Support for Energy Efficiency Donagh Moorehead – Client Manager.

Support for Energy Efficiency

Donagh Moorehead – Client Manager

Potential for significant cost effective energy efficiency improvement

Source: Performance & Innovation Unit, February 2002

0%

10%

20%

30%

40%

Industry Services Domestic Transport

Energy Efficiency improvement potential(% current use)

24%21%

37%35%

0%

10%

20%

30%

40%

Industry Services Domestic Transport

Energy Efficiency improvement potential(% current use)

24%21%

37%35%

How the Carbon Trust can help your business

Understand your carbon footprint

Identify saving opportunities

Access the best knowledge

Finance your energy plan

Energise your employees

Achieve sustained energy

reductions

Show your carbon commitment

Implemented Site Survey Savings by Technology

Energy management

26%

Lighting17%

Compressed air7%

Air conditioning4%

Office equipment3%

Other15%

Motors & drives3%

Operation & maintenance

3%

Heating13%

Process heating & cooling

6%

Instrumentation & control

3% 2,200+

surveys

£100m+

investment

£70m+ pa

saving

Source: Carbon Trust survey analysis 2008

Our primary method for delivering cost effective Energy/Carbon savings to businesses right now are a range of free technical surveys carried out by independent specialist consultants approved and sourced by the Carbon Trust.

Site Survey Case Study – Local Engineering Company

1,233 206,432 3,655,805Total Energy

50.8%1,5560.6%23,684LPG

51026.1%53,94653.7%1,961,989Fuel Oil

71873.1%150,93045.7%1,670,132Grid Electricity

tonnes%£ / year%kWh/ year

CO2 emissions

CostPurchased EnergyUtility

0.7132,850761,131260.546,442Total

-

- ICT - General Awareness9

0 - 3 Months0.525,00097,49542.09,652Factory Extraction System Drive Motor - VSD8

0 - 3 Months1.353502,8681.2260Lighting Considerations - Sensors7

0 - 3 Months1.0115,000149,98364.514,848Factory Lighting - Upgrading6

0 - 3 Months-0294,98976.58,092Steam Boiler Plant - Heating & DHWS5

0 - 3 Months0.762,50033,00614.53,268HP Air Compressor System - Leakage4

3 - 6 Months0.9710,000182,79061.710,322Implement Training & Awareness Programme3

0 - 3 Months-000.00Raise Staff Awareness2

0 - 3 Months-000.00Energy Policy Development1

£kWhtonnes£

Energy Savings

CO2 Savings

Financial Savings

Suggested Timescale

for completion

Payback period (years)

Estimated Cost of

Measure

Estimated Annual Savings

Recommendations and Key ActionsPriority


Energy Consumption Guide 40 – Compressing Air Costs, GenerationEnergy Consumption Guide 41 – Compressing Air Costs, LeakageEnergy Consumption Guide 42 – Compressing Air Costs, Treatment

Relevant Publications:

Carry out full leak survey. Identify and log issues. Develop action plan within shutdown/quite periods to fix leaks.Subsequent to this it is recommended that the systems be considered for 3 -monthly air audits by on site staff.Obtain publications from the Carbon Trust.

Next Step:

Increased costs and poor control of a very expensive commodity. H.P. air is a very useful process tool but requires significant investment in its upkeep and ongoing maintenance.Plant access to equipment may be difficult due to operational needs.

Risks:

Leaks represent a significant waste of energy. Leak surveys and the subsequent repair of those leaks should be part of a pro-active maintenance regime. Pressure regulation is a fundamental ‘good practice’ requirement of compressor management.Compressed air is expensive’ – it costs the equivalent of c50p/kWh.

Rationale:

The main air compressor units and associated drier are sited in a dedicated area in an outbuilding to the side of the manufacturing area. The system provides compressed air at 7bar gauge via a piped delivery system that does not form a complete ring-main. Two in number compressors supply the system:1 x Mattei 350, 55kW constant speed machine – currently only used as back up in the event of failure.1 x VS Electra saver, 75kW variable speed drive unit. This unit provides for the normal daily supply of compressed air. Leak CheckingLeak checking is not carried out currently as a pro-active maintenance regime. Consideration needs to be given to addressing this issue in the immediate future as significant leakage was identified on the compressed air systems - these are a high cost to the operation and seriously reduce the overall system efficiency.Most compressor systems can save upwards of 30% in energy by simple measures such as identifying and fixing leaks. Reference: Energy Consumption Guide (ECG 41) Industry leakage can be as much as 40% - For the purposes of calculation 30% leakage is assumed - and reduced by survey and repairs as required to 10%. Calculation above considers the variable speed machine at an average 65% utilisation and repair costs of £1000. A leak survey can be completed within 1-2 days on a site of this type and size would cost within £750 - 1500, due to access and safety requirements. Successful leak management requires a strict cleaning and maintenance regime in order to sustain the significant savings. Plant/process air leakage was evident throughout the manufacturing areas - in particular on the use of flexible connections and air tools and filter/regulator units on machines.

Detail:

Payback0.76Years

Cost£2,500

(estimate)

Energy Savings33,006

kWh/year

CO2 Savings14.52

Tonnes/year

Cost Saving£3,268

per year

H.P. Air Compressor – System Leakage Priority 4


CIBSE (Chartered Institution of Building Services Engineers) offer lighting guides for refurbishment & new build options, i.e. LG1 – industrial Lighting.Some case study literature from the Carbon Trust may be of relevance to this sites operation.HSE (Health & Safety Executive) publication, ‘lighting for work’. Lighting Guide 006 – Carbon Trust

Relevant Publications:

Contact Author / Lighting professional to have lighting schemes reviewed.Contact proprietary owner (Chalmor) or original contractors to re-instate lux controllers and set up central controller. Claims against the original contractor may be difficult without sufficient evidence and facts re original specification etc. The controller is open circuited in several out stations and from on-site discussions (CT Consultant with proprietary Technical Support Engineer) it would appear that the original settings have been tampered with or where never set correctly hence no control exists for daylight factor integration. The position of the lux sensors also requires investigation as excellent daylight is available via the roof lights and current sensors do not appear to be placed in a representative layout to maximise control. Lighting equipment is included in the ECA Energy Technology List. Contact author for further information and/or go to: www.eca.gov.uk. Section 5.5 provides further information on ECA.

Next Step:

Lighting needs to be considered in respect of lux levels etc. this will obviously have to be a managed and controlled in full consideration of both area task and Health and safety requirements. A project of this nature would need operational, technical and quality control approval in line with the business function. It may well be an option to have a mixed lighting scheme, which can still deliver savings.Costs are not quotes. It is worthy of note at this point to state the ever increasing costs of electricity will have a impact on this calculation and hence the project. Savings originally predicted for the photocell operation have increased from £3,826 to £5,740 at current prices. Savings shown include for converting existing twins to singles (reflected with HF control gear). Considers T8 lamps as existing – T5 could be used with adaptors currently available to the market OR new units incorporating T5 lamps; the latter option would extend paybacks and would possibly be the least favoured option due to expenditure already incurred. Savings do not include energy saved by switching off circa 15% of the detailed lights that are illuminated above no/reduced occupancy areas e.g. old machine stores by bay 1, occupancy sensors for overhead lighting for integral open ceiling stores etc. A further ‘Full’ lighting survey will allow firm quotes to be generated (e.g. check condition of lamp fittings and assess suitability for twin to single upgrade, confirm lighting design layouts are appropriate for area functions, re-design options considered from an energy efficiency perspective may offer additional benefits in respect of lighting levels, etc.)

Risks:

T8 fluorescent tubes use 8% less energy compared to the older T12 fluorescent tubes. T5 tubes can offer up to 50% energy savings plus increased lumens/watt (light output). Retrofit upgrade option by replacement of internal gear, single lamp, high frequency control gear and reflector provide savings estimated as: Lighting controls will provide at least 20% saving in this factory if applied through correctly applied lux sensors, occupancy detectors and a centralised controller correctly set and with ease of operation.

Rationale:

Upgrades to the factory lighting have been carried out in recent years (actual date not known due to change of staff but believed to be within past 1-2 years). The upgrade information (fine detail) is not fully documented so comments are made in respect to what is currently existing against what could be attained through re-visiting this project and further enhancing the savings.Original upgrade scope was to replace old fittings in operational bays only i.e. bays 2,3 and 4; with High Frequency twin and single open batten fluorescents utilising Triphosphor colour 840 lamps. In addition to fit 6 in number photocells to allow interaction of daylight factor into the lighting scheme.Total energy savings predicted where £16,109 with a payback of 1.48 years.Currently the lighting scheme is as stated above with the following exceptions;1.Daylight control via the sensors is not operational – and is stated as having never been operational. 2 Fitting of twin lights to some areas i.e. end rows where skylights are not fitted – this is considered as extra lighting possibly due to the closed roof area however it is considered that single reflected units could have been used here and interacted with some daylight that presents itself from the glazed walling areas at the end of the factory. 3. Zoning of the lighting scheme is effectively none existent with several large areas being lit when no/intermittent occupancy (and in some cases redundant areas) occurs. 4. Adjacent areas such as washrooms and link corridors have not been included in the upgrade and remain lit with mains frequency controlled twin fittings etc. These issues need to be corrected in order to ensure full and effective control is achieved and predicted savings are identified, achieved and sustained.

Detail:

Payback1.01Year

Cost£15,000

(estimate)

Energy Savings149,983

kWh/year

CO2 Savings64.5

Tonnes/year

Cost Saving£14,848per year

Factory Lighting Considerations Priority 6


http://www.eca.gov.uk/

Energy Efficiency - Cutting carbon now

Key achievements in Northern Ireland include:

Saving our customers over £70m per annum through reduced energy bills

Reducing carbon emissions by over 685,000 tCO2 per annum

Stimulated over £100m of investment in energy efficiency and low carbon technologies

Identified a further £100m+ pa of energy savings and associated carbon savings of nearly 1mtCO2

Awarded over £11m in interest-free loans to enable 212 local companies to invest in energy and carbon saving technologies that will reduce their energy costs by over £5m pa

Over 6,300 delegates have attended 115 low carbon skills and knowledge transfer seminars and workshops

Interest-Free Loan Scheme

Key features of the NI Loan Scheme:

£3,000 to £400,000 0% Interest No other fees UnsecuredRepayment period reflects energy payback – up to max 48 monthMinimum ‘red tape’

The objective of the Carbon Trusts loan scheme is to encourage end-user investment in energy efficiency & renewable energy projects.

Loan offers can be made in 2 weeks from receipt of a complete application

Loan Scheme Project Type

•212 loans offered

•£11.7m dispersed

•£5 m saving

•Over £27m total project costs

Boilers10%

General4%

Biomass18%

Comp Air17%New Process

Equipment15%

Renewable3%

Refrigeration7%

Lighting21%

CHP3%

VSD2%

Electricity Spend = £7.6m

Cost savings = £2.3 pa

Implementation costs = £3.0m

Payback = 16 months

Percentage savings = 31%

tCO2 savings = 26,409 pa

Electricity savings = 42 GWh pa

Significant potential for cost effective energy efficiency improvement

Case Study : NI compressed air initiative

Ref: CTS010, Mar 06

Energy effective lighting case studies

Montupet – new lighting scheme T12 to T5. Capex of £110,000 offers annual savings of £130,000 and reduces CO2 emissions by 1,022 tonnes pa.

Armaghdown Creameries – more efficient metal halide lamps, repositioned with daylight control. Capex of £4,000 offers annual savings of £1,000 and reduces CO2 emissions by 3 tonnes pa.

Ref: CTS011, Mar 06

Refrigeration & Lighting case study: Henderson Group (Retail)

Bespoke partnership with family-owned business incorporating five companies and 400 independent retailers and 55 company-owned convenience retail outlets and petrol stations throughout Northern Ireland

Lighting– Typical energy savings of 25%– Payback on additional cost was

0.8 years

Refrigeration– Typical energy savings of 17%.– Payback was immediate

“Given the continual increase in energy costs, we have made a conscious effort to reduce our energy consumption and CO2 emissions. With the support of the Carbon Trust and the conclusive findings of the energy audits, we have been able to implement energy-efficient corporate refrigeration and lighting specifications which satisfy our objectives and provide an enhanced retail environment at reduced operating costs.”

Philip Wright - Senior Property Manager

CHP & Energy Management:Ryobi Aluminium Castings Ltd

Highly successful partnership with a global corporation.Projects to date include:– 1.4MWe CHP– Process EMS– Compressed air modifications– Expert plant utilisation study

Annual electrical and thermal energy savings of more than £250,000Emissions savings of approximately 1,150 tonnes CO2 per annumNearly £1m investment in energy efficiency over the past three years, offering a simple payback of about 3.3 years

“Ryobi’s senior management has beenvery supportive of the various projectsthat we’ve initiated to reduce energycosts. Each success opens our eyes tofurther opportunities.”

Edwin Turner – Facilities Manager

Consumption of heavy fuel oil has been

cut by over 300,000 litres pa

The time required for dyeing was cut by

over 10%, increasing the throughput

The water to be discharged is now

cooler, so additional cooling is no

longer needed

Annual cost savings of £68,000

Payback <10 months

CO2 savings of ~1,000 t pa

Heat Recovery: Ulster Carpets

“Ulster Carpets places great importance on managing its environmental impact. The company has been delighted by the energy saving results of this project.”George Ussher – Technical Service Manager

BombardierAerospace

Gas consumption Reduced by 7%

Electricity consumption Reduced by 8%

HFO consumption Reduced by 100%

Metering monitoring & targetingNew natural gas boiler installationLighting upgradesCDA optimisationNew boilersCultural transformation

Pritchitts

New high efficiency steriliser unit

Heat recovery

Dew point sensing control to CDA system

Staged evaporative condenser installation

Magnetic bearing turbo compressor installation

Company Perspective‘I can honestly say that we have never lived to regret any of our investments in energy efficiency.’Alan Flack,Engineering Manager, Pritchitts

Capital Cost £1,000,000

Annual Cost Savings £2,000,000

LaFargeCookstown

Capital cost £295,000

Interest free loan £200,000

Annual cost savings £80,000

Annual CO2 savings 566 tCO2

Simple Payback 3.7 years

Centralised air compressorsVariable speed drive compressorIncrease the size of CDA pipeworkZero purge desiccant dryerReduced maintenanceInterest free loanEnhanced capital allowances

Company Perspective‘Specialist implementation advice, an interest free loan and Enhanced Capital Allowances combined

with and significant energy and maintenance savings made this project a an all-round winner.’David Kelly, Energy Manager at LaFarge Cookstown

3Y Group

Replacement dual fired heating system.

Modern process extraction.1,400 kW waste wood

& dust boilerSaving 2,000 MWh






Replacement process equipment

Single new machine replacing 3 old inefficient machines

Reduced energy consumption of 200,000 kWh






FP McCann

Insulated Silo for recycled product

Installation of aggregate sheds to ensure drier product





Company Perspective‘These projects will help make FP McCann more energy efficient and commercially competitive through the significant reduction of unnecessary energy consumption. We take our responsibility to the environment very seriously and strive to reduce carbon emissions. The Carbon Trust has been most helpful in highlighting and implementing a number of energy saving projects that benefit both the environment and our company’Don Mulholland, Financial Director – FP McCann Limited

Dale Farm

Replacement of existing chilling system with a single energy efficient unit utilising high efficiency motors and heat recovery.





Simple Payback 5 years



Annual CO2 savings 1,900 tCO2

Simple Payback 2 years

Upgrading of thermal insulation at both the Pennybridge and Dunman sites to current best practice standard.

Company PerspectiveAs a leading dairy, Dale Farm strives to be best in class in all its activities. The company has an ongoing programme of continuous improvement, which includes a strong focus on energy efficiency to both reduce utility costs and respond to the threats posed by sustainability issues around hydrocarbon energy sources. We appreciate the assistance of the Carbon Trust in the outworking of this programme and will continue to work closely with them in the future. Gary Shields, Energy Manager – United Dairy Farmers

Carbon Trust Publications

Making Business Sense of Climate Change

The contents of this presentation are the copyright of the Carbon Trust and may not be copied or republished without the prior written consent of the Carbon Trust. The trade marks, service marks and logo used in this presentation are the

property of the Carbon Trust and no licence or right is granted to use any such marks or logo.

For further advice and to access the services from the Carbon Trust, visit our website at:

www.carbontrust.co.ukor ring our customer centre on:

0800 085 2005

Summary

Improving resource efficiency - business opportunity

– Makes business sense– CSR – Competitive advantage

Carbon Trust has the experience and expertise to help

– opportunity identification and quantification– implementation assistance– financing.

Support for Energy Efficiency Donagh Moorehead – Client Manager.

Documents

Transcript of Support for Energy Efficiency Donagh Moorehead – Client Manager.