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Integrated Systems + Principles Approach

Integrated Systems + Principles Approach. Manufacturing Energy End-Use Breakdown. Source: California Energy Commission (2000). Energy Systems. Lighting Motor drive Fluid flow Compressed air Steam and hot water Process heating Process cooling Heating, ventilating and air conditioning

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Integrated Systems + Principles Approach

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  1. Integrated Systems + Principles Approach

  2. Manufacturing Energy End-Use Breakdown Source: California Energy Commission (2000)

  3. Energy Systems • Lighting • Motor drive • Fluid flow • Compressed air • Steam and hot water • Process heating • Process cooling • Heating, ventilating and air conditioning • Cogeneration

  4. Principles of Energy Efficiency • Inside Out Analysis • Understand Control Efficiency • Think Counter-flow • Avoid Mixing • Match Source Energy to End Use • Whole-system, Whole-time Frame Analysis

  5. Integrated Systems + Principles Approach • Integrated systems + principles approach (ISPA) = Systems approach + Principles of energy efficiency • ISPA is both effective and thorough.

  6. 1. Inside-out Approach

  7. Inside-out Approach

  8. Inside-out: Amplifies Savings Reduce pipe friction: Savings = 1.00 kWh Pump 70% eff: Savings = 1.43 kWh Drive 95% eff: Savings = 1.50 kWh Motor 90% eff: Savings = 1.67 kWh T&D 91% eff: Savings = 1.83 kWh Powerplant 33% eff: Savings = 5.55 kWh

  9. Inside-out: Reduces Costs • Original design: 95 hp in 14 pumps • Re-design: • Bigger pipes: Dp = c / d5 • (doubling d reduces Dp by 97%) • Layout pipes then equipment • shorter runs, fewer turns, valves, etc… • 7 hp in 2 pumps

  10. Avoid Outside-in Thinking Traditional Analysis Sequence for Reducing Energy Use Traditional Analysis Sequence for Reducing Waste Result: Incremental improvement at high cost

  11. Think from Inside Out! Inside-Out Analysis Sequence for Reducing Energy Use Inside-Out Analysis Sequence for Reducing Waste Result: Significant improvement at minimal cost

  12. 2. Understand Control Efficiency • Systems design for peak load, but operate at part-load • System efficiency generally changes at part load • Recognize and modify systems with poor part- load (control) efficiency

  13. Control Efficiency

  14. Air Compressor Control FP = FP0 + FC (1 – FP0)

  15. Power and Flow Control

  16. Chiller Control

  17. Boiler Control

  18. Data Scatter Indicates Poor Control

  19. 3. Think Counter Flow • Heat transfer • Fluid flow

  20. Counter-flow Improves Heat Exchange T Q Parallel Flow x T Q Counter Flow x

  21. Stack Furnace Pre-heats Charge Reverb Furnace Stack Furnace

  22. Molten Glass Transport:Each Exhaust Port Is A Zone

  23. Counter-flow Within Zones Increases convection heat transfer by 83% Contact length = 2 x (5 + 4 + 3 + 2 + 1) = 30 feet Contact length = (10 + 9 + 8 + 7 + 6 + 5 + 4 + 3 + 2 + 1) = 55 feet

  24. Tile Kiln (Counter flow?) Tile Exit Tile Entrance

  25. Counter Flow Cooling Enables Cooling Tower Cross-flow cooling of extruded plastic uses 50 F water from chiller

  26. 4. Avoid Mixing • Availability analysis… Useful work destroyed with mixing • Examples • CAV/VAV air handlers • Separate hot and cold wells • Material reuse/recycling

  27. HVAC Applications Cooling Energy Use Heating Energy Use

  28. Cooling Applications Separate hot and cold water tanks

  29. 5. Match Source Energy to End Use

  30. Match Source Energy to End Use

  31. Utilize Current Daylighting Wright Brothers Factory, Dayton Ohio

  32. Replace Colored / Fiberglass Windows with Corrugated Polycarbonate

  33. Employ Skylighting Skylights: • Highest quality light • Reduce lighting energy costs • Increase heating/cooling costs

  34. 6. Whole System Whole Time Frame Design • Design heuristic derived from natural evolution • Nothing evolves in a vacuum, only as part of a system • No optimum tree, fan, … • Evolutionary perspective: ‘optimum’ synonymous with ‘perfectly integrated’ • Optimize whole system, not components • Design for whole time frame, next generation

  35. Whole System “Lean” Manufacturing

  36. Whole System Energy EngineeringOptimum Pipe Diameter • Dopt = 200 mm when Tot Cost = NPV(Energy)+Pipe • Dopt = 250 mm when Cost= NPV(Energy)+Pipe+Pump • Energy250 = Energy200 / 2

  37. Whole System Accounting • Budgeting and capital processes separate from operational processes • Organizational structures within companies constrains optimum thinking • Enlarge system boundary to include entire company

  38. Whole-Time Frame Accounting“Efficiency Gap” • “Numerous studies conclude 20% to 40% energy savings could be implemented cost effectively, but aren’t…..” • Discrepancy between economic and actual savings potential called “efficiency gap”. • Puzzled economists for decades: “I can’t believe they leave that much change lying on the table.”

  39. Don’t Eat Your Seed Corn • SP = 2 years is ROR = 50% • SP = 10 years is ROR = 10%

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