Program Name or Ancillary Texteere.energy.gov Software Tools and Information Resources Software Tools and Information Resources Michael R. Muller USA Rutgers University, Center for Advanced Energy Systems U.S.- Brazil Industrial Energy Efficiency Workshop Rio de Janeiro, Brazil August, 2011

2 | Industrial Energy Efficiencyeere.energy.gov Lois Horowitz, author of “Knowing Where to Look: The Ultimate Guide to Research” “Not having the information you need when you need it leaves you wanting. Not knowing where to look for that information leaves you powerless. In a society where information is king, none of us can afford that.” Information

3 | Industrial Energy Efficiencyeere.energy.gov Where to Obtain Software Tools and Information PURCHASE commercial tools –Not our focus today FIND free publicly available tools –There are plenty and more every day DEVELOP tools – great for local knowledge Energy Software Tools

4 | Industrial Energy Efficiencyeere.energy.gov Developing an energy management plan Identifying good projects –Initial Ideas –Quantifying Energy/Cost Savings –Implementation Cost Estimating Administrative Hurdles –Permitting and other paperwork –Knowing rebates and tax incentives Design/Build –ensuring value –ensuring performance Categories Today’s Focus

5 | Industrial Energy Efficiencyeere.energy.gov Energy Management

6 | Industrial Energy Efficiencyeere.energy.gov EnergyStar –Well known brand Spreadsheet based Not quantitative Energy Management - EPA

7 | Industrial Energy Efficiencyeere.energy.gov Several new standards have recently appeared Recognizing that many good projects don’t get done –An energy management plan can increase activity Talked about elsewhere at this workshop Energy Management Standards The Management System for Energy (ANSI/MSE )

8 | Industrial Energy Efficiencyeere.energy.gov New focus from USDOE –Supported the development of ISO USDOE is moving one step beyond ISO by supporting the development of Superior Energy Performance (SEP) certification…and Global Superior Energy Performance (GSEP) USDOE is developing an energy management tool suite to support ISO and SEP activities by industry. USDOE has existing technical tools for identifying energy savings opportunities in energy-intensive systems. Energy Management - USDOE

9 | Industrial Energy Efficiencyeere.energy.gov Under Development Currently Available Overall Energy Management Toolkit Structure 3

10 | Industrial Energy Efficiencyeere.energy.gov Will consist of: –Corporate, Facility and Project analysis tools (also source of metrics) –Full and Lite versions of Self-Paced Module (LEADER Company, non-LEADER Company) –System area tools, calculators and scorecards (simple, expert) User will be able to access resources: –Systematically, self-paced –Individually (go straight to tools they want to use) Site index will be provided –Example- User will be able to access simple calculators individually via the system area pages or view and all at once via the site index –Example- User will able to access all analysis tools via the self- paced process or individually via the site index –Example- Recommendations Portfolio, Project Prioritization Tool, and Project Tracker Tool will be available as part of the facility-plant- corporate analysis tools and also as the “Implementation Portfolio” Energy Management Toolkit 4

11 | Industrial Energy Efficiencyeere.energy.gov First steps are to understand the energy use by the plant –It is surprising how many plants don’t have a good picture Great tool from DOE – a “plant energy profiler” Beyond Planning Old Management Adage: You can’t control what you don’t measure

12 | Industrial Energy Efficiencyeere.energy.gov Quick Plant Energy Profiler QuickPEP Web-based plant energy profiling and evaluation tool The profile includes: o Plant energy and resources usage and costs o Production types and levels o Maintenance procedures Identifies potential energy saving opportunities for further investigation More detailed analyses can be conducted with the system tools Future upgrades to include multiple languages

13 | Industrial Energy Efficiencyeere.energy.gov QuickPEP Tool Website

14 | Industrial Energy Efficiencyeere.energy.gov Plant Energy Profiler (QuickPEP 2.0) Energy-Carbon Footprint and Energy Baseline Calculators

15 | Industrial Energy Efficiencyeere.energy.gov QuickPEP Tool Results Identify Energy Savings Opportunities By System Establish Baselines Help/References QuickPEP Tool SSST/SSAT PHAST N X EAT MotorMaster+ AirMaster+ PSAT 3E+ CHP Tool FSAT CWSAT

16 | Industrial Energy Efficiencyeere.energy.gov OUTPUTS Overall picture of energy use and efficiency End-use breakout Potential areas for energy efficiency improvement Overall energy use reduction potential INPUTS Description Utility bill data System information IT Cooling Power On-site gen Specialized Case Data Center Profiler (DC Pro)

17 | Industrial Energy Efficiencyeere.energy.gov Generating Ideas

18 | Industrial Energy Efficiencyeere.energy.gov Provides two easy tools IAC Program iac.rutgers.edu/database

19 | Industrial Energy Efficiencyeere.energy.gov Top Ten Lists

20 | Industrial Energy Efficiencyeere.energy.gov ARC Manual is an “Idea List”

21 | Industrial Energy Efficiencyeere.energy.gov The DOE provides an extensive set of industrial assessment software tools These tools are both high quality and fully supported The latest versions are always available online Primary Tool Categories –Plant-wide –Steam –Process Heating –Motor-Driven –Data Centers DOE ITP Software Tools

22 | Industrial Energy Efficiencyeere.energy.gov Energy Use and Potential Energy Savings Potential Energy Saving Opportunities Typical Energy Consumption Rates * Other ancillary energy usages such as lighting represent less than 2% of energy consumption Process Heating/ Steam Systems 60 – 80% Electric Motor Systems 8-15% Pumping Systems 7-15% Compressed Air Systems 2-7% Other * < 2% 10% to 30%5% to 10%10% to 20% 5% to 10 %

23 | Industrial Energy Efficiencyeere.energy.gov DOE ITP Software Tools DOE ITP Software Tools and Resources can be found at

24 | Industrial Energy Efficiencyeere.energy.gov Developed and supported by energy assessment experts Designed to meet the specific needs of an industrial energy assessment Used to identify energy savings opportunities across the United States Well documented with manuals and case studies DOE provides training in tool use Continually developed and improved Free to the public Available in English and Metric Units, and different currencies DOE ITP Software Tools Notes

25 | Industrial Energy Efficiencyeere.energy.gov Plant-wide Industrial Facilities Tool Suite Quick Plant Energy Profiler/Integrated Tool Suite (QuickPEP) Process Heating Combined Heat and Power (CHP) Application Tool NOx and Energy Assessment Tool (NxEAT) Process Heating and Survey Assessment Tool (PHAST) Data Centers DC Pro Software Tool Suite Steam Steam System Scoping Tool (SSST) Steam System Assessment Tool (SSAT) 3E Plus Motor-Driven AirMaster+ Fan System Assessment Tool MotorMaster+ MotorMaster+ International Chilled Water System Analysis Tool (CWSAT) Pumping System Assessment Tool (PSAT) DOE ITP Software Tools

26 | Industrial Energy Efficiencyeere.energy.gov Quick PEP Helps plants assess plant- wide operation to identify savings and efficiency opportunities. PHAST Helps assess energy use in furnaces and identifies ways to improve performance. SSAT Assists in assessing potential benefits for specific steam-system improvements. CHP Application Tool Enables users to evaluate the feasibility of CHP for heating systems. 3EPlus Insulation Tool Calculates most economical thickness of insulation for various operating conditions. NxEAT Assesses NOx emissions and applications of energy efficiency improvements at petroleum refining and chemical plants.  Motor Master+ International Aids in energy-efficient motor selection and management.  PSAT Assesses efficiency of pumping system operations and quantifies benefits of system optimization.  Air Master+ & LogTool Provides comprehensive information on assessing compressed air systems.  FSAT Assesses efficiency of fan system operations and quantifies benefits of system optimization.  CWSAT Determines chilled water system energy requirements and evaluates energy and costs savings opportunities. DOE ITP Software Tools

27 | Industrial Energy Efficiencyeere.energy.gov Time does not permit us to give details about all the tools –Look at 2 Steam MotorMaster+ Compressed air and process heating are discussed in other presentations DOE ITP Software Tools

28 | Industrial Energy Efficiencyeere.energy.gov Steam System Tool Suite Steam Tools are bundled into the Steam System Tool Suite (SSTS) These tools include: o Steam System Scoping Tool o Steam System Assessment Tool o 3E Plus – An insulation energy savings calculator

29 | Industrial Energy Efficiencyeere.energy.gov Steam System Scoping Tool Quickly evaluates overall quality of steam system operation Consists of 26 qualitative questions based on all major components of a steam system The questions are separated into these primary areas: o Steam System Profile o Steam System Operating Practices o Boiler Plant Operating Practices o Steam Distribution, End Use, Recovery Practices The score is out 340 points and also given as a %

30 | Industrial Energy Efficiencyeere.energy.gov Sample Page Steam System Scoping Tool

31 | Industrial Energy Efficiencyeere.energy.gov Steam System Assessment Tool Steam system modeling software Common energy recovery projects can be added into an alternate model This allows “what if” evaluations based on the addition or removal of various projects Steam system model requires the balancing of: Mass Energy Economic -based on fuel and water costs Steam System Assessment Tool

32 | Industrial Energy Efficiencyeere.energy.gov Major Equipment Simulated: –Boiler –Back pressure turbines –Condensing turbine –Deaerator –Steam traps, leaks, insulation losses –Letdowns –Flash vessels –Feedwater preheat exchangers Choice of 1, 2, or 3 header pressure models Schematics of model steam systems Estimates of site environmental emissions Steam System Assessment Tool

33 | Industrial Energy Efficiencyeere.energy.gov Steam System Assessment Tool Modifications can be simulated on an alternate model generated from the original Savings estimates can be determined for individual and combinations of the various energy projects The “Results Summary” page details the cost and energy usage of both the original and alternate models

34 | Industrial Energy Efficiencyeere.energy.gov Provides simple tabulated information for heat loss (or gain) and surface temperatures Provides simple tabulated information for energy costs and savings Can provide an Economic Insulation Thickness for a particular application 3E Plus: Insulation Energy Savings Calculator

35 | Industrial Energy Efficiencyeere.energy.gov Motor-Driven Equipment Tools Pumping System Assessment Tool (PSAT) AirMaster+ & LogTool (Compressed Air Systems) Fan System Assessment Tool (FSAT) Motor System Management Tool (MotorMaster+) Chilled Water System Assessment Tool (CWSAT)

36 | Industrial Energy Efficiencyeere.energy.gov MotorMaster+ International MotorMaster+ International has multi-language capability (with the current release supporting Spanish, French and English) Assists in the development of a decision based motor management plan.

37 | Industrial Energy Efficiencyeere.energy.gov The current version of the software contains manufacturer’s databases for over 25,000 NEMA motors and over 7,200 IEC motors. Full- and part-load efficiency values Technical data to help optimize drive systems, (power factor, full-load speed, etc.) Motor purchasing information, including list prices and motor weights Includes Important Motor Data

38 | Industrial Energy Efficiencyeere.energy.gov Analysis includes selection of the “best available” motor for a given application giving: –energy savings, –demand reductions, –dollar savings, –GHG emission reductions, –simple payback, –cash flows, –ROI New Motor Selection

39 | Industrial Energy Efficiencyeere.energy.gov Motors don’t live forever Since motors are involved in the process, the fastest way to get them back into service is rewinding –This reduces efficiency! MotorMaster+ helps plants decide which motors can tolerate rewinding or which need to be replaced Plants should then stock backup motors for critical systems Repair or Replace?

40 | Industrial Energy Efficiencyeere.energy.gov Software tool results are only as good as the tool and the data input. Tools should be used in support of engineering analysis, not as a replacement. Using a software tool without understanding how it works (using a “Black Box” recommendation”) increases risk Misuse and user-error are always possible –Common sense and “sniff” tests of results are needed A Necessary Caution

Um Novo Dia!!!

42 | Industrial Energy Efficiencyeere.energy.gov Michael R Muller Center for Advanced Energy Systems (CAES) Rutgers, The State University Of New Jersey 73 Brett Road Piscataway, NJ United States of America phone: fax: Contact Information