Cascade Presentation 130811

7/31/2019 Cascade Presentation 130811

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Best Practices in RefrigeratedWarehouse Energy Efficiency

Low and No-Cost Methods ofReducing Refrigerated Warehouse

Energy Consumption

By

Marcus Wilcox, President


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2011 Cascade Energy, Inc. Slide 1

Our Company

Offices in Oregon, Utah, and Washington

Staff of 75 (incl. 45 Engineers)

Industrial energy efficiency consulting Food processing, warehouses, pulp & paper, petrochemical, manufacturing Worked on 700 to 800 ammonia refrigeration systems (incl. 250 refrigerated

warehouses)

Services include: Energy Management (EM) program design and implementation Tune-ups (i.e., kaizen blitzes or retro-commissioning) Retrofit & new construction project assistance Design and management of utility energy efficiency programs

A few of our corporate EM customers: Americold Sysco

GCCAs Service Partner for Energy Management


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Typical PRW Energy Use & Cost

Typical Annual Energy Use

3,000,000 to 30,000,000+ kWh/yr(Average U.S. Home = 10,000 kWh/yr)

Some natural gas

Average rate of 4 to 16/kWh

Annual cost of $100k to $5 million /yr


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Energy Management Pyramid


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The ROI Sweet Spot


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Successfully Driving Action

Establish corporate commitment & goals

Implement a fair performance measurement

Roll out training

Push out best practices

Pursue the quick, easy and low cost

Carefully invest in retrofits

Include efficiency in construction or EOL replacement

Invest in innovation, pilots, research, etc.

Continuous improvement (there is no finish line)


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Breakdown of PRW Energy Use

Refrigeration (60%)

Warehouse Lighting (20%)

Battery Charging (10%)

Miscellaneous (10%) Dock & Freezer Doors (Heaters & Blowers)

Freezer Floor Heating

Offices (Lighting, HVAC, Plug Loads)

Exterior / Parking Lot Lighting Truck Shops

Dry Warehouse HVAC



Refrigeration (60% of Energy)

Most PRW facilities utilize ammonia refrigeration

Engineered and built-up

Hybrid ammonia/CO2 is now available

Some utilize air-cooled packaged systems

R-404a, 507, 134, 22, etc.

Blast freezing and process loads can increase refrigerationpercentage dramatically



Typical Ammonia System Equipment

Warehouse Evaporators Blast Freezing Screw Compressors

Reciprocating Compressors Rotary Vane Compressors

Condensers



Typical Packaged System Components

Recip., Scroll or Discus Compressors Condenser Fans Electric Defrost

Evaporator FansPressure or Temperature Switches Time Clocks



Interviewing Larry King

Investigation Sherlock Holmes

Typical Activities Measuring

Repair

Tuning

Improving Practices Improving Schedules

Collaborating with Trade Allies

Pursuing Low & No-Cost Opportunities



The Interview Process



The Investigation Process


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13

Is Regular Cleaning Occurring?



Cleanliness = Energy Efficiency



There are Dumb Experts Out There



Are Control Components Working?



Have There Been Bad Upgrades



Fix Problems RIGHT NOW



Are Condensers in Good Shape?



Is Water Treatment Working Well?



Is Water Flowing?



Are Fans Performing?


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Is Periodic Maintenance Occurring?


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Is Equipment Turned On?


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Do You Have Good Information?


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Are Control Set Points Optimum?


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Are Frequency Drives Optimized?


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Lighting (20% of Energy)

Ensure motion sensors are functioning and tuned

Install automated controls

Target appropriate light levels

Current technologies

Metal Halide

T8 and T5 Fluorescent

LED

h f


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Battery Charging (10% of Energy)

Unfortunately, it is the Wild Wild West

There are no guidelines for rating efficiency

What matters?

Energy into the charger vs. energy out ofbattery a.k.a., round trip efficiency

Idle power draw

Impact on peak demand Ability to facilitate or cooperate in demand

management
http://www.imdb.com/media/rm3064107520/tt0058855


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Are Your Chargers Setting Your Peak Demand?

Charger Current vs Main Meter Power

-

200

400

600

800

1,000

1,200

1,400

1,600

1,800

Tue-11/11 Wed-11/12 Thu-11/13 Fri-11/14 Sat-11/15 Sun-11/16 Mon-11/17 Tue-11/18 Wed-11/19 Thu-11/20 Fri-11/21

Date

MainPulseMeter(kW)

-

50

100

150

200

250

300

350

400

450

500

BatteryChargers(Amps)

Main Meter

Chargers

Chargers

Main Meter

T di i l T h l


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Traditional Technology

Relatively slow

High maintenance

Susceptible to damage

Extremely high heatingrequirements in freezerapplications

Radiant heaters

Heated blowers

In some cases, 5% to 15% oftotal facility energy use!

M d R ll U D


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Modern Roll-Up Doors

Less infiltration

High speed

Self-healing

Fewer sealing edges to leak

Insulated

Minimal to no heatingrequirement

R i l t Ai C t i


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Recirculatory Air Curtains

Appropriate for some

applications Safety considerations Productivity considerations

Consider fan energy use

Consider air heating energy Avoid electric if possible Avoid hot gas with high ammonia

pressure requirement

Consider hybrid configuration Mated to fast or bi-parting door,

VFD on fans, heating disabled,advanced controls

Mi ll L d


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Miscellaneous Loads

Freezer Floor Heating

Offices (Lighting, HVAC, Plug Loads)

Exterior / Parking Lot Lighting

Truck Shops

Dry Warehouse HVAC

A id M i T h l i


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Avoid Magic Technologies

Avoid equivalent of fuel line magnets

There are no magic solutions that connect to yourelectrical system

Dont mistake power quality for demand or energy savings

Avoid products that claim to trick your electric meter Correcting quality (e.g., transients, harmonics) may be

helpful, but does not save energy

Correcting Power Factor reduces cost, not energy

Other than lighting and battery charging, it is all aboutshaft horsepower

S C St d


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Sysco Case Study

110 food distribution

centers (DCs) Freezers, coolers, dock,

and dry warehouse space

Rolled out program inMarch, 2006 Announced by corporate

management

Managed by project

engineering group

Aggressive goals: 10% after 1st year 25% after 3rd year

Another 5% by 6th year

Four-Prong approach Corporate goal and

commitment

Energy Information Systems

Tune-ups at every DC in 18

months Retrofits and high-

efficiency new construction

E t bli h d B h ki S t


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Established Benchmarking System

Cubic feet weighted by freezer,

cooler/dock, and dry as well as averagewet bulb for a normalized EfficiencyFactor

Entire company can be benchmarked

Rank within company Rank within benchmark group

Rank within region

This report is seen across company.

Requires monthly collection of 500+utility bills

S l T U P f


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Sample Tune-Up Performance

B li C id P f


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Baseline Companywide Performance

Energy Use vs Facility Size - June Utility Bills

- 2,000 4,000 6,000 8,000 10,000 12,000

Weighted Cubic Feet

kWh/day

2005

P f Aft T U


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Performance After Tune-Ups


- 2,000 4,000 6,000 8,000 10,000 12,000

Weighted Cubic Feet

kWh/day

2005

2007

Most Recent Performance


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Most Recent Performance


- 2,000 4,000 6,000 8,000 10,000 12,000

Weighted Cubic Feet

kWh/day

2005

2007

2010

Year to Year Performance


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Year to Year Performance

Total Broadline Energy Intensity

Jan

Feb

Mar Ap

rMay Ju

n Jul

Aug

Sep

Oct

Nov

Dec

kWh/day/1000weightedft

3

2004

2005

2006

2007

2008

2009

2010

Closing Questions


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Closing Questions

Do you have energy policy & goals? Do you accurately and fairly track energy

performance? Is Energy Management a topic & priority for

executive team? Is there executive support and funding to

meet energy goals? Do you have an Energy Champion in place?

How will you vet investment opportunities? How are you going to achieve real,

substantial, sustainable savings?

Thank You


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Thank You

Marcus Wilcox, President, P.E.Cascade Energy, [email protected]

Cascade Presentation 130811

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