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TECH GROUP EUROPE DUBLIN S.E.I. ENERGY MAP WORKSHOP 4

TECH GROUP EUROPE DUBLIN S.E.I. ENERGY MAP WORKSHOP 4. Keith Henderson. Items to Cover. Total Energy Consumption Energy Survey and Metering Register of Opportunities* Project Charter* – Compressed Air Programme Plan

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TECH GROUP EUROPE DUBLIN S.E.I. ENERGY MAP WORKSHOP 4

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  1. TECH GROUP EUROPE DUBLINS.E.I. ENERGY MAP WORKSHOP 4 Keith Henderson

  2. Items to Cover • Total Energy Consumption • Energy Survey and Metering • Register of Opportunities* • Project Charter* – Compressed Air • Programme Plan *Please note that there are documents linked to these sections that must be downloaded. Please see resource box for these items.

  3. Total Energy Consumption 12 months up until 1st November 2006, Annual Electricity Bill – in the region of €1.2m Increase of 31% for 2007 Forecasted Electricity Bill for 2007 (assuming same consumption as previous year) - in the region of €1.6m

  4. Energy Survey and Metering • Energy Survey carried out throughout the plant to identify areas of saving opportunity. • High level metering installed to provide electricity split to Business Units. • Hand held meter purchased for evaluation of individual items.

  5. Energy Surveying

  6. High Level Metering

  7. Energy Split per Business Unit • The Effect of the Price Increase

  8. Hand Held Metering Examples of metering carried out so far :- • Air compressor – Receiver Comparison • AHU for clean room 1 – AHU 6 Shut Down • Chillers – Old Tricool v new York Chiller

  9. Compressor Comparison Before and After Receiver Installation

  10. Compressed Air – Effects of Larger Receiver Installation • Before receiver installation – average kW of compressor of 93.19 kW • After receiver installation – average kW of compressor of 83.09 kW • Estimated savings due to receiver installation is approximately €9,000

  11. Clean Room 1 - Air Handling Unit 6 Survey

  12. Clean Room 1 – Air Handling Unit 6 Survey • Air Handling Unit Average Energy – 14.68kW • Approximate Annual cost to run AHU 6 - €14,000 • Weekend Shutdown Hours – 63 hours • Estimated savings due to switching off AHU6 at weekends when not used €5,000 !!! • Savings could be considerably higher as the AHU costs would rise during the summer months due to cooling load being increased.

  13. Chiller Comparison

  14. Chiller Comparison

  15. Register of Opportunities • Is placed in the folder P:\Energy along with other material relating to the energy saving projects. Register of Opportunities.xls • Will be incorporated into the company’s overall Lean Policy. • Will be viewable, but password protected for changes and co-ordinated by Keith Henderson. • Ideal scenario is to carry out a savings validation, by first measuring the usage, then measuring after project to show savings. See previous Compressed Air example.

  16. Project Charter • New standard form being created to add to QMS and Lean Charter Introduction. • Project charter now produced for compressed air project. Energy Project Charter.doc • Project charters will be used for all projects requiring capital funding.

  17. Projects Completed • Metering installed at high level of distribution system to split business units. • New Chiller installed for Business Unit 1 Process Chilled Water. Approx saving €15,000 per year • Power factor correction improvements to avoid bill charges. Approx saving €10,000 per year!!!

  18. Projects Ongoing • MIC Level increase • Complete survey of all equipment in the plant. • Occupancy Sensors for lighting in areas of irregular / infrequent occupancy. • Compressed Air – New air receiver installed and pressure reduction program to commence. • AHU Filters – New project started to find more efficient filtration in air handling units. • Cooling Tower refurbished and awaiting installation of replacement variable speed drive. • Clean Room 1 key-switch operation for AHU Shutdown when not in use – wired to BMS, awaiting software change.

  19. Projects Planned • Lighting load reduction throughout the plant. Lighting accounts for approx. 8% of our electricity costs. €96,000. • Chilled water temperature assessment to determine optimum required temperature in each area. • Envirostart units to fit to injection moulding machines. • Investigation of cold water spray/evaporative humidification to replace steam humidifiers on AHU 7 and AHU 8.

  20. Programme Plan • Programme Plan currently being drawn up as part of our company’s new lean manufacturing introduction. • Separate budget to be allocated to the energy programme plan.

  21. TECH GROUP EUROPE DUBLINS.E.I. ENERGY MAP WORKSHOP 4END Keith Henderson

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