michael r. muller usa rutgers university, center for advanced energy systems

Program Name or Ancillary Text eere.energy.gov

Software Tools andInformation Resources

Software Tools andInformation Resources

Michael R. MullerUSARutgers University, Center for Advanced

Energy Systems

U.S.- Brazil Industrial Energy Efficiency WorkshopRio de Janeiro , BrazilAugust, 2011

2 | Industrial Energy Efficiency eere.energy.gov

• Lois Horowitz, author of “Knowing Where to Look: The Ultimate Guide to Research”

“Not having the information you need when you need it leaves you wanting. Not knowing where to look for that information leaves you powerless. In a society where information is king, none of us can afford that.”

Information


Where to Obtain Software Tools and Information

• PURCHASE commercial tools– Not our focus today

• FIND free publicly available tools– There are plenty and more every day

• DEVELOP tools – great for local knowledge

Energy Software Tools


• Developing an energy management plan• Identifying good projects

– Initial Ideas

– Quantifying Energy/Cost Savings– Implementation Cost Estimating

• Administrative Hurdles– Permitting and other paperwork– Knowing rebates and tax incentives

• Design/Build– ensuring value– ensuring performance

Categories

Today’s Focus


Energy Management


• EnergyStar– Well known brand

• Spreadsheet based• Not quantitative

Energy Management - EPA


• Several new standards have recently appeared• Recognizing that many good projects don’t get done

– An energy management plan can increase activity

• Talked about elsewhere at this workshop

Energy Management Standards

The Management System for Energy (ANSI/MSE 2000-2008)


• New focus from USDOE –Supported the development of ISO 50001

• USDOE is moving one step beyond ISO 50001 by supporting the development of Superior Energy Performance (SEP) certification…and Global Superior Energy Performance (GSEP)

• USDOE is developing an energy management tool suite to support ISO 50001 and SEP activities by industry.

• USDOE has existing technical tools for identifying energy savings opportunities in energy-intensive systems.

Energy Management - USDOE


Under Development Currently Available

Overall Energy Management Toolkit Structure

3


• Will consist of:– Corporate, Facility and Project analysis tools (also source of metrics)– Full and Lite versions of Self-Paced Module (LEADER Company, non-

LEADER Company)– System area tools, calculators and scorecards (simple, expert)

• User will be able to access resources:– Systematically, self-paced– Individually (go straight to tools they want to use)

• Site index will be provided– Example- User will be able to access simple calculators individually via the

system area pages or view and all at once via the site index– Example- User will able to access all analysis tools via the self-paced

process or individually via the site index– Example- Recommendations Portfolio, Project Prioritization Tool, and

Project Tracker Tool will be available as part of the facility-plant-corporate analysis tools and also as the “Implementation Portfolio”

Energy Management Toolkit

4


• First steps are to understand the energy use by the plant– It is surprising how many plants don’t have a good picture

• Great tool from DOE – a “plant energy profiler”

Beyond Planning

Old Management Adage:

You can’t control what you don’t measure


Quick Plant Energy ProfilerQuickPEP

• Web-based plant energy profiling

and evaluation tool• The profile includes:

o Plant energy and resources usage and costso Production types and levelso Maintenance procedures

• Identifies potential energy saving opportunities for further investigation

• More detailed analyses can be conducted with the system tools

• Future upgrades to include multiple languages


QuickPEP Tool Website


Plant Energy Profiler (QuickPEP 2.0)

Energy-Carbon Footprint and Energy Baseline

Calculators


QuickPEP Tool Results

Identify Energy Savings

Opportunities By System

Establish Baselines

Help/References

QuickPEP ToolQuickPEP Tool

SSST/SSATSSST/SSAT

PHASTPHAST

NXEATNXEAT

MotorMaster+ MotorMaster+

AirMaster+AirMaster+

PSAT PSAT

3E+3E+

CHP ToolCHP Tool

FSAT FSAT

CWSAT CWSAT


OUTPUTS• Overall picture of

energy use and efficiency

• End-use breakout• Potential areas for

energy efficiency improvement

• Overall energy use reduction potential

INPUTS• Description• Utility bill data• System information

• IT• Cooling• Power• On-site gen

Specialized Case

Data Center Profiler (DC Pro)


Generating Ideas


• Provides two easy tools

IAC Program

iac.rutgers.edu/database


Top Ten Lists


ARC Manual is an “Idea List”


• The DOE provides an extensive set of industrial assessment software tools

• These tools are both high quality and fully supported• The latest versions are always available online• Primary Tool Categories

– Plant-wide– Steam– Process Heating– Motor-Driven– Data Centers

DOE ITP Software Tools


Energy Use and Potential Energy Savings

Potential Energy Saving Opportunities

Typical Energy Consumption Rates

* Other ancillary energy usages such as lighting represent less than 2% of energy consumption

Process Heating/ Steam Systems

60 – 80%

Electric MotorSystems

8-15%Pumping Systems

7-15%CompressedAir Systems

2-7%Other*< 2%

10% to 30% 5% to 10% 10% to 20% 10% to 20% 5% to 10%



DOE ITP Software Tools and Resources can be found athttp://www.eere.energy.gov/industry/


• Developed and supported by energy assessment experts• Designed to meet the specific needs of an industrial energy

assessment• Used to identify energy savings opportunities across the

United States• Well documented with manuals and case studies• DOE provides training in tool use• Continually developed and improved• Free to the public • Available in English and Metric Units,

and different currencies


Notes


Plant-wide• Industrial Facilities Tool Suite • Quick Plant Energy

Profiler/Integrated Tool Suite (QuickPEP)

Process Heating• Combined Heat and Power

(CHP) Application Tool • NOx and Energy Assessment

Tool (NxEAT) • Process Heating and Survey

Assessment Tool (PHAST)

Data Centers• DC Pro Software Tool Suite

Steam• Steam System Scoping Tool

(SSST)• Steam System Assessment Tool

(SSAT)• 3E Plus

Motor-Driven• AirMaster+ • Fan System Assessment Tool • MotorMaster+ • MotorMaster+ International • Chilled Water System Analysis

Tool (CWSAT)• Pumping System Assessment

Tool (PSAT)



• Quick PEP Helps plants assess plant-wide operation to identify savings and efficiency opportunities.

• PHAST Helps assess energy use in furnaces and identifies ways to improve performance.

• SSAT Assists in assessing potential benefits for specific steam-system improvements.

• CHP Application Tool Enables users to evaluate the feasibility of CHP for heating systems.

• 3EPlus Insulation Tool Calculates most economical thickness of insulation for various operating conditions.

• NxEAT Assesses NOx emissions and applications of energy efficiency improvements at petroleum refiningand chemical plants.

Motor Master+ International Aids in energy-efficient motor selection and management.

PSAT Assesses efficiency of pumping system operations and quantifies benefits of system optimization.

Air Master+ & LogTool Provides comprehensive information on assessing compressed air systems.

FSAT Assesses efficiency of fan system operations and quantifies benefits of system optimization.

CWSAT Determines chilled water system energy requirements and evaluates energy and costs savings opportunities.



• Time does not permit us to give details about all the tools– Look at 2

• Steam• MotorMaster+

• Compressed air and process heating are discussed in other presentations



Steam System Tool Suite

Steam Tools are bundled into the Steam System Tool Suite (SSTS)

• These tools include:o Steam System Scoping Toolo Steam System Assessment Toolo 3E Plus – An insulation energy

savings calculator


Steam System Scoping Tool

• Quickly evaluates overall qualityof steam system operation

• Consists of 26 qualitative questions based on all major components of a steam system

• The questions are separated into these primary areas:o Steam System Profileo Steam System Operating Practiceso Boiler Plant Operating Practiceso Steam Distribution, End Use, Recovery Practices

• The score is out 340 points and also given as a %


Sample Page

Steam System Scoping Tool


Steam System Assessment Tool• Steam system modeling software• Common energy recovery projects

can be added into an alternate model• This allows “what if” evaluations based

on the addition or removal of various projects

Steam system model requires the balancing of:

• Mass• Energy• Economic

- based on fuel and water costs

Steam System Assessment Tool


• Major Equipment Simulated:– Boiler– Back pressure turbines– Condensing turbine– Deaerator– Steam traps, leaks, insulation losses– Letdowns– Flash vessels– Feedwater preheat exchangers

• Choice of 1, 2, or 3 header pressure models• Schematics of model steam systems• Estimates of site environmental emissions




• Modifications can be simulated on an alternate model generated from the original

• Savings estimates can be determined for individual and combinations of the various energy projects

• The “Results Summary” page details the cost and energy usage of both the original and alternate models


• Provides simple tabulated information for heat loss (or gain) and surface temperatures

• Provides simple tabulated information for energy costs and savings

• Can provide an Economic Insulation Thickness for a particular application

3E Plus: Insulation Energy Savings Calculator


Motor-Driven Equipment Tools

Pumping System Assessment Tool (PSAT)

AirMaster+ & LogTool (Compressed Air Systems)

Fan System Assessment Tool (FSAT)

Motor System Management Tool (MotorMaster+)

Chilled Water System Assessment Tool (CWSAT)


MotorMaster+ International

MotorMaster+ International has multi-language capability (with the current release supporting Spanish, French and English)

Assists in the development of a decision based motor management plan.


• The current version of the software contains manufacturer’s databases for over 25,000 NEMA motors and over 7,200 IEC motors.

• Full- and part-load efficiency values

• Technical data to help optimize drive systems, (power factor, full-load speed, etc.)

• Motor purchasing information, including list prices and motor weights

Includes Important Motor Data


• Analysis includes selection of the “best available” motor for a given application giving:– energy savings, – demand reductions, – dollar savings, – GHG emission reductions, – simple payback, – cash flows,– ROI

New Motor Selection


• Motors don’t live forever• Since motors are involved in the

process, the fastest way to get them back into service is rewinding– This reduces efficiency!

• MotorMaster+ helps plants decide which motors can tolerate rewinding or which need to be replaced

• Plants should then stock backup motors for critical systems

Repair or Replace?


• Software tool results are only as good as the tool and the data input.

• Tools should be used in support of engineering analysis, not as a replacement.

• Using a software tool without understanding how it works (using a “Black Box” recommendation”) increases risk

• Misuse and user-error are always possible– Common sense and “sniff” tests of results are

needed

A Necessary Caution

Um Novo Dia!!!


Michael R MullerCenter for Advanced Energy Systems (CAES)Rutgers, The State University Of New Jersey73 Brett RoadPiscataway, NJ 08854United States of America

phone: 732.445.5540fax: 732.445.0730

Contact Information

michael r. muller usa rutgers university, center for advanced energy systems

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