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Tips for Highly Effective Energy Management - Ken Currie


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Tips for Highly Effective Energy Management - Ken Currie

  1. 1. 7 Habits of Highly Effective Energy Managers Dr. Ken Currie, Director, Center for Manufacturing Research – Tennessee Tech University Associate Director of Industrial Assessment Center
  2. 2. • Fans & Pumps are usually oversized to consider worse case scenarios. Variable speed drives allow for a throttled output with a corresponding variable electrical load to reduce flow. • Furnaces are designed for peak product flow but typical flow may only require a subset of the burners to be in service. Habit #1: Engineers Design for “Just- In-Case” NOT Energy Efficiency
  3. 3. • Compared to electric motors, the work that is conducted by compressed air is 7 times more expensive. • Inappropriate uses and leaks are common losses in a compressed air system resulting in significant wasted energy – i.e. In a system that is running a 200 hp compressor, 30% represented by inappropriate uses and leaks can cost approximately $4,500/yr in a single shift operation. Habit #2: Air is Free, but Compressed Air is Very Expensive • Poor management of air supply can yield inefficiencies for costs and also in meeting demand events.
  4. 4. Habit #3: Motel 6 Got it All Wrong – They Should Not Have Left the Lights On • Changing bulbs is a good first step, but all light is not created equal and replacing one fixture for another fixture may yield more lumens than what is needed. Consider reducing the number of bulbs to reduce lighting levels as appropriate for the task. • Sensors and controls allow for occupancy sensors, daylighting, and timers.
  5. 5. • Few industrial operations are truly 24/7 • One company assumed that these compressors were being turned off when in fact there was a perceived production requirement that they be left on – reality was quite different. • Improper compressor sequencing and controls can adversely affect energy efficiency. Habit #4: Reality is Usually Somewhere Between our Expectations and Total Chaos.
  6. 6. • Air & steam leaks, HVAC efficiency losses, results of poor maintenance, equipment degradation all result in the need for a continual management process. Habit #5: Low Hanging Fruit Always Seem to Grow Back
  7. 7. Habit #6: Production Needs vs. Energy Reduction – Can’t We Just All Get Along! • Perceived needs for quality, production throughput, and refusing to change anything that may cause a production perturbation often conflict with changes to reduce energy. • Energy Management Systems create a cross- functional energy management team working to analyze and improve processes at the lowest possible energy consumption.
  8. 8. Habit #7: You Can’t Reduce What You Don’t Measure, and You Can’t Measure What You Don’t Meter This project is funded under an agreement with the State of Tennessee. This material is based upon work supported by the Department of Energy under Award Number DE-EE0000160. CFDA 81.041. • Sub-metering helps to align energy consumption with significant energy uses allowing for concentration of effort. • Measuring energy performance should be calculated as a basis of production (energy intensity) without consideration for rate changes – MMBtu/unit production