Loureiro Engineering
Associates, Inc. (LEA)
Electrical Energy
Management
June 2013
Kevin Vidmar, CEM
© LEA 2013
1
Agenda
 General
Concepts
– High level, very condensed
 Typical
Opportunities – by
electrical energy use systems
 Questions
© LEA 2013
2
Loureiro Engineering Associates



Started in 1975
Offices in Plainville CT, Manchester
NH, Rockland MA, Wakefield RI
Multidiscipline – 100+ emp., 14 PEs
– Environmental, Health & Safety,
Remediation, Brownfield, SMEP
(Structural, Mechanical, Electrical and
Plumbing), Energy Services,
Construction, WorkWaste

Employee Owned
© LEA 2013
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Energy Services Background –
Kevin Vidmar, Vice President


25 years industrial experience before LEA
Wide Ranging Experience – Pratt & Whitney, The
Stanley Works, Cookson Group
– Energy Director, Corporate 5S trainer, Lean
Manufacturing Team Trainer, TPM Team Member, Kaizen
Facilitator, Six Sigma Team Leader, Maintenance
Manager, HSE Manager, Process Improvement Manager,
Plating Manager (CEF)


Certified Energy Manager (CEM), Certified Energy
Auditor (CEA), Carbon Reduction Manager (CRM)
30+ Training sessions a year, AEE & otherwise
© LEA 2013
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How much coal is needed to run one 100 W
light bulb for one full year (8760 hrs)
 65
pounds
 107
pounds
 551
pounds
 714
pounds
 1020
pounds
copyright LEA
Definitions
Energy use (KWH) =

kW
(eff)
x
Hours
(cons)
Conservation
– reduced consumption with reduced
results

Efficiency
– the ratio of output to the input of any
system
– reduced consumption with same
results


There is a difference, and synergy
Thinking about both forces more
and better opportunities
So you want to reduce
electricity use?

Define “What” – by energy use systems
– Data Analysis
– Energy Audit – AERO
 ASHRAE
level 1,2,3
– Kaizen Energy Treasure Hunt
– Behavioral Energy Change (BEC)

Then Define “How”
– Typical Implementation - Utilities, vendors, site
– Energy Support Programs

Energy 5S, BEC, Six Sigma,
© LEA 2013
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What does your data say?

Look closely

Benchmarks – to yourself and others

View data many different ways

Not just month to month
© LEA 2013
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Internal Metric - Demand
Macro View

KW data by type of day, whole year and
December (ECAM)
© LEA 2013
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Typical Electrical Systems for
Conservation and Efficiency


Typical areas, and manufacturing
percentages (+/-)
To Cover
Quickly
Synergies abound
Compressed Air
% of Electrical KWH
Drying Systems,
6%
Plug Load, 6%

Lighting

HVAC

Motors

Comp. Air

Plug Load
Cooling
Compressed Air,
20%
Motors
Dust Collection
Heating
Systems, 10%
Lighting
Heating Systems
Plug Load
Drying Systems
Lighting, 10%
Cooling, 18%
Dust Collection,
14%
Motors, 16%
© LEA 2013
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3 Steps to Lighting Savings
1.
2.
3.

Meet Target Light
levels
Efficiently produce
and deliver the light
Control lighting auto or manual
The right amount of light, at
the right efficiency, at the
right time
11
copyright LEA
Lighting - Conservation
 Turning
them off!
– Sensor study – define
value
– Sensors – (vandal
resistant)
– Manual – BEC, 5S
© LEA 2013
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Lighting –
Efficiency





Replace HID with T-5 or T-8
LF, CFL, Inductance, LED
Replace T-12 with T-8, T-5,
LED
Replace older T-8 with
Super T-8
Replace with half the
number of bulbs
Replace 3 bulb T-8, with 2b
© LEA 2013
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HVAC – from low to high cost
 Conservation
– Control Exhausts
– Setback
– Ductwork sealing
– Proper operation - occupancy
 Efficiency
– Rooftop or chiller efficiency changes
– Cooling towers
© LEA 2013
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Example of event data
logging


15
Fan
cycling
stopped
when
placed in
setback
From this can calculate fan motor
savings AND cooling savings
copyright LEA
Motors
 Conservation
– Only run when needed
 Efficiency
– Load changes (belts)
– Change motor efficiency – longer
run hours
– VFD – including stagnant
– Energy Saving Motor Controllers
© LEA 2013
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Compressed
Air

Conservation
– Leaks – DOE/Others
25%, LEA 50%
– Eliminate improper uses

Efficiency
– Change compressor –
VFD
– Compressor Controls


Can be 10% or more
of electrical
Have had up to 92%
© LEA 2013
reduction
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Office/plug Load - What does
This
have to do with
This?
c
If every house in America buys one digital picture frame,
we would need to add 5 250 MW power plants
Shows the overall importance of plug load, and its
growth!
copyright LEA
Plug Load

Do an audit, be surprised!

Conservation
– Eliminate or remove printers
– Power save on computer equipment
– Power save strips – for other plugs

Efficiency
– Energy Star computers, appliances
© LEA 2013
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Overall Electricity Reduction
AERO, Six Sigma, BEC



From 2000 kWh/day to 1200 – with primarily just
conservation AERO, BEC, Six Sigma, asking why!
Drop from 1200 to 700 kWh/day with VFDs install
2009 was 50% less than 2008 with conservation and
efficiency BEC
2100.0
2000.0
1900.0
1800.0
1700.0
1600.0
1500.0
1400.0
1300.0
1200.0
1100.0
1000.0
900.0
800.0
700.0
600.0
11-Jul
20
7 day
rolling
average
31-Jul
20-Aug
9-Sep
29-Sep
19-Oct
8-Nov
© LEA 2012
28-Nov
18-Dec
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BEC Example site


Team Training on energy use systems at
their site – 4 hours
Outside ID and quantification of
opportunities by energy use system

Team ID and quantification as well

BEC program development and rollout

Six Sigma incorporation

One hour conference calls – 10 total

(True) Celebration
21
>50% energy
use reduction,
saving
© LEA 2012
$50K/yr
21
Summary
 Evaluate

Data – get dissatisfied
Macro and Micro
 Conservation
and Efficiency
– Lighting, HVAC, Motors,
Compressed Air, Plug Load, etc.
 Systematic,
significant reduction
can occur even if you have done
many equipment changes
already – BEC, Kaizen, 5S, Lean
© LEA 2013
22
Loureiro Engineering
Associates, Inc. (LEA)
Electrical Energy
Management
June 2013
Kevin Vidmar, CEM
© LEA 2013
23