Energy Matters - Winter 2001 · 2013-09-26 · Energy Matters, Winter 2002 3 Project Background...

Winter 2002

ISSUE FOCUS:

Smart Systems

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A BestPractices PUBLICATION ON IMPROVING INDUSTRIAL ENERGY EFFIC IENCY

OFFICE OF INDUSTRIAL

TECHNOLOGIES •

U.S. DEPARTMENT OF ENERGY

www.oit.doe.gov www.oit.doe.gov/bestpractices

In response to the fourth round of solicita-tions, nine industrial companies wererecently named to receive cost-sharedfunding for plant-wide, energy efficiencyopportunity assessments. Each plant hasidentified a team to help them conductthese assessments and identify potentialareas for improvement.

The latest nine bring the total to 32awards made by Oak Ridge National Labo-ratory (ORNL) since initiating the plant-wide assessment program in 1999. Of the23 other plant-wide assessment sites, ninehave completed projects for total estimatedenergy savings of 1 trillion Btu.

The companies submitted proposalsthrough a competitive solicitation held in2001. Each proposed a plan for a cost-shared assessment that could guide theirplants to substantial energy and cost sav-ings, improved productivity, reduced waste,and enhanced global competitiveness.

ORNL will share up to half the cost, or up to$100,000, with each site to conduct theassessments, which will evaluate energyefficiency opportunities in areas such as:

■ Electric motor systems ■ Steam systems ■ Compressed air systems ■ Combined heat and power systems ■ Process heating systems ■ Process modifications ■ Adoption of new emerging technologies

In addition to the cost-shared funding,each site will gain benefits such as nationalrecognition and access to the whole rangeof the Office of Industrial Technologies (OIT)emerging technologies, tools, and resources.

Solicitations for the next round of plant-wide assessments will be announced onthe OIT and BestPractices Web sites.Watch for announcements at www.oit.doe.gov/bestpractices. ●

Fourth Round of Plant-Wide Assessments Could Improve Performance at Nine More Sites

Augusta Newsprint Showcase, see insert.

IN THIS ISSUE

4th Round of Plant-Wide Assessments . . 1

Weirton Steel and OIT Team Up . . . . . . 2

Combustion Control Strategies . . . . . . . 4

Compressed Air System Optimization . . 6

Ask the Clearinghouse . . . . . . . . . . . . . . 7

What’s the Right Level of Automation? . 8

Collaboration Advances Motor Efficiency . . . . . . . . . . . . . . . . . . . . 9

Upgraded Tools CD . . . . . . . . . . . . . . . . 9

Improved Compressor PerformanceInformation . . . . . . . . . . . . . . . . . . . . . . 10

AIRMaster+ and Specialist Training . . . 10

Energy Solutions for California . . . . . . 11

Life Cycle Cost Analysis . . . . . . . . . . . . 11

Letters to the Editor . . . . . . . . . . . . . . . . 11

EM Extra Highlights . . . . . . . . . . . . . . . . 11

Coming Events . . . . . . . . . . . . . . . . . . . . 12

INSERT:

OIT Showcase at Augusta Newsprint

Charter Steel, Saukville, Wisconsin, plans a plant-wide energy study focusing on processequipment, including plant utilities. The company will assess the impact of an emerging technol-ogy on energy savings and manufacturing costs.

Commonwealth Industries, Uhrichville, Ohio, will assess two aluminum sheet production oper-ations (chill casting and continuous casting) and provide direct comparisons of energy require-ments and future savings opportunities for the different process technologies.

Ford Motor Company, Cleveland, Ohio, will address the production process and will apply the prin-ciples of lean manufacturing to identify energy and cost reductions in the manufacturing operation.

Formosa Plastics, Port Comfort, Texas, and its partners will conduct a plant-wide study todevelop and implement methods and strategies that address energy efficiency, waste reduction,productivity, and global competitiveness.

Georgia Pacific, Crossett, Arkansas, developed a plan to evaluate the plant as an integratedentity to achieve system-wide gains. The plant will use computer-modeling tools to verify milldata and perform system-wide optimization.

Jernberg Industries, Chicago, Illinois, will apply lean manufacturing principles and identifywaste stream and productivity opportunities that can save energy.

North Star Steel, Wilton, Iowa, will focus on energy, waste, and productivity and will initiate atotal assessment audit to identify opportunities in the manufacturing systems facility.

Pechiney Rolled Products, Ravenswood, West Virginia, intends to identify potential improve-ments in the aluminum casting and rolling mill. The company’s key interest is to document effi-ciency improvements and develop energy accounting procedures to track and analyze plantequipment and practices.

Weyerhaeuser, New Bern, North Carolina, will apply an innovative systems approach to electri-cal load and efficiency for each key process and support system.

Fourth Round Plant-Wide Assessment Awards Made by ORNL

2 Energy Matters, Winter 2002

ENERGY MATTERSis published quarterly by the U.S. Department of Energy’s(DOE) Office of Industrial

Technologies.

Information contained in thenewsletter can be reproduced

without permission provided dueacknowledgement is given (the

U.S. Department of Energy’s Energy Matters newsletter) and

a copy of the publication is supplied to the editor.

■

EDITORIAL BOARD

Rob Boteler, representingNational Electrical Manufacturers

Association

Lynda Butek, representing Electrical Apparatus Service

Association

Keith Davidson, Energy NexusGroup

Glenn Hahn, Spirax Sarco

Aimee McKane, representing theCompressed Air Challenge®

Arvind Thekdi, E3M, Inc.

Chuck Whelan, DuPont

■

DOE STAFF

Chris Cockrill, BestPractices,Motors

David Crouch, BestPracticesCommunications

Bob Gemmer, BestPractices,Process Heating

Fred Hart, BestPractices, Steam

Peter Salmon-Cox, BestPracticesProgram Manager

■

COMMENTS?

Contact:

Michelle Mallory, Energy Matters Editor, at 303-275-3627, or e-mail

[email protected] Cole Blvd., MS 1609

Golden, CO 80401

For address/subscription changes,please contact the editor.

For new subscriptions, go towww.oit.doe.gov/

bestpractices/energymatters/energy_matters.shtml

Many companies are feelingthe heat of intense global com-petition, and Weirton Steel isno exception. But the companyhas fought back by partneringwith OIT, developing an energymanagement plan, and upgrad-ing its steel manufacturingplant in Weirton, West Virginia.

In 1996, the company com-missioned a comprehensiveenergy management study ofthe facility, which provided thebasis for an energy manage-ment control strategy. Central tothis strategy was replacing theplant’s antiquated utility controlequipment with a “smart sys-tem” that allows plant managersto monitor and control utilitiesfrom one computerized center. The upgradeis ongoing, but so far, Weirton’s investmentof $16 million for this project has saved thecompany $18 million per year.

Company BackgroundHeadquartered in Weirton, West Vir-

ginia, Weirton Steel has been in businesssince 1910. It is the largest industrialemployer in the state of West Virginia andthe eighth-largest steel producer in the

United States. Weirton Steel provides anextensive array of tin mill and sheet steelproducts as well as steel products for thebuilding and construction market to cus-tomers all over the world. Weirton’s prod-ucts include high-quality galvanized steelthat is purchased and used by manufactur-ers of steel framing for residential and com-mercial applications.

Weirton Steel and OIT Team Up to Save Millions

Weirton Steel’s turbine/generator floor in the powerhouse is monitored and controlled fromthe new central control room.

Weirton Steel’s new computerized controls respondrapidly to changing energy demands, enabling more effi-cient use of power and fuels.

(continued on page 3) �

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Energy Matters, Winter 2002 3

Project BackgroundWeirton’s first control system modern-

ization project (Level I) replaced antiquatedcontrol equipment with a group of mod-ern, state-of-the-art, computer-controlledsystems monitored from a central room.The production processes at a steel plantare cyclical and dynamic, which createsconstantly shifting energy demand patterns.The new controls modulate the variousprocesses more rapidly, which allows aquicker response to changing energydemands, and enables more efficient useof power and fuels. In fact, the new con-trols have allowed the plant to use fewergenerators, boilers, and blowers, plus cap-ture and harness heat and steam to gener-ate more steam and power.

For example, the production processesin the blast furnaces and the basic oxygenplants give off large quantities of blast fur-nace gas and waste steam. These byprod-ucts can now be captured and used withinthe systems instead of being released intothe atmosphere, which causes energy lossand pollution.

These improvements alone haveresulted in a 30% gain in the efficient useof blast furnace gas and waste steamrelease and an 8% reduction in the amountof fuels needed, leading to $18 million inannual savings.

Howard Snyder, Weirton’s technicaldirector of operations, says that Level I“has dramatically streamlined the controlstrategy for our energy utilities.”

Further Improvements AheadWeirton has plans to add a higher level

of automation to leverage the existing sys-tem’s statistical, technical reporting, andcontrol capabilities.

“Level II will build on Level I by provid-ing the tools to help operators make busi-ness decisions, based on past costinformation,” according to Snyder.

Weirton plans to start on Level II in2002. The new project will engage a teammade up of Asea Brown Boveri–CombustionEngineering (ABB-CE), Fisher/Rosemount,OIT, and West Virginia University. ABB-CEwill conduct a technical evaluation of theoperating practices, production rates,equipment capacities, and system controlstrategies. Then it will combine the evalua-tion data with process logic from diagnosticequipment to create the new system.

The new system will allow for real-timecommunication data flow between 22 dif-ferent operating units. Weirton estimatesthat the project, with a capital cost of$570,000 will save $541,524 per year inpurchased energy costs.

ApplicationsYour manufacturing facility could

potentially save money and energy, andcut emissions by implementing a modern,computerized central-control system. Learnmore about “smart” sensors and controlson the OIT Sensors and Controls homepage at www.oit.doe.gov/sens_cont/. Formore information on how OIT and thesteel industry are collaborating to developand implement technologies crucial to theindustry’s future, see the OIT Steel Industryof the Future home page at www.oit.doe.gov/steel. ●

Weirton Steel and OIT Team Upcontinued from page 2

SHOWCASE PARTICIPATION

Weirton has a history of partnering with OIT. In May of 2000, the com-pany gave plant tours as part of the Pittsburgh Regional TechnologyShowcase, “A Celebration of the New Steel.” The technologies thatWeirton demonstrated included a basic oxygen furnace optical sen-sor, a galvanneal temperature measurement sensor, an infrared-basedpreheating system for strip metal, nickel aluminide radiant tubes, andnickel aluminide seal rolls. Read more in the showcase fact sheet atwww.oit.doe.gov/factsheets/steel/pdfs/pittsburgh_steel_showcase.pdf.Learn more about showcases on the BestPractices Web site at www.oit.doe.gov/bestpractices and in the special supplement of this issue.

Operators regulate these turbine generators from Weirton’s central control room.

This building houses Weirton Steel’s utilitiescentral control room.

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By David C. Farthing, Federal Corporation,Oklahoma City, OK

Today’s economic and environmentaldemands dictate that we get the greatestpractical efficiencies from our plants. To dothis we must have a basic understanding ofwhat those efficiencies are and how toimplement them.

Advanced automatic systems for com-bustion control are excellent methods forimproving systems and process automationsuccess. New technology available todayhelps improve overall combustion effi-ciency and burner stability when loads anddemands are variable. The most sophisti-cated systems can eliminate the need foroperator input during load changes whilemaintaining safe and reliable fuel/air ratios.

This discussion describes several sys-tems, from the simplest to the most ele-gant, and focuses on the features, benefitsand applications of several systems appliedto single-burner packaged boilers.

A Look at Combustion StrategiesHere are some control strategies to con-

sider for improving burner efficiency. Theright strategy depends on boiler loads,demands—and economics.

Fixed Position Parallel Controls. Thesimplest form of combustion control forpower burners is the fixed position parallelcontrol (FPC) (Figure 1)—also known asdirect or jack-shaft control. This strategyincorporates a single positioning motor,which drives both the fuel and air position-ing devices via an interconnected singlemechanical link, the jack-shaft.

The simplicity of the FPC control strat-egy makes it a very economical choice forsmall burners with modest firing ratechanges. However, because fuel and airare fixed, the fuel/air ratio is also fixed. Theburner cannot compensate for environ-mental changes, such as combustion airtemperature or fuel pressure. Additionally,the FPC strategy lacks feedback to the

control element, which can cause fuel tocross over the airflow and cause a fuel-richfurnace or other burner efficiency losses.

To help prevent a fuel-rich furnace, FPCsystems are set to allow 4% to 8% excessoxygen to the furnace. In practice, the excessoxygen is normally set at 6% to 7%, allow-ing for seasonal air temperature changes.

Parallel Positioning Control Systems.These systems function similarly to FPCsystems, except that fuel and air end-devices are separated and driven by indi-vidual positioners. Modern electronicparallel positioning controls (PPC) incorpo-rate end-device positioning signals toensure accurate placement of fuel and airpositioners for specific firing rates. Thesesignals make PPC systems much improvedover FPC systems.

The new systems are gaining accep-tance over FPC systems because they offeran economical means to improve overallcombustion efficiency. PPC systems aresuitable for 100 to 900 boiler horsepower(Bhp) boilers that operate with relativelystable loads. Larger systems are alsobecoming more prevalent.

PPC systems can hold excess oxygenlevels to within 3% to 4% in many appli-cations, but because they lack true processvariable feedback in the fuel/air systems,they should be used cautiously in applica-tions with extremely fast load swings. LikeFPC systems, PPC systems cannot compen-sate for changes in fuel or combustion air characteristics.

Series Metered Control Systems. Boilerslarger than 750 Bhp commonly incorporateseries metered control (SMC) systems,where load changes are neither large norfrequent. In this application, both fuel andair are metered. The boiler master con-troller regulates combustion airflow with aset point. The airflow controller cascadesthe airflow signal to the fuel controller asits remote set point. A ratio algorithm signalsent to the fuel controller adjusts thefuel/air ratio.

Combustion Control Strategies for Single and Dual Element Power Burners

Figure 1. Fixed position parallel jack-shaft combustion system with fuel/air ratio establishedthrough fixed mechanical linkages.

Fixed Position Parallel Control

Steampressure

PT

Master pressurecontroller

Air flow damper

2nd fuel flowcontrol valve(optional)

Fuel flowcontrol valve


NEW TECHNOLOGY IMPROVES

OVERALL COMBUSTION EFFICIENCY

AND BURNER STABILITY

WHEN LOADS AND DEMANDS

ARE VARIABLE.


This ratio algorithm has an inherent lagbecause the air controller directs the fuelcontroller’s function. This lag provides adesirable lean furnace on demand rise.However, on a fast falling demand, the lagbetween the air and fuel controllers cancause a fuel-rich furnace.

Because of the lag on a falling demand,the SMC is only adequate for near steady-state conditions. Excess oxygen levels areusually set at 5% to 8%; however, by usingan oxygen trim system, levels can beadjusted to 3% to 4% during steady-stateoperation.

Metered Parallel Positioning ControlSystems. Boilers operating at 1,000 Bhp orhigher may incorporate metered parallelpositioning control (MPPC) systems. Theseoperate the fuel and air control loops inparallel from a single setpoint generated bythe boiler master controller. A combustionair set point ratio establishes the fuel/airproportions.

This fuel/air customization featuremeans excess oxygen in the exhaust gasesmay be reduced to 3% to 4%. To maintainan air-rich furnace on transition, MPPCsystems are normally set with additionalexcess air to compensate for fuel flow dur-ing setpoint excursions. In practice, theexcess air is set at 4.5% to 5% to compen-sate for barometric changes in air density.During steady-state operation, this can beadjusted to 2.5% to 3% using an oxygentrim system.

Like the series system, the traditionalMPPC system lacks feedback to the oppos-ing flow controllers, which can result incombustion imbalance on large or very fastload swings. These systems require nearlyidentical responses from both the air andfuel control loops to prevent fuel or air-rich mixtures in the furnace. This limits theMPPC system to boilers with modestdemand swings.

Cross-Limited Parallel Metered ControlSystems. This strategy improves on MPPCby interlocking fuel/air ratio control to pre-vent a fuel-rich furnace. The cross-limitedcontrol (CLC), or lead-lag control (Figure 2),is dynamic and easily adjusts to different

response times of the fuel and air enddevices. This flexibility allows its use insystems with sudden and large load swingsand provides precise combustion control atsteady-state operation.

CLC systems easily maintain excessoxygen levels at 3% to 4% in gas burnersand 2.5% to 3% in #2 oil systems. Addi-tionally, the cross-limiting feature preventsfuel from overshooting airflow.

Because of its capability for close toler-ance control, CLC systems are suited for allsizes of boilers that can support the sys-tems installation cost. Additionally, theCLC system can be readily adapted to oxy-gen trim control and is suitable for mostlow-NOX burner applications.

Selecting a StrategyThe economic balance between fuel

cost, safety, boiler load, and control systemcost will eventually determine which ofthese systems best suits your process. How-ever, in practice, the use of parallel posi-tioning systems on boilers up to 900 hp isusually the most economical. Cross-limitedsystems are typically used in critical loadapplications of 1,000 hp and higher. ●

David Farthing has 28 years of experiencein thermal processes. He is both a practitioner and an academic in the field of boilers and thermal process controlsystems, as Sales Manager for Federal Corporation and adjunct instructor at Oklahoma State University. Contact him at [email protected] or 405-239-7301. The full version of thispaper is available on Energy Matters Extraat www.oit.doe.gov/bestpractices/energymatters/emextra.

Combustion Control Strategiescontinued from page 4

Figure 2. Cross limiting, or lead-lag fuel/air ratio control, is the most dynamic of all combustioncontrol strategies.

RemoteSP

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Cross-Limited Parallel Metered Control


For Modern Forge of Tennessee, adding anew air compressor at first seemed to bethe solution for meeting the pressure levelrequirements of its end-use applications.However, a system-level survey revealedseveral opportunities to optimize the exist-ing five compressors—and that proved tobe a better solution than purchasing a sixthcompressor.

By implementing improvements acrossthe compressed air system, Modern Forgenow requires fewer compressors, hasimproved product quality, and has in-creased productivity. With energy cost savings of $120,000, or 2.4 million kWhannually, the plant has reduced its totalelectricity costs by 8%. The companysaves another $40,000 per year in mainte-nance costs and has avoided a $120,000capital investment to purchase a new aircompressor. At a cost of $105,000 the pay-back on the project was just 8 months.

The plant, located in Piney Flats, Ten-nessee, is a subsidiary of Modern DropForge Company. Its 235 employees manu-facture forged metal components for themining and construction industries, auto-motive suspensions and transmissions,motorcycle frames, plus hand and specialtytools. Compressed air is important in theplant’s production process because itdirectly supports grinding, pressing, anddie forging.

Before the project, the plant had to oper-ate all five compressors, totaling 2,000 hp,to maintain a minimum system pressure of100 psig. Each compressor’s dischargepressure ranged from 120 to 125 psig toaccount for pressure drop of 20 to 25 psig.This wasted energy and meant frequentmaintenance.

Survey Identifies Inefficiencies Modern Forge called on Compressed

Air Management, a BestPractices AlliedPartner, to evaluate the system. The surveyfound two main sources that prevented theplant’s compressed air system from main-taining a stable pressure level.

■ A lack of storage meant the plant had torun compressors even when demandwas low or nonexistent. Compressed airwas being wasted, but this was the onlyway to meet the minimum 100-psig airrequirements in the forge shop, the mostimportant air application in the plant.

■ Excessive pressuredrop was caused inpart by the inter-mittent demandfrom the forgeshop, and exacer-bated by poorlyengineered point-of-use componentsand dirty filtrationdevices. In addi-tion, the pipingsystem in the forg-ing shop was parti-tioned by closedisolation valves inthe header, which increased the pres-sure gradient in that part of the plant.

Modern Forge also discovered that theantiquated compressor controls lackedenough control points to gauge air demandand properly sequence the compressors.This caused the compressors to workagainst each other and made the controlsystem inefficient and unreliable.

Furthermore, the survey revealed thatthe system was leaking air at a rate ofabout 20% of its output and had a problemwith lubricant and moisture carryover.Finally, the 200-hp compressor used onweekends for packaging and support oper-ations was oversized for these applications.

System-Level FixesAfter considering the survey recommen-

dations, Modern Forge realized that imple-menting system-level modifications wouldyield better results than simply addinganother compressor.

The plant took action by:

■ Adding two receivers to provide 7,500gallons of storage.

■ Modifying the piping distribution sys-tem and opening the valves in the forgeshop header.

■ Replacing the run/modulation sequencerwith a programmable logic control (PLC)system to centralize control of all fivecompressors, maintain adequate pres-sure differentials, and sequence themmore effectively. The system was linkedto the pressure/flow controllers toobtain accurate air demand signals.

■ Installing pressure/flow controllers in theforge and die shops to stabilize headerpressure as required in each area.

■ Purchasing and installing a dedicated40-hp compressor for weekend packagingoperations and some die shop functions.

■ Installing another dryer and replacingfilters.

■ Implementing a leak detection/repaircampaign that includes replacing wornpoint-of-use components and trainingpersonnel.

Benefits of an Optimized SystemOnce the project was completed, the

system began to function more efficiently.The pressure/flow controllers stabilized thepressure levels, diminishing the pressuredrop that had previously plagued the sys-tem. Opening the isolation valves in theforge shop header spread the load acrossall of the compressors and reduced thepressure gradient.

The new PLC control system respondsquickly and accurately to air demand pat-terns and allows the system to operate with

Compressed Air System Optimization Improves Production at Metal Forging Plant


Storage, along with pressure/flow controllers,have stabilized Modern Forge’s compressedair system.

Modern Forge of Tennessee evaluated its compressed air system,and then implemented several changes to optimize the system.


Ask theClearinghouseVariable Speed Drive

Part-Load Efficiency

This column highlights key questions fromindustrial customers to the OIT Clearing-house. Through the OIT Clearinghouse, youcan access the full portfolio of OIT resourcesand get technical advice about motor,steam, compressed air, combined heat andpower, and process heating systems.

Clearinghouse engineers and technicalstaff expertly answer industrial efficiencyquestions, 11 hours a day, Monday throughFriday. The Clearinghouse also has accessto industry experts around the country. Callthe OIT Clearinghouse at 800-862-2086,or go to www.oit.doe.gov/clearinghouse/.

Q: What is the efficiency of a variablespeed drive when it is operating at

reduced speeds?

A: One manufacturer provides efficiencyvalues for pulse-width modulated

variable frequency drives (VFDs) as a func-tion of operating speed for both variabletorque loads (centrifugal fans and pumps)and constant torque loads (cranes, hoists).

Remember that, according to the affinitylaws for variable torque loads, the driven-equipment horsepower requirement variesas the cube or third power of the operatingspeed ratio. For constant torque loads, thehorsepower required varies linearly withrotating equipment speed.

Power Requirement for Centrifugal Loads

hp2 = hp1 x (RPM2)3 / (RPM1)3

Where:hp1 = driven-equipment horsepower

requirement at original operating speedhp2 = driven-equipment horsepower

requirement at reduced speedRPM1 = original speed of driven equip-

ment, in revolutions per minute (RPM).RPM2 = reduced speed of driven equip-

ment, in RPM

The table (at right) provides efficiencyvalues for VFDs of various horsepower ratings when serving motors connected tovariable torque loads.

It is apparent that efficiency decreaseswith decreasing load, and that the declinein efficiency is more pronounced with drives of smaller horsepower ratings. This

reduction in efficiency is not as detrimentalas it first seems, however. Consider a vari-able speed drive coupled to a motor thatdelivers 5 hp to an exhaust fan. When thefan is operated at 25% of its rated speed,the drive efficiency is 29.6%. At 1⁄4 of itsrated operated speed, the fan delivers 25%of its rated airflow, but requires only 1⁄64th ofits full-load power. Even with the low driveefficiency, with variable speed operationthe power required by the fan is reducedfrom 5 hp to 0.26 hp (1/64 x 5 hp/ 0.296). ●

fewer compressors. Instead of having tooperate 2,000 hp worth of compressorcapacity, the plant only requires between650 and 1,100 hp, depending on demand.

The new controls also eliminated lubri-cant carryover by preventing frequentloading and unloading of the rotary screwcompressors. Thanks to more consistentand lubricant-free air, product quality hasimproved and the plant has reduced pro-duction rejects. In addition, the forginghammers are more productive.

Modern Forge’s leak detection andrepair operation omitted the largest leaks inthe system, including those at the point-of-use components (regulators, filters, andhoses) and reduced air lost to leaks by10%. Meanwhile, the additional dryer,new filtration equipment, and the pneu-matic condensate drains eliminated prob-lems from moisture carryover.

Finally, the training sessions havehelped plant personnel make better use ofthe system. Now that they are moreinformed, personnel operate compressorsat lower pressure levels than before.

Lessons LearnedWhen a compressed air system does not

deliver as required, a complete systemevaluation could provide valuableanswers. In Modern Forge’s case, an evalu-ation led to improvements that allow thesystem to perform to its full potential and

averted the need for another compressor.In addition, Modern Forge has realized thebenefits of reduced energy use, energy andmaintenance cost savings, and improvedproductivity. ●

SMART CONTROLS FOR MULTIPLE COMPRESSOR SYSTEMS

Modern Forge took an important step by upgrading its compressor control system. This mightbe an approach for other plants to consider as part of an overall strategy for improving com-pressed air system efficiency. In the past, industrial plants have relied on cascading set pointsto control multiple compressor systems. With this approach, the plant established individualoperating pressure set points to either add or subtract compressors to meet air demand.

Today, however, new control strategies can control multiple compressors with single set pointlogic. The most sophisticated of these strategies, system controls, coordinate compressor oper-ation regardless of type or make. Individual compressor controls, linked together, respondquickly to changes in air demand patterns. All compressors operate within a single pressureband in a sequence tailored to maintain system pressure within specific limits and in the most cost-effective manner. Compressors brought online as system pressure begins to decaybecome fully operational before the pressure falls below production’s minimum requirements.

Learn more about applying compressed air system controls in the Compressed Air Challenge’sImproving Compressed Air System Performance sourcebook’s “Fact Sheet #6” available onthe BestPractices Web site at www.doe.gov/bestpractices/compressed_air/. Also check theBestPractices training page at www.oit.doe.gov/bestpractices/training for opportunities tolearn more about managing your plant’s compressed air system.

VFD Efficiency (in Percent) as a Function of Percentage of Full Operating Speed

Variable Speed Drive Percent of Full Operating Speedhp Rating 25% 50% 75% 100%

1 9.4% 44.2% 70.5% 82.5%5 29.6% 74.7% 88.3% 92.4%10 35.3% 79.0% 90.3% 93.5%25 35.6% 79.4% 90.6% 93.8%50 43.3% 83.5% 92.1% 94.4%100 54.8% 89.1% 95.0% 96.6%250 61.2% 91.3% 96.1% 97.3%

These values are provided by a VFD manufacturer.There is no widely accepted test protocol that allowsfor efficiency comparisons between different drivemodels or brands. An inverter can be set up many ways and that can affect operating efficiency.

Compressed Air System Optimizationcontinued from page 6


By David Berger, Contributing Editor, Plant Services Magazine

To automate or not to automate, that is thequestion. Finding the answer requires eval-uating a number of cost/benefit factors,including cash flow, organizational readi-ness, ease of implementation, availabilityof resources, technological maturity andavailability, and probability of success.

Cost/Benefit. Top of mind for mostsenior managers is finding some way tosort out the never-ending stream ofrequests for what appears to be worthyautomation projects. In many cases, thisincludes structuring the business case in astandardized format, which allows seniormanagement to compare apples to apples.

Hard Savings. These include items suchas reduced headcounts, increased produc-tion volume and improved product quality.Hard savings are then compared to thehard costs associated with attaining thebenefits, using standard financial ratios.But how hard is hard? True hard savingscan be difficult to determine. Implement-ing a management information system(MIS) that monitors various measures doesnot automatically guarantee cost savings.

If management is unwilling or unable totake timely and appropriate action, or ifthe source data is inaccurate, then hardsavings will be unattainable.

Soft Savings. In most circumstances,hard benefits are more of a priority thansoft, which have no direct and indisputableimpact on the bottom line. Occasionally,companies go through periods when cer-tain soft benefits are all the rage. Savvymiddle managers incorporate these trendsinto their requests for automation.

Cash Flow. Another critical factor ishow much cash is available. A company isfar more likely to forego automating itsMIS, where savings are longer term andless tangible, if the company is downsizing,

is in a high growth mode, or is heavily indebt. Such tradeoffs are commonplace.This is one reason why joint ventures, out-sourcing, and application service providersare gaining in popularity.

Organizational Readiness. Companiesthat have attempted to implement an identi-cal automation program in multiple plantsunderstand the huge differences regardingorganizational readiness that can exist. Ifthe people are not willing or able to makethe project work, then there is little ques-tion as to what the end result will be. This

is especially true when implementing anew or upgraded MIS, because it requiresaccurate data entry, definitive decision-making, and action.

Ease of Implementation. When weighingthe pros and cons, one key consideration isease of implementation. Any automationproject that looks like it will drag on longerthan 3 to 6 months will be less likely to gainapproval from top management. Middlemanagers are well advised to break a largerproject into smaller, easily implementedwork packages, which show the cost/benefitfor each piece.

Availability of Resources. Every com-pany has limited resources and must,therefore, strike a balance between run-ning the business of today and building thebusiness of tomorrow. Automation projectsare less likely to be approved if theyrequire too many good people already bur-dened with line responsibilities or otherworthy projects. This is another reason todivide an automation project into moremanageable pieces or seek help from out-side business partners.

Technological Maturity and Availability.Higher risk may bring greater reward, but itmay also result in greater losses. If thetechnology is “bleeding” edge, then topmanagement is less likely to approve thebusiness case, no matter how great thereward may seem. Even if the technologyis proven in other industries, it may not beapplicable or available to your industry.

Probability of Success. Last, but by nomeans least, is the likelihood of successfullysustaining a given level of plant automationover the short and long term. Projects with ahigher return but lower probability of suc-cess are severely discounted in the eyes ofsenior management. When preparing thebusiness case for automation, make sureyou address the critical success factors, aswell as how you intend to overcome poten-tial barriers to success. ●

This article is excerpted with permissionfrom Plant Services Magazine, ©PutmanMedia 2001. The original appeared in theAugust 2001 issue and is available onEnergy Matters Extra at www.oit.doe.gov/bestpractices/energymatters/emextra.

What’s the Right Level of Automation?

Evaluate cost/benefit factors to find the right

level of automationfor your plant.


Boost your systems’ productivity and reliabil-ity, and save your company money withOIT’s newest release of the Decision Tools forIndustry CD. This portfolio of powerful sys-tem assessment tools now includes two newsoftware programs: AIRMaster+ and 3E Plus.

■ AIRMaster+ is a comprehensive, air sys-tem energy management program thatenables auditors to assess compressedair systems, model existing and futuresystem upgrades, and evaluate theenergy savings and cost-effectiveness ofenergy efficiency measures.

■ 3E Plus helps determine if boiler sys-tems can be optimized by insulatingboiler steam lines. It calculates the mosteconomical thickness of industrial insu-lation for a variety of operating condi-tions using either the built-in thermalperformance relationships of genericinsulation materials or conductivity datafor other materials.

The CD also includes the current ver-sions of other OIT industrial assessmenttools, such as MotorMaster+ 3.0, the Pump-ing System Assessment Tool (PSAT), and theSteam System Scoping Tool.

■ MotorMaster+ 3.0 helps you find outwhen to replace versus repair, and whatmotors to buy.

■ The Pumping System Assessment Tool(PSAT) assists you in assessing pumpingefficiency and calculating energy savings.

■ The Steam System Scoping Tool com-pares your steam system to best prac-tices in industry.

Order your free copy of this CD now bylogging on to the BestPractices Software ToolsWeb site at www.oit.doe.gov/bestpractices/software_tools.shtml, or by calling the OITClearinghouse at 800-862-2086. ●

Upgraded Tools CD Helps Assess and Improve Energy Management Systems

OIT’s Decision Tools CD now includes AIRMaster+ to help you evaluate compressedair efficiency.

With 3E Plus, you can calculate the mosteconomical thickness of industrial insulation.

Industrial electric motor systems consumelarge amounts of energy—roughly 23% ofall electricity sold in the United States. Andthat comes with a price. Energyrepresents more than 97% oftotal motor operating costs. Inlarge industrial plants, motorsystem energy costs can easilyexceed $1 million annually.However, by installing energyefficient motors and applyinggood motor systems manage-ment techniques, a companycan reduce its motor systems energy costsby as much as 18%.

These facts have prompted the NationalElectrical Manufacturers Association (NEMA)and its motor and generator member compa-nies to join forces with the Electrical Appara-tus and Service Association (EASA), theConsortium for Energy Efficiency (CEE), theCopper Development Association, DOE, andseveral other organizations to initiate theMotor Decisions Matter campaign. Facilitatedby the CEE, the nationwide campaign

encourages sound motor management andplanning as a tool for cutting motor systemenergy costs and increasing energy effi-

ciency. In doing so, industrialcustomers can help increase thereliability and quality of motor-driven process systems andreduce plant operating costs.

The campaign targets threekey audiences: executive levelmanagers; maintenance repairand operation employees,plant managers, and engineers;

and distributors and repair firms. To help them develop a sound motor plan, thecampaign offers an online Motor PlanningKit. With a proactive plan, industrial motorusers can be better prepared to make sounddecisions regarding the repair or replace-ment of a motor in the event it fails.

Working to Promote Motor Efficiency Motor Decisions Matter encourages the

use of energy-efficient motors and motorsystems as part of an overall approach to energy management. DOE has partnered

with several of the campaign sponsors.NEMA and DOE have worked together

to promote efficient industrial motor sys-tems since 1993, when NEMA signed on asa “Charter Partner” in the former DOEMotor Challenge Program. DOE continuesto work closely with NEMA to promoteNEMA Premium™ and motor system effi-ciency. EASA was the first Motor ChallengeAllied Partner and has been very active ineducational efforts and has worked todevelop guidelines for motor repair.

In addition, the Copper DevelopmentAssociation, also a long-time Allied Partner,has helped to promote efficient motors anddistribute DOE’s MotorMaster+ software.DOE has also worked with several of the CEEmember utilities and sponsor organizations.

Learn more about Motor Decisions Matterand find a listing of sponsors by visiting theWeb site at www.motorsmatter.org. Formore about publications, software tools, andtraining information specific to motor sys-tems, log onto OIT’s BestPractices Web site atwww.oit.doe.gov/bestpractices/motors/. ●

Collaboration Advances Motor Efficiency


If you analyze your company’s industrialcompressed air system, AIRMaster+ couldbe the right tool to assess energy savingsopportunities. AIRMaster+, availablethrough OIT, is a Windows-based tool thatmodels existing and future system opera-tion and evaluates the potential impact ofenergy-saving measures. Users of AIRMas-ter+ include compressed air equipmentcompanies and distributors, system audi-tors, plant personnel, and utility represen-tatives. AIRMaster+ can help improve yourcompressed air system—and help saveyour company money.

DOE and the Compressed Air Chal-lenge® (CAC) offer AIRMaster+ training tohelp system experts make the most effi-cient use of the tool and maximize its ben-efits. During the course, participants learn:

■ How to use the AIRMaster+ software

■ How to accurately acquire input datafor AIRMaster+

■ How to use the software to evaluatecompressed air systems and develop ameasurement plan

■ How to make measurements for hourlytrends of typical daily data versusdynamic measurements to characterizesystem events, pressure, and flow profiles

■ How to create AIRMaster+ compressoroperating scenarios and account for theeffect of system dynamics, pressure pro-files, flow versus pressure characteris-tics, and compressor control operation

The 21⁄2-day program includes classroominstruction, a practical exam to test hands-on measurement, and a written exam.Learn the software methodology, how tocollect and enter field data, and how tointerpret results.

How to Become a Qualified SpecialistOIT Allied Partners who take the train-

ing and pass the exam can become Quali-fied AIRMaster+ Specialists. TheseSpecialists can better help you to identifysavings opportunities in your plant usingAIRMaster+. DOE and CAC recognizeQualified AIRMaster+ Specialists for theirability to use the AIRMaster+ softwareeffectively with industrial end users.

To become a Qualified AIRMaster+ Spe-cialist, Allied Partners must complete theCAC Advanced Management of Com-pressed Air Systems course as a prerequi-site to the AIRMaster+ training.

Find the list of Qualified AIRMaster+Specialists on the BestPractices Web site atwww.oit.doe.gov/bestpractices/software/airmaster_cert/shtml. If you are a compressed air system expert interested in the AIRMaster+ qualification process,please contact Aimee McKane at [email protected]. Order a copy of AIRMaster+ from the OIT Clearinghouse atwww.oit.doe.gov/clearinghouse, or call800-862-2086. ●

AIRMaster+ and Qualified Specialist Training

Pumping systems account for nearly 20%of the world’s energy demand and, in someindustrial operations, account for 20% to50% of energy costs. However, becausepumps function as a component of largersystems, companies may overlook oppor-tunities for savings and improved pumpsystem performance.

Life Cycle Cost (LCC) analysis is a man-agement tool that can help companiesminimize waste and maximize energy effi-ciency for many types of systems, includ-ing pumping systems. In cooperation withDOE, the Hydraulic Institute (an OIT AlliedPartner), and Europump, have developedPump Life Cycle Costs: A Guide to LCCAnalysis for Pumping Systems. A free exec-utive summary offers highlights of the

larger 200-page guide, assisting plant own-ers and operators in applying the LCCmethodology to pumping systems. Use theguide to identify opportunities for consid-erable cost and energy savings.

Learn more about applying LCC methodsto pumping systems by downloading thesummary from the “Energy Savings” sectionof the Hydraulic Institute Web site atwww.pumps.org, or from the BestPracticesWeb site at www.oit.doe.gov/bestpractices/technical_publications.shtml#pumplifecycle. The 200-page LCC Guide is avail-able for purchase from the Hydraulic Insti-tute at www.pumps.org. ●

Life Cycle Cost Analysis: A Management Tool for Pump System Efficiency

QUALIFIED SPECIALISTS FOR PUMPING SYSTEM TOOL

Don’t forget that Pumping System Assessment Tool (PSAT) Qualified Specialists are alsoavailable to help you. Demand for training has grown, and DOE has responded by train-ing more experts in the PSAT software. With a little instruction from a specialist on usingthe software, you can put PSAT to the test and begin uncovering the pump system sav-ings waiting in your plant. Locate a PSAT Specialist on the BestPractices Web site atwww.oit.doe.gov/bestpractices/software/psat_cert.shtml.

If you are a pump system professional interested in the PSAT qualification process,please contact Vestal Tutterow at [email protected].


Letters to the Editor Energy Matters welcomesyour typewritten letters and

e-mails. Please include yourfull name, address, organization, andphone number, and limit comments to 200words. Address correspondence to:

Michelle Mallory, Letters to the EditorNREL, MS 16091617 Cole Blvd.Golden, CO 80401E-mail: [email protected]

We publish letters of interest to readerson related topics, comments, or criticisms/corrections of a technical nature. Prefer-ence is given to articles that appeared inthe previous two issues. Letters may beedited for length, clarity, and style. ●

EDITOR’S NOTE

A Mil by Any Other NameIn the Figure 2 caption of Don Casada’s Perfor-mance Optimization Tips (page 8, Fall 2001issue) we printed “40-mil” as “40-millimeter”in reference to the gap separating currenttransducer jaws. The figure illustrates thateven a slight gap of 40 mil can cause a con-siderable error in the indicated current. Ourapologies to Don for the error. ●

Read more about “smart systems” and howthey could benefit your company in EnergyMatters Extra. Access more informationabout the OIT Showcase at AugustaNewsprint and OIT’s Forest Products Indus-try of the Future program. Learn more aboutcombustion control strategies, and how OIT is helping to improve heat-deliveryprocesses for greater efficiency, productivity,and quality. Plus, link to more on the MotorDecisions Matter campaign, and find outabout publications, tools, and training infor-mation from OIT’s BestPractices Motors pro-gram. Order the new OIT Decision Tools forIndustry CD, which includes four powerfulsystem assessment tools. And finally, link tothe Hydraulic Institute for more on thepump Life Cycle Cost analysis tool.

Log on to Energy Matters Extra at www.oit.doe.gov/bestpractices/energymatters/emextra. ●

EXTRA

In partnership with the California EnergyCommission, the OIT is hosting a series of1-day events to assist California industriesin improving system efficiency and reduc-ing electrical demand. The second of theseevents took place on January 16, 2002 atthe San Jose Convention Center in SanJose, California. Keynote speaker for theevent was Speaker pro Tem Fred Keeley(D-Boulder Creek), who addressed “TheFuture of Energy Efficiency in a Post EnergyCrisis World.” Co-sponsoring organizationsincluded the Silicon Valley ManufacturingGroup, California Manufacturers and Tech-nology Association, California League ofFood Processors, and the Association ofCalifornia Water Agencies.

Nearly 200 participated in the event,including 103 attendees and 68 represen-tatives from OIT Allied Partner companies.Of the 31 exhibitors, 28 booths were rep-resented by Allied Partners. In addition,speakers offered practical advice and solu-tions for managing electrical demand andimproving system efficiency. Case studiesof California industries illustrated how asystems approach can help companiesreduce electrical energy usage.

The third Energy Solutions for Californiaevent will be May 15, 2002, at the WestCoast Anaheim Hotel in Anaheim. For moreinformation about the upcoming event and acomplete list of participants and case studiesfrom the San Jose event, visit www.projectperformance.net/caenergyevents. ●

Second Energy Solutions for California Event Held in San Jose

The Compressed Air and Gas Institute(CAGI), a trade association representingcompressed air equipment manufacturers,has worked with its member companies to develop standardizedperformance testing forcompressors and com-pressed air dryers. As aresult, data sheets are nowavailable that will help endusers select compressed airsystem equipment suitablefor the planned operatingconditions.

In its 1997 Allied Partner agreement,CAGI made a commitment to standardizetesting and develop data sheets. Com-pressed air equipment manufacturers are responsible for providing the self-certifieddata that completes the data sheets. Pur-chasers can use these data sheets to com-pare like equipment under equal operatingparameters. The standardized data sheetformats for rotary screw and reciprocatingcompressors as well as refrigerant andregenerative desiccant dryers can be foundat www.cagi.org/intro.htm.

Kaeser Compressors, a CAGI memberand an OIT Allied Partner since May 2001,is the first compressed air equipment manu-facturer to publish equipment performance

on its company Web site atwww.kaesercompressors.com/PRODUCTS/CAGIshtL.php. This is significantbecause, for the first time,industrial facility engineersand procurement officialshave ready access to spe-cific model information inthe standardized CAGI for-

mat. Web-based access to model-specificstandardized data allows consumers to eas-ily and reliably compare the performanceof compressor models prior to purchase,something that was previously very diffi-cult. As additional companies followKaeser’s lead, evaluating the performanceof compressed air equipment prior to pur-chase will become even easier. ●

Improved Compressor Performance Information Now Available

INFORMATION

CLEARINGHOUSE

Do you have questions about using energy-efficient process

and utility systems in your industrial facility? Call the OIT Information Clear-inghouse for answers, Monday throughFriday 9:00 a.m. to 8:00 p.m. (EST).

Fax: 360-586-8303, or access our homepage at www.oit.doe.gov/clearinghouse.

HOTLINE: 800-862-2086

DOE Regional Office Representatives

■ David Godfrey, Atlanta, GA, 404-562-0568

■ Scott Hutchins, Boston, MA, 617-565-9765

■ Brian Olsen, Chicago, IL, 312-886-8579

■ Jack Jenkins, Denver, CO, 303-275-4824

■ Chris Cockrill, Seattle, WA, 816-873-3299

■ Joseph Barrett, Philadelphia, PA, 215-656-6957

This document was produced for the Office of Energy Efficiency and Renewable Energy atthe U.S. Department of Energy (DOE) by the National Renewable Energy Laboratory, a DOEnational laboratory.DOE/GO-102002-1501 • Winter 2002

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Printed with a renewable-source ink on papercontaining at least 50% wastepaper, including20% postconsumer waste

ENERGY & ENVIRONMENTAL SUMMIT 2002

■ February 21-22, 2002, San Diego, CA

For more information, contact Jack Flynn at 619-298-5554, or e-mail [email protected]

PAPER SUMMIT 2002 AND TAPPI ENERGY RESULTS SHOWCASE

■ March 3-6, 2002, Atlanta, GA

The event will be held in conjunction with OIT’s Showcase Demonstration at AugustaNewsprint (see below). For more information about the Paper Summit, contact Erin Laytonat 212-268-4160 ext. 125 or e-mail [email protected]. Visit the Paper Summit Website at www.papersummit.net.

OIT SHOWCASE DEMONSTRATION AT AUGUSTA NEWSPRINT

■ March 6-7, 2002, Augusta, GA

For more information, see the special supplement in this issue of Energy Matters, and visitthe Web site at www.energetics.com/augustashowcase.

ANNUAL DISTRIBUTED GENERATION AND ON-SITE POWER CONFERENCE

■ March 11-12, 2002, Atlanta, GA

For more information, call 508-427-9470, or e-mail [email protected].

TAPPI ALLIED PARTNER EVENT

■ April 17, 2002, Delaware Valley, DE

For more information, call Chris Cockrill at 816-873-3299, or e-mail [email protected].

PROCESS HEATING WORKSHOP

■ April 19, 2002, Houston, TX

For more information, call Bob Gemmer at 202-586-5885, or e-mail [email protected].

National Renewable Energy Laboratory1617 Cole BoulevardGolden, CO 80401-3393

FIRST CLASSU.S. Postage

PAIDPermit No. 258

Golden, ColoradoBestPracticesThe Office of Industrial Technologies (OIT)BestPractices initiative and its Energy Mat-ters newsletter introduce industrial endusers to emerging technologies and well-proven, cost-saving opportunities in motor,steam, compressed air, and other plant-wide systems. For overview informationand to keep current on what is happeningoffice wide, check out the newsletter—TheOIT Times—at www.oit.doe.gov/oit-times.

Coming Events

To keep up-to-date on OIT training and other events, check the calendar regularly onEnergy Matters Extra at www.oit.doe.gov/bestpractices/energymatters/emextra.

OIT Showcase Demonstrations are publicevents that highlight the latest energy-man-agement practices and energy-efficienttechnologies emerging from OIT-sponsoredresearch and development. These events,hosted by manufacturers and trade associa-tions in partnership with OIT, spotlightenergy- and cost-saving technologies thathave been implemented at industrial facili-ties. Organizers invite industry representa-tives to tour the host plant(s), attendworkshops, and watch demonstrations tosee advanced energy processes and prac-tices in action.

The Showcase process usually beginswith a plant-wide assessment performedwith the assistance of OIT’s BestPracticesprogram or university-based IndustrialAssessment Centers. Then plants imple-ment assessment recommendations in theform of process or system improvements.Next, an independent third party validatesthe technology performance and costs.Finally, the planning begins for a showcase

event. OIT makes available a wide rangeof resources to host sites, including sharingthe costs for organizing the event. OIT usesshowcases to publicize and promoteenergy-saving technologies and practices.In turn, by showcasing leading-edge tech-nologies that conserve energy, reduce envi-ronmental impact, and boost productivity,host plants enhance their images as leadersin their industries and local communities.

Demonstration to Replication “Showcases provide the opportunity for

participants to learn from and exchangeideas with researchers, colleagues, andOIT staff about industry programs and pro-jects, particularly those that are ready forplant floor application,” explains DeniseSwink, Deputy Assistant Secretary for OIT.

In fact, the BestPractices team estimatesthat improvements made to a manufacturingfacility based on a plant-wide assessmentcan be replicated at five to ten other facili-ties with equivalent systems and energyusage. What better way to disseminate theinformation to those other plants than with aShowcase Demonstration?

Technologies, process improvements,and implementation strategies are oftensimilar, if not identical, across industries. Often, several Industries of the Future worktogether to demonstrate their energy- andcost-saving technologies. Showcases areproving grounds for the success of OIT’scollaborative approach.

Showcasing Results Recent showcases have illustrated sig-

nificant energy savings and productivityincreases. Bethlehem Steel hosted the firstshowcase event at its plant in Burns Har-bor, Indiana, in April 1998. Among thetechnologies profiled during the event wasa steam system improvement that savedapproximately 40,000 megawatt-hours(MWh) of electricity, 85,000 million Btu ofnatural gas, and nearly $3.3 million.

Metal caster Lester Precision Die Cast-ing, in Solon, Ohio, realized a 20% exten-sion in usable time between maintenancecycles, reduced scrap by as much as 20%,and increased production from 50 partsper hour to 60 parts per hour by using avisualization tool to identify die designimprovements. Lester showcased this andother improvements in November 1999.

At the Pittsburgh Regional TechnologyShowcase in May 2000, Weirton Steel, inWeirton, Pennsylvania, featured com-pressed air system improvements that areexpected to save $76,000 in repair andmaintenance costs and $60,000 in energycosts. U. S. Steel and Koppel Steel also par-ticipated in the Pittsburgh Showcase.

Most recently, the State of Utah hosted theUtah 2001 Showcase in Salt Lake City, wherecompanies from three industries—aluminum,mining, and petroleum—demonstrated theirlatest energy technologies and managementpractices. Alcoa North American Extrusionin Spanish Fork demonstrated several

A Special Supplement to Energy MattersOIT’S SHOWCASE DEMONSTRATIONAT AUGUSTA NEWSPRINT

OIT Showcases Emerging Technologies and Energy Practices


The Road to a Showcase Demonstration

Energy use assessment

IAC energy audits, in-plantassessments, and plant-wide assessments

Installation andimplementation

Emerging technologies and system improvements

Validation and verification

Measurements and data analysis

Showcase Demonstration

Five or more OIT-funded technologiesand best practices

A casting company realizes a 20% increase in usable time between

maintenance cycles, a steel plant expects annual savings of $76,000

in repair and maintenance costs, another steel plant modifies its steam

system to the tune of $3.3 million in annual savings, and now a newsprint

company is anticipating annual energy savings of $1.4 million because

of improved energy technologies. These are the kinds of successes that

the Office of Industrial Technologies (OIT) likes to showcase.

The Augusta Newsprint Showcase willhighlight lessons learned from processimprovements that have been imple-mented at the paper mill. Don’t miss thespecial sessions that focus on practicalsolutions to common problems, as well asstate-of-the-art technology to help youimprove energy efficiency and save moneyin your facility. Tour the Augusta Newsprintfacility and learn first-hand how the mill isachieving cost and energy savings.

Who Should Attend?Attend the Augusta Showcase to find

out about state-of-the-art technologies andenergy management practices that canhelp make your facility more competitiveand energy efficient. The event is an idealopportunity for:

■ Maintenance engineers ■ Operations managers ■ Plant managers■ Process engineers

■ Executive managers■ Financial managers■ Researchers■ Research managers

Energy Saving Technologies for Today:Results and Lessons Learned

Choose from the technical presentations(below left) on energy management; qual-ity control; and air, water, and lightingimprovements that will take place onMarch 7, 2002 at the Radisson RiverfrontHotel and Augusta Newsprint. For a com-plete schedule of the 11⁄2-day event andregistration information, please visit www.energetics.com/AugustaShowcase/.

Tour and Showcase Exhibition at AugustaNewsprint Mill

Also on March 7, from 1:30 to 5:00 p.m.Augusta Newsprint will host a tour of itsfacilities and an exhibition. This is yourchance to:

■ See technologies in practice■ Visit the Augusta Training Center for

hands-on training in OIT BestPracticessoftware tools

■ Visit vendor booths ■ Learn about technologies from poster

sessions and detailed case studies. ●

A Look at What’s in Store at the Augusta Showcase

promising new technologies, such as oscil-lating combustion, dross processing, andvertical flotation. The Spanish Fork opera-tion could save an estimated $843,000 peryear by implementing several improve-ments recommended in an OIT IndustrialAssessment Center evaluation. Other partic-ipants in the Utah event were KennecottUtah Copper, Magnesium Corporation ofAmerica, Flying J, and Silver Eagle.

Augusta Newsprint Readies to Host Showcase

Next in the line-up is a ShowcaseDemonstration to be hosted by AugustaNewsprint Company, in Augusta, Georgia,on March 6-7, 2002. The newsprint pro-ducer has invested in $1.7 million worth ofimprovements throughout the mill that willyield $1.4 million in annual energy sav-ings. Learn more about the projects at Augusta and what to expect at the show-case in the pages that follow.

The technologies showcased at Augustawill help meet the Forest Products industry’sgoals set out in its Agenda 2020 roadmap—a research plan established by the industry.Specifically, the industry is interested inimproving manufacturing process efficiency,heat recovery, and the environmentalimpact of energy production and utilization.

In addition, Agenda 2020 lists technologydemonstrations as a step toward commercial

success. It states, “thosefacilities within the industrythat act as host for… demon-strations will become a valu-able and integral element ofcommercial success.” Viewthe Agenda 2020 roadmapon the OIT Web site atwww.oit.doe.gov/forest.

Showcases on the Horizon OIT is working with indus-

try on several upcomingshowcase events. Amongthem is a Texas Showcase in

Spring 2003 highlighting efficiency improve-ments at both chemical and petroleumplants. Two mining showcases—one inNevada in August 2003 and the other inGeorgia in Spring 2004—are also in theworks. Check the OIT BestPractices Web sitewww.oit.doe.gov/bestpractices and futureeditions of Energy Matters for more informa-tion on upcoming showcase events. ●

OIT Showcasescontinued from page 1

Vertical flotation was a new technology demonstrated at the Utah 2001 Showcase.

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Augusta Newsprint Technical Presentations on March 7, 2002

Time Track 1 Track 2 Track 3

8:00 a.m. Compressed Air Best Economic Benefits from Environmental Regulation Practices: Technical and Advanced Quality Control of Challenges for the Electric Financial Solutions TMP Mills IndustryE-Group Invensys Pacific Simulation Georgia Power

9:00 a.m. Introduction to the Modern Dryer Drainage and Energy Reduction Energy Opportunity in Control Systems for the Opportunities at a Compressed Air Paper Machine Linerboard Paper MillGoodrich Air-Science The Johnson Corporation Dean Oliver International Engineering Division

Break

10:10 a.m. Smart Pumping Systems: Power and Energy Energy and Asset The Time is Now Management Solutions for PerformanceGoulds Pumps Today’s Industry General Electric Company

Rockwell Automation

11:10 a.m. Pulp & Paper Industry Tie Line-Advisory/Control Paper Mill Energy Lighting: Whys and Why Nots Applications ManagementHolophane Lighting Honeywell Measurex Corp. Emerson/Fisher Rosemount

2 OIT Showcase Demonstration at Augusta Newsprint

Augusta Newsprint Company of Augusta,Georgia, is one company that has part-nered with OIT and used these resources tosave $1.4 million and approximately 130billion Btu per year. The company will bedemonstrating some of the projects that arehelping it achieve these savings March 6-7,2002, during the OIT Showcase at AugustaNewsprint, presented in conjunction withthe Institute of Paper Science and Technol-ogy (IPST), the Technical Association of thePulp and Paper Industry (TAPPI), andAgenda 2020.

Company Background Augusta Newsprint’s roots go back to

1965, when, as Cox Newsprint, it con-sisted of one paper machine and a ground-wood mill. Today, the mill’s facilitiesinclude two paper machines, a wood yard,a thermo-mechanical pulp (TMP) mill, arecycled newsprint (RNP) mill, a barkboiler, utilities, and support areas. Itemploys 390 people and produces 1,200tons of newsprint per day. Abitibi-Consoli-dated is the managing partner that ownshalf of the mill, and The Woodbridge Com-pany, a holding company for the Thomsonfamily, owns the other half.

The mill, like all for-est product businessesin the country, is contin-ually challenged by for-eign competition andother economic forces.To remain competitive,management constantly seeks ways toimprove the bottom line. In May of 2000,IPST introduced Augusta Newsprint to OIT,which subsequently assisted mill manage-ment with assessing energy use and identi-fying energy-saving opportunities, plussharing costs and providing technical assis-tance for improvements.

A Corporate Strategy on Energy Management

Augusta Newsprint has set a goal ofreducing energy use by 1% each year forthe next 5 years. Chuck Amos, the plant’sEngineering Manager, says that the millwill be able to achieve this goal for 2002.

Part of the company’s strategy is workingin partnership with OIT.

“Augusta Newsprint is open to new waysof doing things, taking some calculatedrisks, and trying new technologies,” Amossays. “The showcase idea seemed like agood vehicle to improve partnerships withvendors, OIT, and IPST. We saw it as achance to learn and grow and to focus onenergy costs and savings. And, frankly, theshowcase deadline helped keep the projectsmoving. We had to have the numbers toshow the projects’ success. You know, somany mills never optimize projects becauseno one checks the numbers.”

“It turns out there were some things wecould do that were very simple,” accordingto Amos. One relatively simple project thatprovided “phenomenal” results was a light-ing replacement project that saves the mill$46,000 per year. But there were greateropportunities to save dollars and energy inprocess systems.

Investments in Energy Efficiency Bring Financial Rewards

Augusta has implemented many energy-saving projects. Some of these, which willbe demonstrated at the showcase, follow.

Compressed Air. After doing a com-pressed air survey, management decided toincrease system storage capacity, tie twomill systems together with improved con-trols, and repair leaks. These actions, whichcost $75,000, are saving the mill $60,000

Augusta Newsprint’s advanced computer modeling system con-trols these refiners, which are driven by 12,000-hp motors.

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“THE SHOWCASE IDEA SEEMED LIKE A

GOOD VEHICLE TO IMPROVE

PARTNERSHIPS WITH VENDORS, OIT,

AND IPST… WE HAD TO HAVE THE

NUMBERS TO SHOW THE PROJECTS’

SUCCESS. YOU KNOW, SO MANY MILLS

NEVER OPTIMIZE PROJECTS BECAUSE

NO ONE CHECKS THE NUMBERS.”

Augusta Newsprint installed a plate-style,boiler blowdown to preheat boiler make-upwater.

See New Energy-Saving Technology at Augusta Newsprint

OIT Showcase Demonstration at Augusta Newsprint 3

A s the forest products industry faces increasing

economic challenges, OIT is working in partnership

with forest products companies in many ways: by facili-

tating and collaborating on research and development

efforts, cost-sharing technology implementation, helping

plants identify opportunities through plant-wide energy-use

assessments, and making available technical expertise

and tools to enhance manufacturing operations.


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per year. Amos said that the survey results“surprised all of us. It showed us that, eventhough we’re experienced, we wereunaware of some important issues.”

TMP LD Transfer Pump Upgrade. Thisproject involved removing a 10-inch con-trol valve and installing a variable fre-quency drive to control pump speed basedon flow requirements. It required a $15,000investment, but will save the mill $12,000per year in energy costs on one pump. (Seepage 5 for more about this project.)

#1 Paper Machine Fan Pump MotorReplacement. Augusta Newsprint replaceda 1,250-hp (900-rpm) motor with an 800-hp(720-rpm) motor to more accurately pro-vide only the needed stock flow for the #1paper machine. A total of 500 hp is beingsaved by no longer pumping excessive flowagainst a closed control valve. The millinvested $123,000 on this project and willsave $93,500 per year in energy costs.

Advanced Quality Control Project. TheAdvanced Quality Control (AQC) project isone that may reap the most impressiveresults. “Early on, some of us were skepti-cal about this project,” Amos says, “Butnow we’re really enthusiastic.”

The first phase of the AQC project wasinstalled in the TMP mill of the AugustaNewsprint facility in December of 2001.The two main goals are to minimize energyconsumption and high-cost kraft pulp con-sumption by improving TMP quality. Theproject has been a joint effort between millstaff, Invensys’ Pacific Simulation, and OIT.After investing $1.4 million, the AQC pro-ject is expected to save Augusta Newsprint$1.12 million per year and reduce con-sumption of kraft pulp by 2,000 metrictons. Furthermore, energy use is expectedto be cut by 7,200 MWh per year. (Seebelow for more about this project.)

Get Involved!The technologies featured in OIT show-

cases can be replicated throughout U.S.industry. Your company may benefit finan-cially by applying some of the innovationsthat will be on display at the OIT Showcaseat Augusta Newsprint. So register now. Formore information, see the Calendar on theBestPractices Web site at www.oit.doe.gov/bestpractices. To learn more abouthow your company can participate in OIT’sshowcases, see “Acquire New Technology,Tech Support, and Savings–Host a Show-case!” on page 6. You can also log on tothe BestPractices Web site and click on the“Showcase Demonstration” link. ●

New Technology at Augusta Newsprintcontinued from page 3

When Augusta Newsprint and DOEassessed opportunities for improving energyefficiency and productivity throughout theplant, the potential in the mill’s thermo-mechanical pulp (TMP) process could notbe overlooked. The company took steps toimprove the TMP process—among themost significant was implementing anadvanced quality control (AQC) solution.Augusta will demonstrate the project at itsShowcase Demonstration event in March.

TMP is the process Augusta Newsprintuses to produce pulp from wood chips. Theprocess uses heat (thermo) and rotatingplates (mechanical) to grind wood chipsinto individual fibers using 12,000-hpmotors. The route from wood chips to pulpdemands large amounts of energy and con-stant quality control. “Any major change inthis area can dramatically improve our bot-tom line,” explains John Green, the ProjectEngineer at Augusta Newsprint who over-saw this project.

The mill focused on making the TMPprocess more efficient, Green says,

“because electrical energy accounts for23% of the cost to produce 1 ton of paper.Of that, the TMP process alone accountsfor 71% of electrical energy use.”

Partnership Leads to Solution To optimize the TMP process, Augusta

Newsprint and Invensys’ Pacific Simulationgroup teamed up to implement AQC. As aresult, Augusta expects improved energyefficiency, reduced manufacturing costs,and improved product quality. Augusta willinvest $1.4 million in the system over the4-year project and estimates annual sav-ings of $1.12 million.

The solution involved installing anadvanced, model predictive multivariantcontroller that works with the mill’s exist-ing distributed control system. The methodprovides real-time and online predictivemodels and modifies control actions tomaximize quality and minimize costs.Using software sensors, the system canpredict difficult-to-measure quality and process variables; its model predictive control algorithms also control quality.

In addition to helping Augusta Newsprintreduce the energy required for manufactur-ing, the AQC solution allows the mill tomodify its production schedule to matchreal-time pricing from the electrical market.A time-of-day production control forecaststhe upcoming market power price usingreadily available data, then adjusts produc-tion rates in the pulping operation to minimize average purchased energy cost.

Mill operators use AQC as a tool for maintaining product quality and reducingcosts in the TMP process.


OIT Showcase Demonstration at Augusta Newsprint 4

Advanced Quality Control Enhances TMP Operation

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PAPER SUMMIT 2002 AND TAPPI EVENT IN CONJUNCTION WITH AUGUSTA SHOWCASE

Take advantage of another opportunity to learn about energy-saving technologies in thepaper industry. In addition to attending the Augusta Newsprint Showcase, plan to attendPaper Summit 2002, including TAPPI’s “Energy Results Showcase: Meeting Today’s Chal-lenges,” being held in Atlanta, Georgia, March 3-6, 2002. Transportation will be availablebetween Atlanta and Augusta for attendees of both the Augusta Showcase and the PaperSummit. For more information on attending Paper Summit 2002 in Atlanta, please contactErin Layton by phone at 212-268-4160 ext. 125, by fax at 212-268-4178, or by e-mail [email protected]. Or, visit the Paper Summit Web site at www.papersummit.net.For more information on attending TAPPI’s Energy Results Showcase, contact the TAPPIMember Connection at 1-800-332-8686 (USA) or 1-800-446-9431 (Canada).


When OIT performed a plant-wide assess-ment at Augusta Newsprint in 2000, themill ranked high in overall energy effi-ciency. However, the assessment revealednumerous opportunities to improve electri-cal energy consumption across the variousmechanical systems in the mill. Among theareas that could be improved wasAugusta’s pumping system. DOE’s UnitedStates Industrial Electrical Motor SystemsMarket Opportunities Assessment 1 report,published in 1998, revealed that centrifu-gal pumps were the single largest energyconsumers in pulp and paper mills. AtAugusta Newsprint, pumps consume 21%of the mill’s energy.

After OIT’s initial assessment, Augustadecided to target process pumps, in gen-

eral, and its thermo-mechanical pulp(TMP) mill, in particular, for more in-depthstudy. Together, with project partners DeanOliver International, an Atlanta-based consulting firm, and ITT Goulds Pumps, asupplier of process pumps to paper millsand an OIT Allied Partner, AugustaNewsprint analyzed and reviewed more

than 150 pumping systems at the mill. Thisincluded motor and pump systems in thepaper mill, the refiner mechanical pulpmill, and the TMP plant. The review alsorevealed areas of improvement in theprocess equipment and control strategiesin the TMP mill.

State-of-the-Art Technology Boosts Pumping System Efficiency at Augusta

Augusta replaced traditional valve control with VFD technology on one of its TMP pumps.

Traditional Pumping System(Fixed speed pump, control valve, transmitter)

Variable Frequency Drive (VFD) Pumping System

Set point

Set point

Controlvalve

Blockingvalve

Lower limitspecification

VFDStarter

Distributed control system Flow indicator

Distributed control system

Process value distribution

Process value distribution

2 Sigma 2 Sigma2 Sigma 2 Sigma

Flow controller

FlowFlow

Software embedded in the controller micro-processor becomes the “brains” of a pumpingsystem. (continued on page 6) �

Just as an intelligent flow control system helped Augusta Newsprintimprove its TMP pump system, this advanced technology could alsohelp other plants achieve energy and cost savings. Learn more aboutsmart pump systems at the Augusta Newsprint Showcase by attending“Smart Pumping Systems: The Time is Now,” a workshop led by OITAllied Partner ITT Goulds Pumps. The discussion will include a morein-depth look at the implementation of intelligent flow control atAugusta Newsprint and will present the potential for wider applications.

According to DOE, most of the motor system energy savings in the U.S.pulp and paper industry are concentrated in pump system improvements,particularly those that involve mid- to large-size pumps. Efficiency mea-sures, such as replacing throttling valves with speed controls, can yieldsavings that range from 5% to 50% of the system’s total energy use.1

The Finnish report, Expert Systems for Diagnosis of the Condition andPerformance of Centrifugal Pumps,2 concurs that there is plenty ofroom for improvement when it comes to pump system efficiency. Areview of 1,760 pumps at more than 20 industrial sites showed thataverage pumping system efficiency was below 40%, with 10% of thepumps operating below 10% efficiency. Furthermore, these studies esti-mate that 70% of pumping systems are oversized and operating with

throttled valves, frequently less than 50% open. Throttled valves causesignificantly higher energy consumption and reduced system reliability.

In the past, using oversized pumps has been the standard practice toensure throughput during peak production periods or to accommodatecapacity growth. However, today’s variable frequency drive (VFD)technologies may offer many advantages to traditional valve-controlledfixed speed systems.

Reliability and unit costs of VFD systems have improved dramatically,and as energy costs continue to increase, VFD technology is gainingwider acceptance as a fundamentally better way to run continuousand, in some cases, batch processes. Smart pump technology involvesembedding intelligence about the pumping system in a microproces-sor-based VFD.

See page 2 for a schedule of the smart pumping system workshop, andplan to attend.

1 United States Industrial Electrical Motor Systems Market Opportunities Assessment,1998, page 14 and page 18 (Table E-7).

2 Jantunen, Erkki Kirsi Vaha-Pietila, and Kimmo Personene, Technical Research Centerof Finland, Manufacturing Technology. Presented at the VTT Symposium 172, COMADEM ’97, 10th International Congress and Exhibit on Condition Monitoring and Diagnostic Engineering Management, Vol. 2.

SHOWCASE WORKSHOP WILL HIGHLIGHT SMART PUMP TECHNOLOGY


Since June 2001, when Dean OliverInternational presented the findings of itsstudy, Augusta Newsprint has implementedseveral of the recommendations. The millwill demonstrate some of the technical andeconomic results when it opens it doors forthe OIT Showcase event this March.

Among the technologies to be demon-strated is the application of smart pumptechnology, which has improved control oflow-density stock level in one of the mill’sTMP storage towers. Before the improve-ment, the mill relied on a valve to controlflow from the tower’s 200-hp fixed-speedpump. This application consumed signifi-cantly more energy because of the high sys-tem head associated with the throttlingcontrol valve. Furthermore, throttling as ameans of controlling flow caused severecavitation across the flow control valve.Cavitation often leads to valve and pipingdamage, resulting in frequent valve failures.

The solution was an installation of astate-of-the-art variable frequency drive(VFD) that incorporates intelligent flowcontrol. This new technology has signifi-cantly reduced energy usage, while elimi-nating the valve and its associated repairs.Augusta Newsprint could achieve a totalsavings of about $231,000 over the 20-year life cycle of the pump, in mainte-nance, operations, and other costs. Thecompany estimates energy cost savings of$12,000 annually from installation of thenew technology on one pump. ●

1 The report is available on the OIT BestPractices Website at www.oit.doe.gov/bestpractices.

If you have upgraded, or are thinking about upgrading your manu-facturing facility to improve its energy efficiency, consider hostingan OIT Showcase Demonstration event. Your company will:

■ Gain access to energy-efficient technologies, technical assistance,decision-support tools, and information from OIT

■ Achieve bottom-line energy savings and productivity improvements■ Validate the benefits of using advanced technologies and best

energy-management practices■ Create good public relations ■ Become a leader in energy and resource efficiency

OIT targets nine energy-intensive industries when selecting Show-case Demonstration companies. These Industries of the Futureinclude agriculture, aluminum, chemicals, forest products, glass,metal casting, mining, petroleum refining, and steel.

To get started, visit the OIT Web site at www.oit.doe.gov and con-tact the team leader for your industry listed on the Industries of theFuture page. Learn more about hosting a Showcase Demonstrationon the BestPractices Web site at www.oit.doe.gov/bestpractices/pdfs/showcases.pdf.

Because of this feature, Augusta can bettermanage energy use while maintaining qual-ity and paper machine production rates. Theillustration at right shows how this leads toimproved profitability for Augusta Newsprint.

The AQC system is not a substitute forAugusta’s skilled and trained operators, butrather provides a flexible and integratedway to enhance their capabilities. Opera-tors now have a tool that allows them torespond to dynamic market and processconditions and operating costs while main-taining product quality.

Although Augusta Newsprint expectsthe system to begin paying off almostimmediately, this is only the first phase ofthe AQC solution. The next phase, whichinvolves performance monitoring and sys-tem optimization, will take place over the

next 3 years. During this time Augusta willcontinue to work in partnership withInvensys’ Pacific Simulation group toensure long-term and sustainable results. ●

At the Augusta Newsprint Showcase, youwill see just how the mill’s AQC systemworks in real time. Augusta Newsprint andInvensys’ Pacific Simulation group willdemonstrate via a remote link how the con-trol system interfaces with the existing dis-tributed control system and operators, andpresent the system’s status and benefits.

Invensys will also lead a technical sessionon the “Economic Benefits from AdvancedQuality Control of TMP Mills.” Like AugustaNewsprint, other mills are looking for waysto remain competitive—and applying AQCtechnology could be a major step in thatdirection. Learn why Augusta and other millsare finding that while implementing such asystem can provide measurable results in

the short term, AQC is really a long-termsolution to help improve operations andreduce costs. The presentation will cover:

■ An overview of AQC technology■ Which sites should apply AQC ■ Economic comparisons■ Case study examples

Attend the session to find out how theanalysis performed at Augusta Newsprintmight be applied in other industries toimprove operations and reduce operatingcosts. The discussion will also includeother methods of total plant energy analy-sis that are similar to the AQC analysis.

See the schedule on page 2 and plan toattend this presentation.

Pumping System Efficiencycontinued from page 5

Quality Control Enhances TMP Operationcontinued from page 4

ACQUIRE NEW TECHNOLOGY, TECH SUPPORT, AND SAVINGS–HOST A SHOWCASE!

AQC AT WORK

AQC helps the mill respond to variable economic conditions for purchased kraft or electricity.

Profitability

AQC Increases Quality and Savingsat Augusta Newsprint

Increased specific energy savings

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Energy Matters - Winter 2001 · 2013-09-26 · Energy Matters, Winter 2002 3 Project Background...

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