Industrial Assessment Center—UL Lafayette Theodore Kozman Jim Lee Funding provided by US DOE
Dec 21, 2015
Results of Assessments• ~$173M/year in Energy Saving
Recommendations Made (more than 1650 individual recommendations)– More than $90M/year have a payback period of
less than one year– Longer payback periods include CHP and/or
major operational changes
• ~$35M/year Energy Saving Recommendations implemented within 9 months of the assessment more than 250 plants ($140k/plant/yr.)– ~41% of the total number of recommendations– ~26% of the dollar value of recommendations
Lessons Learned• Short payback periods are
implemented more frequently than longer payback periods.
• Companies with on-going preventive maintenance without plant-wide shutdown implement a higher percentage of recommendations.
• In general, recommendations are proportional to energy utility use (not so with implementation).
Lessons Learned (2)• Steam system (including leaks and
faulty traps) yield the highest dollar savings recommendations and implementations.
• Repair air leaks and lowering the operating pressure of the compressed air system findings are implemented more than any other findings (on percentage basis).
• Recycling can be implemented frequently to save waste/disposal costs.
Lessons Learned (3)• Insulation of hot or cold surfaces
will generally have a payback period of less than one year.
• Steam system efficiency improvement can yield good cost savings—however may require a major shutdown for a period of time.
• Lighting and lighting controller improvements can save significant energy with pay back periods of less than one-year.– Used at home—not at work
Lessons Learned (4)• Using a different energy source or moving
some operations to the second shift can save energy dollars, sometimes (depends mostly on time of day charges).
• Electrically driven tools can consume less than one-sixth the amount of electricity as compressed air-driven tools.
• The amount of energy used by heating and cooling systems can be improved with set-back devices or timers. For some, these may have to be locked.
Lessons Learned [5]• Productivity improvements can save a
great deal of money, the payback period maybe substantial.
• CHP and Combustion changes can have significant savings. However, with current gas and electric prices, the payback period maybe significant. (several years-with different combustion components).
• Use your local IAC if you are a manufacturer desiring to reduce your annual energy cost.
Date
Location
Component
SPOT 1 147 FSPOT 2 135 FSPOT 3 99.9 FLOAD Loaded
Temperature Rise
1 -18 F
19 -63 F
64 -128F
Monitor circuit and component
Monitor & Repair next scheduled maintenance
Schedule Repair ASAP
REPAIR IMMEDIATELYCRITICAL
Possible Solution
Monitor circuit. Clean and tighten connection during next regular maintenance cycle.
Reference
Level of Severity
Minor
Intermediate
Severe
>129 F
Preventative Action
Possible Cause
Conclusion
Component 1 shows a 47.1° and component 2 shows a 35.1º Temperature Rise. These temperatures rise is not within normal operating parameters. The lighting was on at the time and the circuit should be repaired ASAP to avoid any accidents and/or shut downs.
SPOT 2-3 35.1 F
Analysis
Identification3/7/2005
Circuit Room Gueydan
Lighting
TEMP DIFFERENCESPOT 1-3 47.1 F
Centers Close:• Oklahoma/Arkansas/Texas
– Dr. William Kolorik (Oklahoma State)– 405/744-5042
• Texas– Dr. Warren Heffington (Texas A&M)– 979/845-5019
• Mississippi/Arkansas– Dr. B. K. Hodge (Mississippi State)– 662/325-7315
• Louisiana/Arkansas/Texas/Mississippi– Dr. Theodore Kozman (University of Louisiana
Lafayette) 337/482-5717