Smithfield Environmental Training Conference Energy Management

1. Smithfield Environmental Training ConferenceEnergy Management San Antonio, TX August 3-5, 2011

2. Energy Czar • Been tasked by Corporate to facilitate energy projects throughout Smithfield Packing • Assist plants in identifying, prioritizing and executing energy saving projects • 2 year payback

4. Plant Energy Usage • Ammonia Refrigeration • Compressed Air • Steam/Hot Water • Wastewater • Electrical Devices

5. Ammonia Refrigeration • Delta P • Suction Pressure versus Discharge Pressure • the smaller the delta the better • Defrosting Evaporators • Timed or Automatic? • Proper load assignment • High Pressure vs Low Pressure • Air Curtains

6. Compressed Air • LEAKS!!!!!!!!!!!!!!!!!!!!! • Properly sized units for demand • Alternatives to compressed air • Takes 8 HP of electrical energy to produce 1 HP of compressed air energy • Reduced Head Pressure • Using compressed air for cooling • Air Diaphragm Pumps

7. Hot Water/Steam • Steam Pressure • Can you run on 75 psig? • Heat recovery (exhaust) • Heat recovery (fluids) • R.O. Feed Water? • Steam Trap PM • Leaks • Insulation

8. WASTEWATER • Aeration • Tar Heel 1800 HP • Pumps

9. Electricity • Switchgear/Transformer PM • Cleaning • Rendering and other harsh environments • VFDs/Soft Starts • Lighting • Condition MCC Rooms (70 -80 degrees) • Utilize Demand Control, Demand Response, and efficiency control systems

10. FRAMEWORK • Develop a policy for more efficient use of energy • Fix targets and objectives to meet the policy • Use data to better understand and make decisions concerning energy use and consumption • Measure the results • Review the effectiveness of the policy • Continually improve energymanagement.

11. WHY? • $42,000,000 • 10% Reduction = $4.2 Million/Year

12. Case Studies • Grayson • Reduced steam pressure from 75 psi to 50 psi. • 5 psi increments • $50,000 year savings • Shut off a boiler • No Capital

13. Case Studies • Kinston • Utilizes an RS Energy Metrix system to track energy use • Discussed peak demand times with City and made operational changes at wastewater and other areas to avoid peak charges • $0.07/kw versus $16.9/kw

14. Case Studies • Tar Heel • enlisted Ingersoll Rand to conduct a compressed air study investigation in order to examine the efficiency and effectiveness of the supply, demand and distributionsystems. • it was determined that peak demand was lower than the theoretical capacity. Further investigation exposed inadequate piping of the 300 hp Sullair compressor • Due to the improper piping, the 300 hp air compressor was discharging into a high pressure header, which causes the 300 hp machine to deliver only 25% of its capacity. Maintenance Department relocated the connection from the high pressure header to a low pressure header in order to bypass the ammonia dryer/receiver • $180,000/year energy savings with $1,500 capital costs.

15. Energy Audits • I will develop a project summary spreadsheet that contains all energy projects submitted to Foods and AMI since 2005. • Will forward to Plant Engineers and Corporate Engineering • Plants will review and select projects that might apply to their facilities • Follow up with energy audit at each plant to begin developing projects.

16. Energy Audit • Elements of a Successful Energy Management Strategy • Make Commitment • Assess Past and Present Performance • Set Goals for Improvement • Develop and Implement Action Plan • Evaluate Progress • Recognize Achievements

17. Energy Audit • Potential Barriers to Success • Lack of Top Level Support • Organizational Barriers • Lack of Communication • Poor Understanding of How to Create Support • Limited Finances • Poor Accountability for Measures • Organizational Inertia

18. Take Aways • Identify potential energy projects • Prioritize for project development • Implement plan do check act method to manage projects within EMS • Larger facilities invest in energy management systems