Utility Bills Reduction by Energy Consumption Management Ali Razban, PE, CEM, CP EnMS arazban@iupui.edu August,17 2016

Why Managing Energy Consumption? Energy is the largest cost for maintaining a buildings and manufacturing environmental footprint Energy efficiency provides financial returns

Benefits of Energy Consumption Management Reduce utility bills Improve profits Improve processes Reduce emissions Reduce risk to energy price fluctuations

Steps for Energy Consumption Management Create a corporate culture of continuous improvement in energy efficiency Establish an awareness program at all levels with energy management Create a verified record of energy intensity/efficiency improvement.

Energy Review Identify significant energy users and relevant variables HVAC system Lighting Compressor Furness/oven Boiler Motors

Available Resources E-Guide, Dept. of Energy website, WWW.energy.gov Energy Audit, Industrial assessment Center(IAC) at IUPUI

Industrial assessment Center Industrial Assessment Centers Started at Department of Commerce in 1976, Moved to the U.S. Department of Energy (DOE) Provide FREE services to small and medium- sized manufacturing companies to reduce unnecessary costs from inefficient energy use. Has achieved over $4.5 billion of implemented energy cost savings since its inception.

Eligibility Criteria Within Standard Industrial Codes (SIC) 20-39. Within 150 miles of a host campus Gross annual sales below $100 million. Fewer than 500 employees at the plant site. Annual energy bills more than $100,000 and less than $2.5 million. No professional in-house staff to perform the assessment. Exceptions may be made through an approval process

IUPUI IAC Statistics

IUPUI IAC Statistics

IUPUI IAC Statistics

IUPUI IAC Statistics

Types of Center Recommendations

Energy Management Recommendations

Energy Management Combustion Systems

Energy Management Combustion Systems, Boilers

Energy Management Thermal Systems

Energy Management Thermal Systems, Heat Containment

Energy Management Electrical Power

Energy Management Motor Systems

Energy Management Motor Systems, Air Compressors

Energy Management Motor Systems Operation

Energy Management Motor Systems, Other Equipment

Energy Management Building and Grounds

Energy Management Building and Grounds; Lighting

Energy Management Building and Grounds; Lighting

Energy Management Building and Grounds; Space Conditioning

Waste Minimization/Pollution Prevention

Direct Productivity Enhancements

Case Study 1 Demand Peak Shaving Annual Company Electric Utilities - $219,556 Total Savings - $28,155 Percentage of Annual Utility Bill Saved – 12.8% Month Date Day Time Current Demand (kW) Proposed Demand (kW) Peak Difference (kW) September 9/16/2014 Tuesday 8:15 573.84 420 153.84 October 10/21/2014 12:00 523.98 103.98 November 11/18/2014 9:30 570.42 150.42 December 12/16/2014 7:45 557.46 137.46 January 1/7/2015 Wednesday 10:45 551.16 131.16 February 2/10/2015 9:45 532.26 112.26 March 3/10/2015 13:45 633.06 213.06 April 4/8/2015 10:30 550.26 130.26 May 5/26/2015 12:15 575.28 155.28 June 6/22/2015 Monday 14:30 596.16 176.16 July 7/30/2015 Thursday 568.08 148.08 August 8/11/2015 10:15 563.04 143.04 Total   6,795 5,040 1,755

Case Study 2 Replace Pneumatic with Electric Mixers Annual Company Electric Utilities - $545,622 Total Savings - $3,273 Percentage of Annual Utility Bill Saved – 0.6% Rebates - $1,078 ($0.07 per kWh up 50% of the capital costs in any custom energy saving project)

Case Study 3 Increase Refrigeration Suction Pressure Annual Company Electric Utilities - $474,380 Total Savings - $1,414 Percentage of Annual Utility Bill Saved – 0.3%

Case study 4 Air Compressors Annual Company Utilities - $213,935 Total Compressor Savings - $15,886 Percentage of Annual Utility Bill Saved – 7.4% AR Name Annual Savings Implementation Costs Payback (ROI) Reduce Air Compressor Setting $1,887 None Instant Eliminate Leaks in Compressed Air Lines/Valves $1,515 $140 1 month Recover heat from Air Compressor $3,900 $1,320 4 months Install Direct Acting Units $2,700 $1,250 6 months Install VFDs for Compressors $5,124 $4,678 11 months Use Outside Air for Intake $760 $1,216 19 months $15,886 $8,604

Case study 5 Solar Panel Installation Annual Company Utilities - $281,259 Total Solar Savings - $69,019 Percentage of Annual Utility Bill Saved – 24.5% Implementation Costs - $314,300 (After $134,700 rebate) Payback - 55 months

Contact Us www.engr.iupui.edu/IAC iupuiiac@iupui.edu Dr. Jie Chen, Director jchen3@iupui.edu 317-274-5918 Dr. Ali Razban, PE, CEM, CP EnMS, Assistant Director arazban@iupui.edu 317-274-8458 Dr. David Goodman, CEA, Assistant Director dwgoodma@iupui.edu 317-274-5381

Thank you Questions ?