The Industrial Facilities Quick PEP Test Excel File

Michael MacDonald

Background and How to Use

June 2008

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Intent

Scorecard in Quick PEP

Industrial Facilities

Quick-cut analysis of rough range of possible savings from buildings measures

Quick PEP Step 8Step 8 — Energy Savings Opportunities

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Download the Excel file:http://eber.ed.ornl.gov/indtest/

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Excel file simulates Quick PEP

Users of Quick PEP will handle data at different steps, e.g., energy use input

Score Cards are at Step 8 of Quick PEP

Calculations in Quick PEP will be invisible to users, but the Excel file is meant to allow testers to see what is happening

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Facilities Score Card test tool, ver 1.0b

This Score Card is being developed for implementation in Quick PEP, Step 8 ver test-1.0b 4/29/2008For info on Quick PEP, go to the Best Practices website, Software Tools, first item

This test tool is intended to add capabilities for a rough, quick assessment of energy used by buildings at a plant, and gives a quick assessment of energy measures that can be considered for further investigation.

Go to the "How-To" Sheet (next sheet) to read directions on how to use this test Score Card

Opening sheet of Excel file

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Second sheet is How-to

Quick PEP

Step 8 - Energy Savings Opportunities

Facilities Energy Score Card test version 1.0b

How to Use this test tool

STEP0 Go to the RESULTS sheet, Part 3, to see the example savings estimates

A Go to next sheet, PctFac, Part 1:1. Enter industry fraction(s) in column G,use "Other" if needed

The total in cell G33 should equal 100%2. If cell D16 is zero, then the value in cell D15 will be used in D193. If cell D16 is NOT zero, then the value in cell D16 will be used in D194. Only change values in G7:G31 or D16; do not change any other cells

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Step 0: Go to the RESULTS sheet, Part 3, to see the example savings estimates

Quick PEP Part 3

RESULTSFacilities Energy Score Card test version 1.0b

REVIEW these as necessary on other sheets>> DO NOT CHANGE THESE VALUES HERE <<

Estimated Percent of TOTAL Plant Energy that might be savedSAVINGS ESTIMATES = A/100 x C x D

Facilities Energy System percent Electricity Fuel/Steam

Envelopes 0.15% 0.50%

Lighting 2.84% 0.00%

Space Conditioning 1.11% 2.60%

Ventilation 0.00% 0.00%

Miscellaneous (incl hot water) 0.00% 0.42%

TOTAL 4.1% 3.5%Quick PEP users will enter total electricity use and fuel/steam use prior to using a Score CardThus, this test Score Card can only show percentages of the total energy to be entered

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Quick PEP Part 3

RESULTSFacilities Energy Score Card test version 1.0b

REVIEW these as necessary on other sheets>> DO NOT CHANGE THESE VALUES HERE <<

NAME of sheet to review ---> PctFacPERCENT of total plant site energy that is for facilties: 28.00% DNAME of sheet to review ---> Scorecard

A

Facilities Energy SystemScorecard

Score out of 100

Electricity Fuel/Steam Electricity Fuel/Steam

Envelopes 35 5% 17% 2% 5%

Lighting 56 30% 0% 18% 0%

Space Conditioning 26 30% 70% 15% 35%

Ventilation 0 20% 10% 6% 3%

Miscellaneous (incl hot water) 50 15% 3% 0% 3%

TOTAL 100% 100% 41% 46%

Estimated Percent of TOTAL Plant Energy that might be savedSAVINGS ESTIMATES = A/100 x C x D

Facilities Energy System percent Electricity Fuel/Steam

Envelopes 0.15% 0.50%

Lighting 2.84% 0.00%

Space Conditioning 1.11% 2.60%

Ventilation 0.00% 0.00%

Miscellaneous (incl hot water) 0.00% 0.42%

TOTAL 4.1% 3.5%Quick PEP users will enter total electricity use and fuel/steam use prior to using a Score CardThus, this test Score Card can only show percentages of the total energy to be entered

end-useB

End-Use Breakout of Facilities Energy

C

Maximum Pct Facilities Energy that can be saved

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Quick PEP Part 1

Percent Facilities Energy --------------->>>> # 1\/

Facilities Energy Score Card test version 1.0b SELECTIndustry Default Quick PEP Industry Facilities Energy

Facilities energy is only a fraction of total energy use Fractions Industry % of total that is facilities energyat industrial sites, sometimes small and sometimes large. 0 Ag, Forestry, Fishing 16%The defaults shown at the right are what Quick PEP assumes 0 Chemical 8%for specific industries, but you can set the actual percent here: 0 Aluminum / Alumina 3%

0 Cement 0%# 2 CHANGE the percent, item 'b' below if needed 0 Computers, Elec, Appl 40%

0 EAF Steel 8%Setting the percent of energy used by facilities 0 Fab Metal Prod 19%If you set a percent other than zero in 'b' it will be used instead: 0.3 Food, Bev, tobacco 15% a. Current default percent = 10.10% 0 Foundries 15% b. Percent to use instead = 28.00% 0 Furniture and related 16%

0.7 Glass and glass products 8%The percent value here will be used [do not change this ] 0 Heavy machinery 35% c. Percent that will be used = 28.00% 0 Integrated Steel 7%

0 Mining (except oil and gas) 0%0 Non-metallic mineral products 16%0 Oil and Gas extraction 16%0 Petroleum and Gas products 16%0 Petroleum Refining 8%0 Plastic and Rubber products 16%0 Primary Metals 16%0 Printing, Pub, allied 16%0 Textiles, Apparel, Leather Goods 22%0 Transportation equipment 29%0 Wood products, Pulp, Paper 7%0 Other 16%

100.00% Industry fractions should add to 100%.

Step A: Go to next sheet, PctFac, Part 1

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Energy Percents

Excel file simulates calculations using percentages

Percents cascade from total plant to end uses to ECM savings

Electric is separate from fuel/steam

Simplified single percent of total plant energy that is facilities-related

End-use breakout percents for electric and fuel/steam

Technical savings percents by end-use for electric and fuel/steam

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How-to Steps B-EB Go to the sheet after that, end-use, Part 2:

1. You may not need to change anything on this sheet2. If you need to change some values, change in the columns specified

The sums in row 20 should not be changedThe sums shown in row 20 should equal 100%

3. Only change values in B15:E19; do not change any other cells

C Go to the sheet after that, RESULTS, Part 3:1. Make sure cell D7 is the same as cell D19 in Sheet "PctFac"2. Make sure the values in rows 12-16 match the data in rows 15-19 in Sheet end-use

"end-use" columns B and C should match "RESULTS" columns C and D"end-use" columns F and G should match "RESULTS" columns E and F

3. Do not change any cells on this sheet

D Go to the "Scorecard" sheet, Part 4, Fill out or change the scorecard values according to your assessment of the plant or buildingThe assessment must cover the facilities included in the total energy data entered in Quick PEPDo not change any TOTALS on this sheet; only enter responses in column D

E Return to the RESULTS sheet, Part 3, to see the savings estimates

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Step B: Go to the sheet after that, end-use, Part 2: can modify yellow cells

Column 'B' Column 'C' Column 'D' Column 'E' Column 'F' Column 'G'

Electricity Fuel/Steam Electricity Fuel/Steam Electricity Fuel/Steam(%) (%) (%) (%) (%) (%)

Envelopes 5% 17% 30% 30% 2% 5%Lighting 30% 0% 60% 0% 18% 0%Space Conditioning 30% 70% 50% 50% 15% 35%Ventilation 20% 10% 30% 30% 6% 3%Miscellaneous 15% 3% 0% 100% 0% 3%

SUM 100% 100% 41% 46% The sum of columns B and C should be 100%

Percent of Facility energyMax percent savings

considered achievableMax percent Result for

Facilities Energy

Facility End-Use

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Columns B and C, Part 2

Columns B and C are simpler to understand

These percents are the estimated facility energy breakouts for electric and fuel/ steam

The total = 100%

Column 'B' Column 'C'

Electricity Fuel/Steam(%) (%)

Envelopes 5% 17%Lighting 30% 0%Space Conditioning 30% 70%Ventilation 20% 10%Miscellaneous 15% 3%

SUM 100% 100%

Percent of Facility energy

Facility End-Use

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Columns D and E, Part 2

Columns D and E need explanation

These percentages are the “technical maximum” potential savings for the particular end uses

E.g., when the envelope needs a lot of work, and the best possible set of envelope measures is installed, 30% of envelope-related electrical and steam might be saved

In the final Score Card, we need to think about how users might be able to change these directly

Column 'D' Column 'E'

Electricity Fuel/Steam(%) (%)

30% 30%60% 0%50% 50%30% 30%0% 100%

Max percent savings considered achievable

EnvelopesLightingSpace ConditioningVentilationMiscellaneous

Facility End-Use

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Desired Feedback 1

User suggestions are welcomed regarding appropriate end-use breakout data Regional values might be appropriate if you

can provide - estimate – develop

Suggestions on how to handle user specification of facilities energy is also welcomed (go to the Quick PEP web app, start a dummy case, and go to Step 7)

Suggested values or methods on handling maximum possible savings by end use are also welcomed

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Launch Quick PEP with dummy case

Go to website (see p 2 of this presentation)

Select Launch Quick PEP

Pass Step 1 by entering (dummy) Case Name and picking any industry besides “Other”

Click the Next button

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Select Step 7 at the top for facility

Step 7 provides default percent “process” breakouts

One “process” is Facility Energy Use

Users can enter the appropriate values for facilities energy percents here

One page for electricity and one for fuel /steam

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Back to the EXCEL file: Scorecard Questions, Part 4 Once all the

“percents” are acceptable, the Scorecard questions are answered (6th sheet in file)

Questions are asked for envelopes / infiltration, lighting / daylighting, space conditioning, ventilation, and misc hot water

Quick PEP Part 4

Scorecard QuestionsFacilities Energy Score Card test version 1.0b

YES = '1' for this sheet

enter percents as percents, not fractions

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Two sheets past Scorecard is Score Info, with more info about questions

Envelope / infiltration questions are E1 – E6

Similarly, lighting / daylighting, L1 – L6

L2 and L4 should not add up to more than 25% together

Space conditioning is HC1 – HC6

Ventilation is V1 – V6

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Score info indicates maximum scores for each question, total 100

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Building Envelopes / Infiltrationrequired YOUR YOUR MAX

response Response SCORE SCORE

E1

Enter percent of total building wall and roof/attic areas of all heated and/or cooled buildings that could have insulation (or additional insulation) added?

percent 50 25 50

E2Could large unsealed openings or broken windows in walls or roofs be sealed or repaired?

yes/no 0 20

E3Could other major air leakage paths in a significant fraction of buildings or facilities be sealed?

yes/no 0 10

E4Could large expanses of glass that are not needed be insulated?

yes/no 1 10 10

E5Could large loading dock building sections that do not have air sealing to limit air infiltration have air sealing installed?

yes/no 0 5

E6

In buildings with air conditioning, could large window or glazing sections that allow excessive solar heat to enter be covered or insulated?

yes/no 0 5

TOTAL 35.00

Building Envelopes / InfiltrationAll the responses below apply only to buildings or facilities that are heated and/or cooled.

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Lighting / Daylightingrequired YOUR YOUR MAX

response Response SCORE SCORE

L1

If a large amount of daylight is presently provided in most spaces, could electric lighting be dimmed in response if not already?

yes/no 0 15

L2What percent of total floor area is lit by older fluorescent (T12) or incandescent lighting that could be retrofit to T8?

percent 75 18.75 25

L3

What percent of total floor area has lighting left on all the time or most of the time when little or no activity is occurring? Or lights cannot be turned off due to lack of switching?

percent 75 37.5 50

L4

What percent of indoor lighting could be reduced by removing lamps? Or what percent could have task lighting installed and overhead lights be kept off?

percent 0 25

L5Could use of outdoor lighting be reduced? And could outdoor lighting be switched to fluorescent with motion sensor control?

yes/no 0 10

L6Can high-bay lighting be switched to fluorescent with motion sensor control or can fixtures be lowered and wattage reduced?

yes/no 0 10

TOTAL 56.25

The responses for L2 and L4 are mutually exclusive and should not exceed 100. So choose either one or the other, or split the percents.

Lighting / Daylighting

All the responses below apply mainly to buildings or facilities that are significantly lit by electric lighting.

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Space Conditioningrequired YOUR YOUR MAX

response Response SCORE SCORE

HC1

Enter percent of total building floor areas of all heated and/or cooled buildings that do not reduce space conditioning during periods of low occupancy or non-work hours now, but could do so?

percent 70 14 20

HC2

Enter percent of total building floor areas of all heated and/or cooled buildings that heat and cool air supply at the same time (simulataneous heating and cooling fighting each other), that could have this energy-wasting situation corrected?

percent 25 7.48502994 30

HC3

If boilers or boiler heat supply could be shut off to building systems during mild and hot weather -- OR if process heat recovery could supply some space heating, and this is not currently done, could either shutoff orheat recovery be implemented?

yes/no 0 15

HC4If too much air is supplied for heating and cooling, could this flow be reduced?

yes/no 0 15

HC5

If there are significant building areas that are heated and/or cooled that do not need to be conditioned, could space conditioning be turned off or disconnected in these areas?

yes/no 0 15

HC6If excess heating or cooling is provided for any reason, could the excess be reduced?

yes/no 1 5 5

TOTAL 26.49

Space Conditioning

All the responses below apply mainly to buildings or facilities that are significantly heated and/or cooled, and do not include mopajor ventilation systems or envelope effects (handled under other categories).

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Ventilationrequired YOUR YOUR MAX

response Response SCORE SCORE

V1

If makeup air or exhaust systems are operating at a static pressure higher than needed to provide required functionality, could static pressure be reduced?

yes/no 0 20

V2

If makeup air or exhaust systems are operating at flow rates higher than needed to provide required functionality, could flow rates be reduced?

yes/no 0 40

V3

If excessive outdoor air for ventilation, based on CO2 readings, is provided for human occupancy in non-process areas (see chart for CO2 readings), could the excess outdoor air be reduced?

yes/no 0 20

V4If air over 150 F is exhausted to atmosphere with no heat recovery, could heat be recovered for useful purposes?

yes/no 0 10

V5Could enthalpy wheels, heat pipes, or other devices be used to recover total enthalpy in exhaust air flows?

yes/no 0 10

TOTAL 0.00

All the responses below apply to ventilation provided by building space conditioning, makeup air, aor exhaust systems.

Ventilation

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CO2 parameters indicating effective ventilation provided for reference

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Miscellaneous hot water

required YOUR YOUR MAX

response Response SCORE SCORE

W1Can process heat recovery be used to heat domestic hot water? Enter the percent of domestic hot water that could be heated.

percent 50 50 100

TOTAL 50.00

Miscellaneous hot water

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After Scorecard Questions, RESULTS

Scorecard questions will be blank for users initially, and the values shown here are just so testers see that numbers are generated

But you must change inappropriate answers to zero or blank

RESULTS sheet, Part 3, should not be modified in any way

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Quick PEP Part 3

RESULTSFacilities Energy Score Card test version 1.0b

REVIEW these as necessary on other sheets>> DO NOT CHANGE THESE VALUES HERE <<

NAME of sheet to review ---> PctFacPERCENT of total plant site energy that is for facilties: 28.00% DNAME of sheet to review ---> Scorecard

A

Facilities Energy SystemScorecard

Score out of 100

Electricity Fuel/Steam Electricity Fuel/Steam

Envelopes 35 5% 17% 2% 5%

Lighting 56 30% 0% 18% 0%

Space Conditioning 26 30% 70% 15% 35%

Ventilation 0 20% 10% 6% 3%

Miscellaneous (incl hot water) 50 15% 3% 0% 3%

TOTAL 100% 100% 41% 46%

Estimated Percent of TOTAL Plant Energy that might be savedSAVINGS ESTIMATES = A/100 x C x D

Facilities Energy System percent Electricity Fuel/Steam

Envelopes 0.15% 0.50%

Lighting 2.84% 0.00%

Space Conditioning 1.11% 2.60%

Ventilation 0.00% 0.00%

Miscellaneous (incl hot water) 0.00% 0.42%

TOTAL 4.1% 3.5%Quick PEP users will enter total electricity use and fuel/steam use prior to using a Score CardThus, this test Score Card can only show percentages of the total energy to be entered

end-useB

End-Use Breakout of Facilities Energy

C

Maximum Pct Facilities Energy that can be saved

Total plant energythat might be savedthrough facilitiesenergy measures

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Desired Feedback 2

Suggestions for simplifying or modifying the Scorecard questions

Suggestions for enhancements to Scorecard approach

Ideas about how users might be instructed on use of the Scorecard or what examples might be useful

Additions to system questions, but remember we need to keep it simple

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Contact Information

Rolf Butters, DOE ITP 202-586-0984 Rolf.Butters@hq.doe.gov

Mike MacDonald, ORNL 865-574-5187 macdonaldjm@ornl.gov