capped at 70% of the project cost.

• Assistance from the program with identifying opportunities, handling paperwork and approvals, post-project M&V, and shepherding projects.


There’s More!

But wait . . .


• Ongoing energy savings for life of the measure.

• Often reduced maintenance cost from turning off or

turning down equipment.

• Aesthetic and comfort improvements – e.g. better

lighting, better HVAC.

• Conservation: The gift that keeps on giving!

You’ll also get:


How do I get started?

• Do you buy electricity from a ―public‖ or an ―investor

owned‖ utility?

– If an IOU, call them and ask to talk with a conservation

specialist.

– If it’s a public utility, they are probably in the program, so ...

• Call or email me, and I can get the process started.

– [email protected]

– 971-244-8581

• Or call your local utility representative and let them

know you are interested.

mailto:[email protected]


ESI Utilities Within WashingtonWASHINGTON (WEST)

Blaine, City of

Centralia City Light

Clallam County PUD

Clark Public Utilities

Cowlitz County PUD

Eatonville, Town of

Grays Harbor PUD

Klickitat PUD

Lakeview Light & Power

Lewis County PUD

Mason County PUD #1

Mason County PUD #3

McCleary, City of

Orcas Power & Light Cooperative

Pacific County PUD #2

Peninsula Light

Port Angeles, City of

Seattle City Light

Skamania County PUD #1

Snohomish County PUD

Sumas, City of

Tacoma Power

Tanner Electric Coop

Wahkiakum PUD

Whatcom County PUD #1

WASHINGTON (EAST)

Asotin County PUD

Benton PUD

Benton REA

Big Bend Electric Coop

City of Cheney Light & Public Works

City of Chewelah Electric Dept.

Columbia REA

Consolidated Irrigation District

Coulee Dam, Town of

Ellensburg, City of

Ferry County PUD #1

Franklin PUD

Grant County PUD

Inland Power & Light

Kittitas County PUD

Modern Electric Water Co.

Nespelem Valley Electric Cooperative

Okanogan Co PUD #1

Pend Oreille County PUD

Richland, City of

Vera Water & Power District


Energy Management - Pilot

Energy Project

Manager (EPM)

Addresses

End User

Staffing

Track and Tune

(T&T)

Addresses

O&M

Savings

High

Performance

Energy Mngt.

(HPEM)

Addresses

Corporate

Management

And Culture

Trade Ally Driven

Small

Industrial

(SI)

Addresses

Small

Projects

NW Trade

Ally Network

(NW TAN)

Addresses

Lighting

Projects

Technical Service Proposal (TSP) ConsultantsProvides Technical Consulting

Energy Smart Industrial Partner (ESIP)Face of the program

Custom

Projects

Traditional

Capital

Projects

Energy Smart Industrial Program Components

Green

Motors

Initiative

Motor

Rewinds


Custom Projects

• Pumps

• Fans

• Compressed Air

• Refrigeration

• Lighting

• Motors

• Variable Frequency Drives

• Control Upgrades

• Process Upgrades

- Incentives for traditional capital projects.


-Depending upon utility, but up to $0.25 per kWh saved

in first year.

-Capped at 70% of project cost

-You get the lesser of 25 cents / kWh OR 70% of

project cost.

-Project cost can include design fees, and can be

incremental cost between ―baseline‖ and ―efficient‖

equipment for new construction

-Paid based on Measured and Verified (M&V) savings.

-The payment comes after the project is complete,

so capital funds still needed upfront to cover the

project.



Energy Project

Manager (EPM)

Addresses

End User

Staffing

Track and Tune

(T&T)

Addresses

O&M

Savings

High

Performance

Energy Mngt.

(HPEM)

Addresses

Corporate

Management

And Culture

Trade Ally Driven

Small

Industrial

(SI)

Addresses

Small

Projects

NW Trade

Ally Network

(NW TAN)

Addresses

Lighting

Projects



Custom

Projects

Traditional

Capital

Projects


Green

Motors

Initiative

Motor

Rewinds


What is Small Industrial?

• Addresses small industrial projects

– Independent of facility or sub-system size

• Utilizes simplified analysis tools

– Ex. Compressed Air ≤ 75 hp

– Additional tools in development (refrigeration, VFDs)

• Rapid review and approval process

• Leverages trade allies

• Treated as custom projects for incentives

• No M&V is required

– There will be spot checks to fine-tune process



Energy Project

Manager (EPM)

Addresses

End User

Staffing

Track and Tune

(T&T)

Addresses

O&M

Savings

High

Performance

Energy Mngt.

(HPEM)

Addresses

Corporate

Management

And Culture

Trade Ally Driven

Small

Industrial

(SI)

Addresses

Small

Projects

NW Trade

Ally Network

(NW TAN)

Addresses

Lighting

Projects



Custom

Projects

Traditional

Capital

Projects


Green

Motors

Initiative

Motor

Rewinds


What is NW TAN?

• Existing TAN program currently provides high level

support to utilities and trade allies

• The goal of the KAMs is to increase the number and

magnitude of industrial lighting projects for BPA utility

customers

• Project specific support on industrial lighting projects

• Industrial lighting is often extremely low hanging fruit

with quick paybacks.



Energy Project

Manager (EPM)

Addresses

End User

Staffing

Track and Tune

(T&T)

Addresses

O&M

Savings

High

Performance

Energy Mngt.

(HPEM)

Addresses

Corporate

Management

And Culture

Trade Ally Driven

Small

Industrial

(SI)

Addresses

Small

Projects

NW Trade

Ally Network

(NW TAN)

Addresses

Lighting

Projects



Custom

Projects

Traditional

Capital

Projects


Green

Motors

Initiative

Motor

Rewinds


What is the Green Motors Initiative?

• Participating utilities are offering incentives for rewinds identified by Green Motors Practices Group members as process compliant—Thereby retaining original nominal efficiency values

• Standard NEMA ratings from 15 hp - 5,000 hp with no core damages are eligible

• Incentive amount of $1.00 per hp per motor will be credited instantly on the rewind invoice

• Go to www.greenmotors.org for list of shops

• Saves up to 40% (or more) of the cost of buying new motors

• Recycles 98% of motor materials

http://www.greenmotors.org/


Do you know the muffin man?


Where have I been?

• Do you know your local power and gas account rep?

• Your rep can provide a printout of historical usage and

associated charges.

– Is there a trend?

– Any ―step‖ changes – e.g. switching from chlorine disinfection

to UV . . .?


Where have I been?

• Other issues associated with billing:

– Who reviews and pays your monthly power bill?

– What percentage of your operating costs goes towards

energy?

– How much am I paying for demand vs. consumption?

– Where am I using energy?


Where have I been?

• Has your facility ever performed or received an energy

study or audit?

• Dust off those old energy studies.

– Similar or same equipment still in use? – Probably!

– Ideas that were good then are usually still good now.


• The Basics – Your Power Bill

– What rate are you paying?

– How is power measured?

– What is a ―demand charge‖ and how can I control it?

– What is ―power factor‖ and does it matter?

Where am I now?


Billing Terminology

• kWh = kilowatt hour = 1000 W for 1 hour (or 45 hp for 1

minute!)

– 1 hp = 0.746 kW; 10 hp motor consumes 7.5 kW at full load

– That means a 15 kW unit heater is like a 20 hp motor

• Demand Charge

– The highest 15 - 30 minute average operating load during the

billing month

– Utilities have to have capacity to provide that amount of power,

so it helps pay for the infrastructure.

– ―In-rush current‖ at motor start does not typically impact demand

charge.

• Power Factor

– Think of pulling a rail car.


Power Factor = Real Power / Apparent Power

- the closer this is to 1.0, the happier your utility will be . . .


Meter Reading


Where am I now?

• Benchmarks can be used for your ―Energy Dashboard‖


kWh

Peak kW x 24 x days in billing period X 100 Load Factor =

EPA

Portfolio

Manager

kWh / 1000

lbs. BOD

Removed

kWh /

Million

Gallons

Treated

Real Time

kW

Reading

Monthly kWh to date


Where am I now? - Benchmarking


Where am I now? - Benchmarking

• Some lessons learned:

– Benchmarks are great for tracking your facility’s performance

over time. They are of limited value in comparing your facility to

another.

– You will need to include the energy you produce on-site as well

as the energy you buy to obtain a true picture of your facility’s

efficiency.

– Complicated benchmarks can be useful simply as a tool that

forces you to gather data in a regimented manner.

– Benchmarks are powerful marketing and communication tools.

– Be Consistent! They are only useful if they are developed using

the same methods during each reading.


Where am I headed?

Audits can help you identify opportunities and focus

efforts.


Where am I headed?

Types of audits:

– Plant-wide scoping

• Typically, a walk-through where an energy specialist will look for and

identify common inefficiencies – essentially help tag the low-hanging

fruit.

• Often available without charge from your power company.

– System audit

• Often performed by specialist, e.g. air compressor or pump vendor.

• Focused on one portion of the plant, and will usually involve data

logging or other power monitoring over a period of time.

– Comprehensive audit / tune-up

• Can include workshop / teaching opportunities

• Generally identifies several O&M opportunities as well as capital

projects


You don’t need to wait for an audit, and you

can often find truly great opportunities because

of your knowledge of the plant!


Guidelines for finding conservation

opportunities

• Find loads that run continuously or nearly continuous

• Look at your electrical diagram and pick out big motors

• Look at equipment more than 10 years old

• Systems that are run on simple (or no) control

• Seasonal loading / permit changes


O&M Opportunities

• Four easy ideas for immediate O&M savings within your

facilities.

• Engage your O&M staff to help identify more

opportunities – e.g. scavenger hunts for inefficient

motors; awards & recognition for good ideas and

practices


O&M Opportunities

• #1: Reduce operating pressure and flow of plant wide

fluid and air systems.

– E.g. compressed air, reclaimed water, plant water systems

– On a +/- 100 psig air system, 2 psig reduction saves 1% in

energy costs

– Reclaimed water isn’t ―free‖!

– Lewiston, Idaho: Reduced plant water pressure from 106 psig

to around 60 psig, and performed an ―intentional analysis‖ of

where it was used.

– Will save about $6000 annually on power bill.


O&M Opportunities

• #2: Use your efficient equipment first and most often.

– ―Identical‖ equipment in a line-up isn’t identical in operation!

• Manufacturing tolerances

• Wear

• Installation differences

– You may have multiple resources available.

• Multiple wells

• Surface water vs. ground water

– Portland Water Bureau cut 6% from booster station

consumption.


O&M Opportunities

• #3: Optimize control set points.

– A 0.5 mg/L reduction in D.O. level represents 6 – 7% energy

savings

• 2.0 is nominal, many run lower than that.

• Running above 3 mg/L? Or 5? How about 8?!?!

– Lift station or other low-head pumps can benefit from small

adjustments in wet well level

• E.g.: RAS pump with 20 feet TDH at normal operating point

• Setting wet well ―pump on‖ elevation 6-inches higher reduces head

(and power requirements) by 2.5%


O&M Opportunities

• #4: Now that spring is finally here . . .

. . . SPRING CLEANING!– Sensors for temperature, dissolved oxygen, pH and water

chemistry, ambient and occupancy lighting sensors

– Filters on air, water, and hydraulic systems

– Diffusers, air knives, distribution nozzles – anyplace where the

flow is supposed to be ―distributed‖

– Large impact of small losses in low pressure systems

• Moving a 10 psig aeration system to 9.8 psig results in 1.8% energy

savings


A few capital project ideas to consider. . .


Project ideas

• Main idea:

– Pumping power equation:

• BHP (water hp) = (GPM * TDH’) / (3960 * pump eff.)

• Electrical hp = water hp / motor efficiency

– Similar equations for fans and blowers

– Power can be reduced by:

• Reduce flow rate

• Operate at lower differential pressure

• Higher efficiency equipment


Project ideas – cont.

• Match power (& flow) to load

– VFD’s in lieu of control valves

– VFD’s in lieu of dampers on odor control or foul air systems

– Install an additional, smaller pump in lieu of internal recycle

flows

• Use efficient equipment

– Swap out old motors rather than rebuilding

– If you are rewinding, utilize Green Motors program

– Check that your pump impellers are correct for actual conditions

– Use your most efficient equipment first and most often



• Reduce line pressure or pump lift

– Upsize sewer force main or water main size.

– Question: Why does the system pressure need to be XX psig?

• Identify specific demand locations and address them separately

• Run a lower pressure normally, and bump it up only when needed

– Compressed air systems generally present excellent

opportunities

– Most process pumps are fairly low head, so 2 or 3 feet of

pressure difference can be a good percentage of total head.



• A project doesn’t have to touch an electrical panel to be

an ―energy project‖

– Water conservation strategies

• Leak detection and repair programs

• Backwash / filter operational changes to reduce off-spec water

• Conservation rate structures(?)

– Wastewater reduction strategies

• Inflow / Infiltration reduction programs (?)

• Gray water reuse

• Industrial pretreatment (?)



• Eliminating electrical consumption completely

– Replace lift station with gravity sewer

– Situate the treatment plant to take advantage of gravity

• Using control valves to control gravity flow is a great use of control

valves, since it doesn’t cost anything for the head you’re burning

– Possible to select groundwater source points to reduce or

eliminate pumping energy?

• Or – Use electricity instead of gravity

– Use VFD’s in lieu of reservoirs to avoid pumping up the hill and

then burning that hard earned elevation through a PRV.


Nice ideas – but I want to know ………..

Does this stuff really work?


• 110 Refrigerated

Warehouses

• Building Tune Ups

• Energy Management

• Some Capital

Upgrades

• Some Efficient New

Construction

ESI Track and Tune Case Study – Sysco (first 44 months)

Total Distribution Center Energy Intensity

Jan

Feb Mar

Apr

May

Jun

Jul

Aug

Sep O

ctNov

Dec

kW

h/d

ay/1

000 f

t3

2005

2006

2007

2008

2009


ESI Track and Tune Case Study –

Example of Immediate Improvement at Single Site

Plantwide Impact of Commissioning: Before & After

400

500

600

700

800

900

1,000

1,100

1,200

10/05 10/10 10/15 10/20 10/25 10/30 11/04 11/09 11/14

Date

kW

Commissioning

Changes on 10/25


Making Efficiency Part of Your Operating Strategy

DOES Work!

•Lighting Project

•Facility Tune

• Actual facility history from a Corporate Energy Management client

• 44% savings(Dec 10 vs. Dec 07)

• Lighting Project Oct 2008

• Almost 2 times the projected savings from facility tune-up so far

• Implemented NOcapital projects after tune up


Whether you think you can, or think

you can’t, you’re right.

-Henry Ford

Thanks!

[email protected]

mailto:[email protected]

energy saving opportunities in water & wastewater infrastructure

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