Save Energy Now
Industrial Assessment Report
For
OSU Memorial Union
26th and Jefferson
Corvallis, OR 97331
INDUSTRIAL ASSESSMENT CENTER
OREGON STATE UNIVERSITY
INDUSTRIAL ASSESSMENT CENTER
Sponsored by
U.S. Department of Energy
Managed by
Center for Advanced Energy Systems
Rutgers University
Assessment Report No. 2001
December 17, 2008
Joseph F. Junker, Assistant IAC Director
________________________________
Peter Hanslits, Lead Analyst
________________________________
Assessment Participants
Bryan Kilgore
Elsie Deland
Yuming Qui
Justin Olson
Dr. George Wheeler
IAC Director
Batcheller Hall 341
Corvallis, OR
97331-2405
(541) 737-2515
Motor Analyst
Lighting Analyst and Safety Officer
Chiller Analyst
Energy Analyst
Joseph F. Junker
Assistant Director
Batcheller Hall 344
Corvallis, OR
97331-2405
(541) 737-5034
PREFACE
The work described in this report is a service of the Oregon State University Industrial
Assessment Center (IAC). The project is funded by the U.S. Department of Energy’s Office of
Energy Efficiency and Renewable Energy (EERE) Industrial Technologies Program and
managed by Rutgers University Center for Advanced Energy Systems.
The primary objective of the IAC is to identify and evaluate opportunities for energy
conservation, waste minimization, and productivity improvements through visits to industrial
sites. Data is gathered during a one-day site visit and assessment recommendations (ARs) are
identified. Some ARs may require additional engineering design and capital investment. When
engineering services are not available in-house, we recommend that a consulting engineering
firm be engaged to provide design assistance as needed. In addition, since the site visits by IAC
personnel are brief, they are necessarily limited in scope and a consulting engineering firm could
be more thorough.
We believe this report to be a reasonably accurate representation of energy use, waste generation,
and opportunities in your building. However, because of the limited scope of our visit, the U.S.
Department of Energy, Rutgers University, and the Oregon State University Industrial
Assessment Center cannot guarantee the accuracy, completeness, or usefulness of the
information contained in this report, nor assume any liability for damages resulting from the use
of any information, equipment, method or process disclosed in this report.
Pollution prevention recommendations are not intended to deal with the issue of compliance with
applicable environmental regulations. Questions regarding compliance should be addressed to
either a reputable consulting engineering firm experienced with environmental regulations or to
the appropriate regulatory agency. Clients are encouraged to develop positive working
relationships with regulators so that compliance issues can be addressed and resolved.
The assumptions and equations used to arrive at energy, waste, and cost savings for the
recommended ARs are given in the report. We believe the assumptions to be conservative. If you
do not agree with our assumptions you may follow the calculation methodologies presented
using revised assumptions to develop your own estimates of energy, waste, productivity, and cost
savings.
Please feel welcome to contact the IAC if you would like to discuss the content of this report or
if you have another question about energy use or pollution prevention. The IAC staff that visited
your building and prepared this report is listed on the preceding page.
TABLE OF CONTENTS
1.
Introduction....................................................................................................................... 1
2.
Executive Summary .......................................................................................................... 2
3.
Assessment Recommendations ......................................................................................... 5
4.
AR No. 1.
Pipe Insulation ........................................................................................ 5
Justin Olson
AR No. 2.
Chiller ..................................................................................................... 6
Yuming Qui
AR No. 3.
Winter HVAC ........................................................................................ 7
Peter Hanslits
AR No. 4.
Oven Exhaust Fan .................................................................................. 8
Bryan Kilgore
AR No. 5.
Skylights ................................................................................................. 9
Elsie Deland
AR No. 6.
Halogen Lights ..................................................................................... 10
Elsie Deland
Calculation Methodology ............................................................................................... 11
AR No. 1.
AR No. 2.
AR No. 3.
AR No. 4.
AR No. 5.
AR No. 6.
Pipe Insulation ...................................................................................... 11
Chiller ................................................................................................... 14
Winter HVAC ...................................................................................... 21
Oven Exhaust Fan ................................................................................ 27
Skylights ............................................................................................... 30
Halogen Lights ..................................................................................... 35
APPENDIX
A. Utilities ........................................................................................................................... 41
A.1. Energy Definitions .................................................................................................. 41
A.2. Energy Conversions ................................................................................................ 46
A.3. Energy Accounting ................................................................................................. 47
A.4. Energy Use .............................................................................................................. 55
B. Motors ............................................................................................................................. 59
B.1. Boiler Motor Definitions ......................................................................................... 59
B.2. Motor Inventory ...................................................................................................... 63
B.3. Motor Applications ................................................................................................. 64
B.4. Motor Use Summaries ............................................................................................ 65
B.5. Motor Economics .................................................................................................... 65
B.6. Motor Performance ................................................................................................. 66
B.7. Motor Power Factor ................................................................................................ 67
C. Lighting........................................................................................................................... 68
C.1. Lighting Worksheet Definitions.............................................................................. 68
C.2. Lighting Inventory .................................................................................................. 74
D. Refrigeration ................................................................................................................... 76
D.1. Refrigeration Worksheet Definitions ...................................................................... 76
1. INTRODUCTION
This report describes how energy is used in your building, and includes our recommendations on
cost effective steps you can take to reduce your energy and waste costs. The contents of this
report are based on our recent visit to your building. The report is divided into 4 major sections
and 4 appendices:
1. Introduction. The purpose, contents and organization of the report are described.
2. Executive Summary. Your energy use and waste generation costs, energy and waste
savings, and our recommendations are summarized here with details in the following
sections.
3. Assessment Recommendations. This section contains our Assessment Recommendations
(AR), briefly highlights the current and proposed systems and summarizes the cost savings
available upon implementation. Some of our recommendations will require a significant
investment to implement, while others will cost little or nothing. We have grouped our
recommendations by category and then ranked them by payback period.
4. Calculation Methodologies. This section includes detailed calculations for the Assessment
Recommendations (AR). It includes any data that was collected during the audit, assumptions
we use to estimate savings, our estimate of implementation cost, and the simple payback. We
have grouped the calculations in the same order as the AR’s in Section 3.
Appendix A: Utilities. Your utility bills and energy use by process are summarized and plotted
in detail. Due to the changes in rate schedules and adjustments our calculations are an
approximation and may not be exactly consistent with your bills. When available, we also
include water and solid waste bills.
Appendix B: Motors. Motors are typically a large energy user. This section contains your motor
information including: nameplate information, area of the plant the motor is located in, and
monthly energy use in each section of the plant.
Appendix C: Lighting. The number and type of lighting fixtures are recorded for each area.
This appendix also includes the Lighting Worksheet Definitions, which describe the symbols and
terminology used in our lighting calculations. The lighting power and annual energy use for each
plant area are summarized in the Lighting Inventory worksheet.
Appendix D: Refrigeration. This appendix includes the Refrigeration Worksheet Definitions,
which describes the accompanying Refrigeration Energy Savings worksheets. The worksheet
uses bin weather data to model the refrigeration compressor’s operating conditions.
1
2. EXECUTIVE SUMMARY
This section includes a summary of energy use and waste generation in your building, our
recommendations, and total energy, waste, and cost savings of all recommendations if
implemented.
Recommendation Summary. The following is a brief explanation of each of the
recommendations made in this report. If all 6 recommendations are implemented, the total cost
savings will be $29,430 and will pay for costs in 0.3 years.
AR No. 1: Pipe Insulation
Insulate exposed hot steam and chilled water lines. This will reduce energy lost through these
pipe surfaces by 92%.
AR No. 2: Chiller
Reduce the minimum R-22 discharge (head) pressure on both chiller units. This will reduce
chiller operation costs by 25% through a reduction in compressor energy use.
AR No. 3: Winter HVAC
Turn off five major air handling units during winter night time hours. This will reduce total
building steam use by 31% and reduce fan energy use by 33%.
AR No. 4: Oven Exhaust Fan
Turn off the Pangea oven exhaust fan at night and during the summer. This will reduce electrical
costs for this fan by 43% and will reduce conditioned air exhaust when cooling or heating is
needed.
AR No. 5: Skylights
Install photo sensor/timer units on T8 fixtures in skylights to reduce operating hours. Replace
yellow glass with clear glass to allow more light into hallways. This will reduce lighting costs by
46% in this area.
AR No. 6: Halogen Lights
Replace Halogen fixtures in the ballroom with Compact Fluorescent fixtures. This will reduce
energy usage in this area by 58%.
2
Our recommendations are summarized in the following table.
Assessment Recommendation Summary
Energy
Cost
Implementation
AR#
Description
1
Pipe Insulation
2
Chiller
3
Winter HVAC
4
Oven Exhaust Fan
5
Skylights*
6
Halogen Lights*
Totals
(MMBtu) Savings
44.0
$631
415.3
$5,700
1,301.3 $24,414
58.0
$789
20.6
$415
39.7
$483
1,878.9 $32,432
Cost
$298
$6,000
$0
$100
$1,040
$2,533
$9,963
Payback
(years)
0.5
1.5
Immediate
0.1
2.5
5.2
0.3
*Includes Incentives
Total savings are the sum of the savings for each recommendation. Some of the
recommendations may interact. Therefore, actual savings may be less than the total indicated
above. In our calculations we indicate where we have assumed that other recommendations will
be implemented in order to provide a realistic estimate of actual savings. Total savings, including
interactions among recommendations, can be better estimated after you select a package of
recommendations.
Savings Summary. Total cost savings are summarized by energy cost savings. We then
normalize savings as a percentage of annual building energy costs. For example, Energy Cost%
is energy cost savings divided by the total energy cost from the Utility Summary.
Savings Summary
Source
Qty.
Units
Cost Savings
Energy Cost %
$32,432
17.7%
Energy 1,878.9 MMBtu
Existing Energy Use Summary. We used your utility bills to determine annual energy use for
all fuels. From these bills we summarized annual energy consumption at your plant in the
following table.
Energy costs and calculated savings are based on the incremental cost of each energy source. The
incremental rate is the energy charge first affected by an energy use reduction and is taken from
your utility rate schedules. For example, electrical use and savings include energy (kWh),
demand (kW), reactive power charges (KVARh or power factor), and other fees such as basic
charges, transformer rental, and taxes. However, if a recommendation does not affect your
electrical demand, such as turning off equipment at night, then we use the cost of electrical
energy alone. The fuel costs we used can be found in the Energy Accounting Summary in
Appendix A.
3
Existing Energy Use Summary
Source
Electric Energy
Natural Gas
Steam
Totals
Qty.
1,972,560
10,890
4,067,500
Units
kWh
Therms
lbs
4
MMBtu Energy %
Cost
Cost %
6,732
57.5%
$91,527 50.0%
1,089
9.3%
$12,244
6.7%
3,880
33.2%
$79,316 43.3%
11,702
100.0% $183,087 100.0%
3. Assessment Recommendations
AR No. 1
Pipe Insulation
Recommendation
Insulate exposed piping that is significantly hotter or colder than ambient temperature. This will
reduce energy lost through pipe surfaces by 92%.
Assessment Recommendation Summary
Energy Savings
(MMBtu)
44.0
Cost
Savings
$631
Implementation
Cost
$298
Payback
(years)
0.5
Background
About 33 feet of exposed pipe runs in the commons and bookstore maintenance rooms. Uninsulated pipes contribute to energy losses in heating and cooling systems.
Proposal
Insulate bare piping with suggested insulation to reduce
further energy losses. Insulating these lines will save
energy. Typical types of insulation used for pipes are
listed below:
•
•
•
•
Polystyrene
High density fiberglass shaped for pipes or flat
sections
Blankets of fiberglass or mineral wool
Spray-on foam (Primarily on cooling systems)
We have recommended polystyrene with an aluminum
jacket. This type of insulation results in a payback period
of 0.6 years.
Photo courtesy of The Boiler Burner
For detailed calculation, see Pipe Insulation - Calculation Methodology later in this report.
5
AR No. 2
Chiller
Recommendation
Reduce the approach temperature on both of the chiller cooling towers. This will reduce
compressor energy use while maintaining your chilled water temperature.
Assessment Recommendation Summary
Energy
Energy
Cost
Implementation Payback
(MMBtu) (kWh)* Savings
Cost
(years)
415.3
121,800 $5,700
$6,000
1.1
*1 kWh = 3,410 Btu
Background
Chillers use a refrigerant loop to chill water and transfer the heat to ambient air. The chiller
compressor pressurizes refrigerant, raising its temperature and pressure, then pumps refrigerant
to the condenser where refrigerant condenses into a liquid, rejecting heat. The approach
temperature difference between chiller refrigerant and water approaching the condenser is a good
indicator of whether excess compression is required at the compressor. Your condenser’s
minimum approach temperature is approximately 54 °F. We recommend an approach
temperature of 20 °F.
Proposal
Reduce condenser approach temperature.
This will reduce compressor energy use
while maintaining chilled water
temperature. It is likely that the chiller heat
exchangers will have to be cleaned to lower
approach temperature without effecting
chiller capacity.
As detailed in the Chiller - Calculation
Methodology, there is a 1.1 year payback
with $6,000 implementation cost.
6
AR No. 3
Winter HVAC
Recommendation
Turn off the five major air handling units during winter night time hours. The estimated
reduction in total building steam use is 31% and the estimated reduction in electricity usage for
these five fans is 33%.
Assessment Recommendation Summary
Energy
Steam Energy Net
Implementation
(MMBtu) (lbs)** (kWh)* Savings
Cost
1,301.3 1,273,843 25,251 $24,414
$0
*1 kWh = 3,410 Btu
**1 lb Steam = 903 Btu
Payback
(years)
Immediate
Background
Five major HVAC units currently run constantly throughout the year. During the summer,
HVAC fans are needed at night to circulate cool outside air into the building for a night flush.
However, during the winter, these fans exhaust steam heated air to the outside while bringing in
chilled air that must be heated. While HVAC is needed during the day for circulation, nighttime
usage can be eliminated. Turning off major HVAC units at night during the winter will
significantly reduce building costs without negatively effecting air quality.
Proposal
Turn off five major air handling units at night during
the winter. This action is expected to result in
significant energy savings without negatively effecting
building comfort.
As detailed in the Winter HVAC - Calculation
Methodology, there is an immediate payback with no
implementation cost.
Image courtesy of www.jmcmechanical.com
7
AR No. 4
Oven Exhaust Fan
Recommendation
Turn off the Pangea oven exhaust fan at night and during the summer. This will reduce fan
electrical costs by 43% and loss of conditioned air when cooling or heating is needed. The
heating and cooling savings are not taken into account in this recommendation.
Assessment Recommendation Summary
Energy
Energy
Cost
Implementation Payback
(MMBtu) (kWh)* Savings
Cost
(years)
58.0
17,010
$789
$100
0.1
*1 kWh = 3,410 Btu
Background
The kitchen oven exhaust fan runs constantly, even at night and during the summer when the
ovens are not running. During these times the oven exhaust fan is unnecessarily exhausting
conditioned air and consuming energy.
Proposal
Turn off Pangea oven exhaust fan during nights
throughout the year and keep exhaust fan off during
the summer when the ovens are not running. This
should save approximately 43% of the energy
consumed by exhaust fan.
As detailed in the Oven Exhaust Fan - Calculation
Methodology, cost savings will pay for
implementation costs in 0.1 years.
Image Courtesy of: www.greenheck.com
8
AR No. 5
Skylights
Recommendation
Install photo sensor/timer units on T8 fixtures in skylights to reduce operating hours. Replace
yellow glass with clear glass to allow more light into hallways. This will reduce lighting costs by
46% in this area.
Assessment Recommendation Summary
Energy
Energy
Cost
Implementation Payback**
(MMBtu) (kWh)* Savings
20.6
6,574
$415
*1 kWh = 3,410 Btu
**Cost after incentives
Cost**
$1,492
(years)
3.6
Background
While visiting your building we observed 15 skylights with yellowed glass. Each skylight
contained a T8 fixture that was lit during our visit.
Proposal
We recommend installing a photo sensor/timer unit for each skylight T8 fixture and replacing
yellow glass panes in skylights with clear glass panes. Installing photo sensor/timer units will
reduce the time each light is on and installing clear glass will allow more natural light into the
second floor hallway so the T8 fixtures will be unnecessary on sunny days.
As detailed in the Skylights - Calculation Methodology, there is a 3.6 year payback with $1,492
implementation cost after incentives.
9
AR No. 6
Halogen Lights
Recommendation
Replace halogen fixtures in the ballroom with compact fluorescent fixtures. This will reduce
lighting energy usage in this area by 58%.
Assessment Recommendation Summary
Energy
Energy
Cost
Implementation Payback**
(MMBtu) (kWh)* Savings
39.7
12,650
$483
*1 kWh = 3,410 Btu
**Savings after incentives
Cost**
$2,533
(years)
5.2
Background
While visiting your facility we observed 45 halogen lights in the ballroom. According to
maintenance and a report prepared by an outside source, the halogen lights are 450 watt mini
candelabra lights. We observed them operating on a dimmer at 80% output.
Proposal
Replace candelabra base sockets with mogul base sockets that
will accommodate 150 watt non-dimmable compact fluorescent
bulbs. This will reduce energy consumption and heat produced
by the fixtures. Dimmable compact fluorescent bulbs and
fixtures are available and will save additional energy when
dimmed. They also cost more, so implementation costs will
increase.
As detailed in the Halogen Lights - Calculation Methodology,
there is a 5.2 year payback with $2,553 implementation cost.
Photo courtesy of Amazon.com
10
4. Calculation Methodology
AR No. 1
Pipe Insulation
Calculation Methodology
Recommendation
Insulate exposed piping that is significantly hotter or colder than ambient temperature. This will
reduce energy lost through pipe surfaces by 92%.
Assessment Recommendation Summary
Energy Savings
Cost
(MMBtu)
Savings
44.0
$631
*1 kWh = 3,410 Btu
Implementation
Cost
$298
Payback
(years)
0.5
Data Collected Summary
The bookstore maintenance room (BMR) and commons maintenance room (CMR) contain bare
piping with energy loss. The following table summarizes data collected from those locations.
Bare Pipe Data*
Length Diameter Surface Temp. Ambient Temp.
Area
Description
(in.)
(in.)
(˚F)
(˚F)
BMR Unidentified
84.0
3.8
185˚
88˚
BMR Unidentified
34.3
3.8
210˚
88˚
CMR Steam
28.5
17.0
200˚
85˚
CMR Steam
58.0
4.5
200˚
85˚
CMR Unidentified
49.0
2.3
150˚
85˚
*Only bare pipes with significant temperature differential from ambient are included
Savings Analysis
Uninsulated pipes contribute to energy losses in heating and cooling systems. The system must
make up for heat losses due to radiation and convection. Reducing the heat transfer coefficient
by adding insulation will yield energy and cost savings. Note that the following calculations
assume that the fluid or gas temperature in the pipe is constant.
We used 3E+ software, a free insulation calculation tool prepared by the North American
Insulation Manufacturer’s Association and made available by U.S. Department of Energy, to
compare current and proposed energy losses and cost savings for several insulation thicknesses.
11
Cost savings are based on a steam energy cost of $0.0195/lb. The following table shows different
thicknesses taking the Bookstore Maintenance Room piping at 185˚F as an example.
Energy Savings Summary for Bookstore Maintenance Room
Energy
Insulation
Surface
Energy
Cost
Thickness Temperature Efficiency
Cost
Heat Loss Savings
(inches)
(°F)
(%)
($/ft/yr) (Btu/ft/yr) ($/ft/yr)
Bare
184.9
$27.86 1,860,000
0.5
132.4
80.7
$5.39
359,200
$22
1.0
120.6
87.1
$3.59
239,400
$24
1.5
114.1
90.4
$2.68
178,400
$25
2.0
109.7
92.5
$2.11
140,200
$26
2.5
106.6
93.8
$1.72
114,300
$26
Cost savings (CS) can be found as:
CS
=
=
=
=
Cost savings
FT x EC
7 ft x $26/ft
$182
FT
= Feet of pipe to be insulated
= 7 ft
EC
= Energy cost savings from 3E plus software using 2.0 inch thick insulation
= $26/ft
Where,
Total savings for all bare piping is summarized in the table below. 3E+ calculated each scenario
and the best result was chosen (as in example above).
Area
BMR
BMR
CMR
CMR
CMR
Total
Description
Unidentified
Unidentified
Steam
Steam
Unidentified
Total Cost Savings Summary
New
Energy Cost
Insulation Surface Temp Efficiency
Savings
Thickness
(˚F)
(%)
($/ft)
2.0
109.7
92.4
$26
2.5
110.5
94.1
$35
2.0
110.1
84.2
$30
2.0
110.1
84.2
$30
2.5
98.3
82.4
$15
12
Pipe
Length
(ft.)
7.0
4.9
2.4
4.8
4.0
32.3
Energy
Cost
Savings
$182
$172
$73
$145
$59
$631
Cost Analysis
Implementation costs include material costs for the following insulation:
•
•
•
Insulation Layer 1: Polystyrene, Varied
Outer Jacket Material: Aluminum, oxidized, in service
Outer Surface Emittance 0.1
We used RSMeans Building Construction as an estimation tool of installation cost for the
insulation. The insulation costs from RSMeans Building Construction ($2.87 /ft) seemed low
from previous experience, so we added additional costs of $10/ft for installation to maintain a
conservative estimate.
Area
BMR
BMR
CMR
CMR
CMR
Total
Total Cost Summary
Pipe Length
Description
(ft.)
Unidentified
7.0
Unidentified
4.9
Steam
2.4
Steam
4.8
Unidentified
4.0
Cost
($/ft)
12.9
12.9
12.9
12.9
12.9
Insulation
Cost
$91
$63
$31
$62
$51
$298
Cost savings will pay for implementation in 0.6 years.
Incentive Summary
Incentives don’t apply to energy efficiency projects with less than a one year payback. However,
if this project is combined with another that creates a total project payback of greater than one
year, then some energy incentives may apply.
13
AR No. 2
Chiller
Calculation Methodology
Recommendation
Reduce the approach temperature on both of the chiller cooling towers. This will reduce
compressor energy use while maintaining your chilled water temperature.
Assessment Recommendation Summary
Energy
Energy
Cost
Implementation Payback
(MMBtu) (kWh)* Savings
Cost
(years)
415.3
121,800 $5,700
$6,000
1.1
*1 kWh = 3,410 Btu
Data Collected Summary
From building personnel
• Chillers don’t run in between October and February
Assumptions
• Chiller heat exchangers will require a thorough cleaning or additional capacity
From nameplates and observation
Chiller Nameplate and Observed Operating Conditions Summary
East Chiller
West Chiller
Manufacturer
Carrier
Carrier
Horsepower
35
40
Cooling Tower Type
Wet
Wet
Minimum Approach Temperature
54 °F
54 °F
Currently, the chiller system consists of three separate loops.
1. The chilled loop carries chilled water from the chiller evaporator to the end use, where
the chilled water gains energy by absorbing heat. The chilled water then exhausts heat
into the chiller evaporator.
2. The refrigerant loop carries low energy refrigerant to the chiller evaporator where the
refrigerant absorbs energy from the chilled water. The high energy refrigerant travels
through a compressor and exhausts energy at the chiller condenser. The refrigerant then
travels through the expansion device back to the evaporator again.
14
3. The cooling loop carries low energy cooling water to the chiller condenser where it gains
energy. The cooling water then travels to the cooling tower where it exhausts energy to
the atmosphere. The following diagram is of the chiller system.
Chiller System
End Use
Chilled Loop
Chiller Evaporator
Energy Flow
Refrigerant
Loop
Chiller
Compressor
Chiller Condensor
Cooling Loop
Cooling Tower
The heat exchangers referenced in this recommendation are in the chiller condenser. If the heat
exchanger in the chiller condenser cannot be changed, changes in the cooling tower controls and
maintenance might achieve similar results.
15
From regional weather data
Ambient Temperature Data between September and February 1
Outside Wet Bulb
Winter Hours at this
Outside Wet Bulb
Winter Hours at this
Temperature
Temperature
Temperature
Temperature
(°F)
(Hours)
(°F)
(Hours)
68
13
44
992
67
40
40
811
65
86
36
590
63
158
31
318
61
240
26
163
58
349
20
42
56
473
15
8
53
710
11
2
48
882
7
1
Savings Analysis
A chiller spreadsheet developed by the Oregon State University Industrial Assessment Center is
used to calculate chiller energy and cost savings. The spreadsheet uses weather data, current
operating conditions and proposed operating conditions to find compressor energy savings.
Annual cost savings are calculated by finding the cost savings associated with energy savings.
CS
=
=
=
=
Cost Savings
EC x ES
$0.0464 /kWh x 121,800 kWh
$5,700
EC
=
=
Incremental Energy Cost
$0.0464 /kWh
ES
=
=
=
=
Energy Savings
E+W
62,500 kWh + 59,300 kWh
121,800 kWh
E
=
=
East Chiller Energy Savings
62,500 kWh
W
=
=
West Chiller Energy Savings
59,300 kWh
Where,
Where,
1
Data is collected at and compiled by Salem Airport between the years of 1948 and 1985
16
Chiller Energy Savings are found using the spreadsheets at the end of the Chiller – Calculation
Methodology. Spreadsheet terminology is described in Refrigeration Appendix D.
Total annual cost savings are summarized in the following Savings Summary table:
Savings Summary
Source
Quantity Units Energy (MMBtu)
East Chiller Energy Use
62,500 kWh
213.1
West Chiller Energy Use
59,300 kWh
202.2
121,800 kWh
Total
415.3
Cost Savings
$2,900
$2,800
$5,700
Cost Analysis
Based on the chiller loop temperatures and the refrigerant temperatures, the heat exchangers are
not achieving a sufficiently low condenser approach temperature. Installing larger heat
exchangers would greatly improve heat exchanger performance, but this is not cost effective. We
assume a professional cleaning should improve chiller performance enough to accommodate a
lower approach temperature.
IC
=
=
=
=
Implementation Cost
HC x N
$3,000 /Heat Exchanger x 2 Heat Exchangers
$6,000
HC
=
=
Cost to Professionally Clean the Heat Exchanger
$3,000 /Heat Exchanger
N
=
=
Number of Heat Exchangers
2 Heat Exchangers
Where,
Total implementation costs are summarized in the following Implementation Summary table:
Implementation Summary
Source
Quantity
Units
$/Unit Cost
Heat Exchanger Cleaning Costs
2 Heat Exchangers $3,000 $6,000
Savings will pay for implementation in 1.1 years.
17
Note
If the current chiller heat exchangers are undersized, it may not be possible to reduce approach
temperature even with a thorough cleaning. In this case, larger heat exchanger will greatly
increase implementation costs and payback period.
During our first visit to your building, we observed anomalous chiller behavior including a
cooling water loop approach temperature of over 80 °F. To preserve a conservative estimate in
our calculations, we assume that the approach temperature is constant at 54 °F, the temperature
we observed during our second visit to your building.
18
EAST REFRIGERATION ENERGY SAVINGS
Report:
Application:
Buildings:
Bin Data:
2001
Refrigeration
Bookstore Maintenance Room
Salem, OR
Operating Conditions
Minimum Condensing Temperature (Tm):
Approach Temperature Difference (DT):
Compressor Energy (EC):
Condenser Fan Horsepower (Hp):
Fan Power (FP):
Average Fan Use Factor (UFe):
Fan Energy (FE):
Total Energy Usage:
Total Energy Cost:
Bin Calculation
Dry
Bulb
We t
Bin
Bulb
(Tdb)
(Twb)
107
73
102
72
97
69
92
68
87
67
82
65
77
63
72
61
67
58
62
56
57
53
52
48
47
44
42
40
37
36
32
31
27
26
22
20
17
15
12
11
7
7
2
2
-3
-1
-8
-8
-13
-13
Totals
Cooling
Wate r
Ente ring
Conde nse r (Tcw)
88
87
84
83
82
80
78
76
73
71
68
63
59
55
51
46
41
38
38
38
38
38
38
38
38
Refrigerant:
Energy Cost (E$):
Annual Hours:
Existing
70
54
156,870
3
1.6
100.0%
9,300
166,170
$7,710
Approach
Te mp
Hours
(H)
0
0
2
13
40
86
158
240
349
473
710
882
922
811
590
318
163
42
8
2
1
0
0
0
0
5,810
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
Exist
Cond
Temp
(Tce)
142
141
138
137
136
134
132
130
127
125
122
117
113
109
105
100
95
92
92
92
92
92
92
92
92
Prop
Cond
Temp
(Tcp)
127
122
117
112
107
102
97
92
87
82
77
72
70
70
70
70
70
70
70
70
70
70
70
70
70
Energy and Cost Savings
Compressor Energy Savings (CES):
Fan Energy Increase (FEI):
Total Energy Savings (ES):
Total Cost Savings (CS):
Implementation Cost (IC):
Simple Payback:
Deg-hr
Savings
(DHS)
0
0
42
325
1,160
2,752
5,530
9,120
13,960
20,339
31,950
39,690
39,646
31,629
20,650
9,540
4,075
924
176
44
22
0
0
0
0
232,000
Savings
%
(E%)
0.0%
0.0%
0.0%
0.1%
0.2%
0.5%
1.0%
1.6%
2.4%
3.5%
5.5%
6.8%
6.8%
5.4%
3.6%
1.6%
0.7%
0.2%
0.0%
0.0%
0.0%
0.0%
0.0%
0.0%
0.0%
39.9%
R22
$0.04640 /kWh
5,810
Proposed
70
20
94,370
3
1.6
85.3%
7,900
102,270
$4,750
Compress
Savings
kWh
(CES)
0
0
11
88
313
743
1,493
2,462
3,769
5,492
8,627
10,716
10,704
8,540
5,576
2,576
1,100
249
48
12
6
0
0
0
0
62,500
Savings
0
34
62,500
0.0
0.0
14.7%
1,400
63,900
$3,000
Fan
Increase
kWh
(FEI)
kWh
kWh
Total
Savings
kWh
(ES)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
(8)
(2)
0
0
0
0
0
0
62,500
0
62,500
$2,900
$3,000
1.0
19
Units
°F
°F
kWh/yr
hp
kW
0
0
11
88
313
743
1,493
2,462
3,769
5,492
8,627
10,716
10,704
8,540
5,576
2,576
1,100
249
56
14
6
0
0
0
0
62,500
kWh/yr
kWh/yr
kWh/yr
/yr
years
WEST REFRIGERATION ENERGY SAVINGS
Report:
Application:
Buildings:
Bin Data:
2001
Refrigeration
Bowling Chiller Room
Salem, OR
Refrigerant:
Energy Cost (E$):
Annual Hours:
Operating Conditions
Minimum Condensing Temperature (Tm):
Approach Temperature Difference (DT):
Compressor Energy (EC):
Condenser Fan Horsepower (Hp):
Fan Power (FP):
Average Fan Use Factor (UFe):
Fan Energy (FE):
Total Energy Usage:
Total Energy Cost:
Bin Calculation
Dry
Cooling
Bulb
Wet
Water
Bin
Bulb
Entering
(Tdb)
(Twb)
Condenser (Tcw)
107
73
88
102
72
87
97
69
84
92
68
83
87
67
82
82
65
80
77
63
78
72
61
76
67
58
73
62
56
71
57
53
68
52
48
63
47
44
59
42
40
55
37
36
51
32
31
46
27
26
41
22
20
38
17
15
38
12
11
38
7
7
38
2
2
38
-3
-1
38
-8
-8
38
-13
-13
38
Totals
Energy and Cost Savings
Compressor Energy Savings (CES):
Fan Energy Increase (FEI):
Total Energy Savings (ES):
Total Cost Savings (CS):
Implementation Cost (IC):
Simple Payback:
R22
$0.04640 /kWh
5,810
Existing
70
54
173,370
3
1.6
100.0%
9,300
182,670
$8,480
Approach
Temp
Hours
(H)
0
0
2
13
40
86
158
240
349
473
710
882
922
811
590
318
163
42
8
2
1
0
0
0
0
5,810
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
Exist
Cond
Temp
(Tce)
142
141
138
137
136
134
132
130
127
125
122
117
113
109
105
100
95
92
92
92
92
92
92
92
92
Prop
Cond
Temp
(Tcp)
108
107
104
103
102
100
98
96
93
91
88
83
79
75
71
70
70
70
70
70
70
70
70
70
70
Deg-hr
Savings
(DHS)
0
0
68
442
1,360
2,924
5,372
8,160
11,866
16,082
24,140
29,988
31,348
27,574
20,060
9,540
4,075
924
176
44
22
0
0
0
0
194,000
Savings
%
(E%)
0.0%
0.0%
0.0%
0.1%
0.2%
0.5%
0.9%
1.4%
2.0%
2.8%
4.2%
5.2%
5.4%
4.7%
3.5%
1.6%
0.7%
0.2%
0.0%
0.0%
0.0%
0.0%
0.0%
0.0%
0.0%
33.4%
Proposed
70
20
115,470
3
1.6
85.3%
7,900
123,370
$5,720
Compress
Savings
kWh
(CES)
0
0
20
132
406
873
1,603
2,435
3,541
4,799
7,203
8,948
9,354
8,228
5,986
2,847
1,216
276
53
13
7
0
0
0
0
57,900
Savings
Units
0 °F
34 °F
57,900 kWh/yr
0.0 hp
0.0 kW
14.7%
1,400 kWh
59,300 kWh
$2,800
Fan
Increase
kWh
(FEI)
0
0
0
0
0
0
0
0
0
0
0
0
(192)
(371)
(372)
(241)
(140)
(39)
(8)
(2)
0
0
0
0
0
(1,400)
57,900 kWh/yr
(1,400) kWh/yr
59,300 kWh/yr
$2,800 /yr
$3,000
1.1 years
20
Total
Savings
kWh
(ES)
0
0
20
132
406
873
1,603
2,435
3,541
4,799
7,203
8,948
9,546
8,599
6,358
3,088
1,356
315
61
15
7
0
0
0
0
59,300
AR No. 3
Winter HVAC
Calculation Methodology
Recommendation
Turn off the five major air handling units during winter night time hours. This will reduce total
building steam use by 31% and fan energy use by 33%.
Assessment Recommendation Summary
Energy
Steam
Energy
Net Implementation Payback
(MMBtu)
(lbs)**
(kWh)* Savings
Cost
(years)
1,301.3
1,273,843
25,251 $24,414
$0
Immediate
*1 kWh = 3,410 Btu
**1 lb Steam = 903 Btu
Data Collected Summary
From building personnel
• Building occupancy is minimal between midnight and 6 am
• HVAC during the winter is to provide circulation, not for temperature control
• The building switches between heating and cooling in October and April
• The entire MU is wired at 230 Volts
• Steam costs $0.0195/lb Steam for the 2008/2009 school year
• Bowling Unit runs at 13.6 Amps (live)
• Bookstore Supply Fan #7 runs at 10.1 Amps (live)
• Bookstore Exhaust Fan #2 runs at 9.8 Amps (live)
• Ballroom Unit runs at 21 Amps (live)
• Lounge Unit runs at 21 Amps (live)
From previous reports
• Lounge unit draws heated supply air from the attic
• Steam enthalpy is 903 Btu/lb Steam
Assumptions
• Building heating set-point is 60 °F
• Bookstore Supply Unit #7, Bowling Unit and Ballroom Unit are running at rated airflow
• Live amp readings accurately reflect conditions throughout winter
21
The following table summarizes current winter operating conditions.
Current Winter Operating Conditions Summary
Live Amps Volts kW CFM
Winter Operating Hours
Bookstore Supply Unit #7
10.1
230
2.3 20,000
4,380
Bookstore Exhaust Unit #2
9.8
230
2.2 18,000
4,380
Bowling Unit
13.6
230
3.1
7,500
4,380
Ballroom Unit
21.0
230
4.8 10,000
4,380
Lounge Unit
21.0
230
4.8 13,000
4,380
kWh
10,074
9,636
13,578
21,024
21,024
The following table summarizes average temperature conditions between 1 am to 8 am from
October to April.
Midnight to 8 am Winter Heat Load Summary 2
Building Setpoint Outside Temperature Temperature Difference Winter Hours at this Temperature
(°F)
(°F)
(°F)
(Hours)
60
57
3
43
60
52
8
149
60
47
13
269
60
42
18
336
60
37
23
288
60
32
28
212
60
27
33
95
60
22
38
37
60
17
43
15
60
12
48
5
60
7
53
0
Savings Analysis
For the purpose of this analysis winter is assumed to be a 6 month period when the building
requires heating. Current energy use is calculated using a building set-point of 60 °F. We
propose reducing the winter operating hours of the air handling units by eight hours each night.
This recommendation doesn’t change the maximum power value, so there are no demand
savings. We calculate electrical savings first, then savings from space heating reductions.
2
Data is collected at and compiled by Salem Airport between the years of 1948 and 1985
22
Electrical savings are calculated as the difference between current and proposed electrical energy
use. The Ballroom Unit is taken as an example:
Electrical Savings for the Ballroom Unit
EC
=
=
=
=
Electricity Cost Savings
ES x IE
7,047 kWh x $0.0464/kWh
$327
ES
=
=
=
=
Energy Savings
CE – PE
21,024 kWh – 13,977 kWh
7,047 kWh
IE
=
=
Incremental Energy Cost
$0.0464/kWh
CE
=
=
=
=
Current Winter Energy Usage
CH x CP
4,380 hrs x 4.8 kW
21,024 kWh
PE
=
=
=
=
Proposed Winter Energy Usage
PH x PP
2,912 hrs x 4.8 kW
13,977 kWh
CH
=
=
Current Winter Operating Hours
4,380 hrs
CP
=
=
Current Power
4.8 kW
PH
=
=
=
Proposed Winter Operating Hours
(24 hrs/day – 8 hrs/day) x 182 days/winter
2,912 hrs
PP
=
=
Proposed Power
4.8 kW
Where,
Where,
Where,
23
The following table summarizes existing electrical conditions, proposed electrical conditions and
electrical savings during winter.
Winter Operating Conditions and Electrical Savings Summary
Operating Hours
kW
kWh
Existing Bookstore Supply Unit #7
4,380
2.3
10,074
Existing Bookstore Exhaust Unit #2
4,380
2.2
9,636
Existing Bowling Unit
4,380
3.1
13,578
Existing Ballroom Unit
4,380
4.8
21,024
Existing Lounge Unit
4,380
4.8
21,024
Proposed Bookstore Supply Unit #7
2,912
2.3
6,698
Proposed Bookstore Exhaust Unit #2
2,912
2.2
6,406
Proposed Bowling Unit
2,912
3.1
9,027
Proposed Ballroom Unit
2,912
4.8
13,977
Proposed Lounge Unit
2,912
4.8
13,977
Savings
1,468
0.0
25,251
Cost
$467
$447
$630
$975
$975
$310
$298
$418
$648
$648
$1,172
Heating Savings for major Air Handling Units
We propose to eliminate fan operating hours between midnight and 8 am. This will effectively
eliminate steam heating in these units during these hours. Savings are determined by calculating
the energy required to raise the temperature of outside air to the building set-point during these
hours.
Previous HVAC reports noted that the Lounge Unit draws heated air from the attic that is used
during the winter without requiring additional heating. Also, the Bookstore Exhaust Unit #2 is
not taken into account as no heating occurs within it.
HC
=
=
=
=
Heating Cost Savings
SS x IS
1,345,787 lbs Steam x $0.0195/lb Steam
$26,242
SS
=
=
=
=
Steam Savings
HS ÷ SE
1,215,246,240 Btu ÷ 903 Btu/lb Steam
1,345,787 lbs Steam
IS
=
=
Incremental Steam Cost
$0.0195/lb Steam
Where,
24
Where,
HS
=
=
=
=
Heating Savings
CP x AT x SA x ℓ x 60 min/hr
0.24 Btu/lb-°F x 28,852 °F-hrs x 37,500 cfm x 0.078 lb/ft3 x 60 min/hr
1,215,246,240 Btu
SE
=
=
Steam Enthalpy
954 Btu/lb Steam
CP
=
=
Specific Heat of Air in btu/lbm-degF
0.24 Btu/lb-°F
AT
=
=
Annual Temperature Difference Hours
=
28,852 °F-hrs
SA
=
=
=
=
System Airflow
BU + BS + BA
10,000 cfm + 20,000 cfm + 7,500 cfm
37,500 cfm
ℓ
=
=
Air Density
0.078 lb/Ft3
Where,
∑(60° - T )× H
Where,
Variable Declaration and Winter Temperature Hours between Midnight and 8 am
Temperature Outside Temperature
Hours Spent at this Outside Temperature
Variable
(°F)
Hours Variable
(Hours)
Ta
57
Ha
43
Tb
52
Hb
149
Tc
47
Hc
269
Td
42
Hd
336
Te
37
He
288
Tf
32
Hf
212
Tg
27
Hg
95
Th
22
Hh
37
Ti
17
Hi
15
Tj
12
Hj
5
BU
=
=
Bowling Unit Airflow
10,000 cfm
25
BS
=
=
Bookstore Supply Unit Airflow
20,000 cfm
BA
=
=
Ballroom Unit Airflow
7,500 cfm
Total savings including electrical and heating are summarized in the following table.
Electrical Energy
Electrical Demand
Heating
Total
Savings Summary Table
Quantity
Units
Energy (MMBtu)
25,251 kWh
86.1
0 kW
1,273,843 lbs Steam
1,215.2
1,301.3
Cost
$1,172
$0
$26,242
$27,414
Cost Analysis
An additional cost associated with this recommendation is the labor cost of turning off the air
handling units at night and turning them back on in the morning. From building personnel, there
is maintenance staff onsite as early as 6 am and as late as midnight. Usually, we expect turning
motors on and off to be within normal maintenance duties. However, as this is not an industrial
facility, we assume that $3,000 annually will cover additional labor hours. Total Cost savings
including annual costs are calculated below.
Net Savings Summary Table
Cost Savings
Annual Labor Cost
Net Savings
$27,414
($3,000)
$24,414
There is no immediate implementation cost associated with this recommendation.
Note
A programmable logic controller or a direct digital controller can perform the task of turning the
air handling units on and off at the appropriate hours automatically. This will eliminate the
annual labor cost while increasing the implementation cost. This is not included in the cost
analysis as we were unable to find a price for a suitable controller.
26
AR No. 4
Oven Exhaust Fan
Calculation Methodology
Recommendation
Turn off the Pangea oven exhaust fan at night and during the summer. This will reduce fan
electrical costs by 43% and loss of conditioned air when cooling or heating is needed. The
heating and cooling savings are not taken into account in this recommendation.
Assessment Recommendation Summary
Energy
Energy
Cost
Implementation Payback
(MMBtu) (kWh)* Savings
Cost
(years)
58.0
17,010
$789
$100
0.1
*1 kWh =3,410 Btu
Data Collected Summary
The following data was collected during our visit
• Marathon motor on main Pangea oven exhaust fan
• 7.5 Horse power
• 1760 RPM
• 208 volts
• Operates 24/7, even when ovens are not running
• During the summer and at night, the ovens are not used
Assumptions
• Estimated motor efficiency: 86.5% (based on generic motor efficiency table)
• Estimated load factor: 70%
• Proposed operating hours: 4,980 hrs (based on turning fans off during the 3 summer
months and 6 hours each night)
27
Savings Analysis
Annual cost savings are calculated by finding the difference between the current and proposed
conditions. We neglect any demand savings incurred to maintain conservative cost savings.
ES
=
=
=
=
Energy Savings
EC x ES
$0.0464/kWh x 17,010 kWh
$789
EC
=
=
Incremental Energy Cost
$0.0464 /kWh
ES
=
=
=
=
Energy Savings
CE – PE
39,420 kWh – 22,410 kWh
17,010 kWh
CE
=
=
=
=
Current Energy
P x CH
4.5 kW x 8,760 hrs
39,420 kWh
PE
=
=
=
=
Proposed Energy
P x PH
4.5 kW x 4,980 hrs
22,410 kWh
P
=
=
=
=
Power Usage
(HP x C x LF) ÷ EF
(7.5 hp x 0.746 kW/hp x 0.70) ÷ 0.865
4.5 kW
CH
=
=
Current Hours
8,760 hrs
PH
=
=
Proposed Hours
4,980 hrs
HP
=
=
Horse Power
7.5 hp
Where,
Where,
Where,
Where,
28
C
=
=
Energy Conversion
0.746 kW/hp
LF
=
=
Load Factor
70%
EF
=
=
Motor Efficiency
86.5%
Total annual cost savings are summarized in the following Savings Summary table:
Source
Energy Use
Saving Summary
Quantity Units
Energy (MMBtu)
17,010
kWh
58.0
Cost Savings
$789
Cost Analysis
Turning off the exhaust fan requires only an attentive operator. The power switch is located
behind a refrigerator, but is reachable. Moving the power switch to a location that is accessible is
advised. The cost of moving one power switch will be about $100 for one hour of electrician
work and material.
Cost Summary
Source
Quantity Units
$/Unit
Electrician
1
hrs
50.0
Material
Total
Cost
$50
$50
$100
Cost savings will pay for implementation costs in 0.1 years.
Note
An electronic controller will be more reliable than employee operated switch. However, we did
not include this option in the cost analysis as the savings did not warrant a controller.
29
AR No. 5
Skylights
Calculation Methodology
Recommendation
Install photo sensor/timer units on T8 fixtures in skylights to reduce operating hours. Replace
yellow glass with clear glass to allow more light into hallways. This will reduce lighting costs by
46% in this area.
Assessment Recommendation Summary
Energy Energy
Cost
Implementation Payback
(MMBtu)
20.6
(kWh)
6,574
Savings
$415
Cost
$1,995
(years)
4.8
*1 kWh = 3,410 Btu
Estimated Incentive Summary
ETO
BETC2
Net
Net Payback
Incentive Tax Credit
Cost
(years)
$499
$456
$1,040
2.5
1
Energy Trust of Oregon Incentive
2
Oregon Department of Energy Business Energy Tax Credit
1
Data Collected Summary
The following data was collected during our visit
• 15 Skylights
• Each skylight contains a T8 fluorescent fixture
• Fixtures operate 4,969 hrs unnecessarily annually
Assumptions
• We assume each fixture runs constantly
Savings Analysis
Energy and maintenance cost savings for installing photo sensors are calculated using the Install
Photo Sensor/Timer Units worksheet following this calculation. The lighting worksheet’s
terminology is described in Appendix C.
30
Energy savings are estimated using power, current operating hours, and proposed operating
hours per year. Energy cost savings are estimated with an incremental energy cost of
$0.0464/kWh.
CS
=
=
=
=
Energy Cost Savings
EC x ES
$0.0464/kWh x 6,574 kWh
$305
EC
=
=
Incremental Energy Cost
$0.0464/kWh
ES
=
=
=
=
Energy Savings
CE – PE
12,264 kWh –5,690 kWh
6,574 kWh
CE
=
=
Current Energy Consumption
12,264 kWh
PE
=
=
Proposed Energy Consumption
5,690 kWh
Where,
Where,
Reducing light operating hours will decrease maintenance costs, as estimated in the Install Photo
Sensors table at the end of this calculation methodology. The maintenance material savings total
$60 per year, while maintenance labor savings total $50 per year. Therefore, the total
maintenance savings sum to $111 annually. Total annual cost savings are summarized in the
following Savings Summary table:
Saving Summary
Energy
Source
Quantity Units (MMBtu) Cost
Energy Use
6,574 kWh
22.4
$305
Maintenance Material
$60
Maintenance Labor
$50
Total
22.4
$415
31
Cost Analysis
Implementation costs for photo sensors and clear glass panes include material and installation
costs. Each skylight requires 1 photo sensor/timer unit and 24 glass panes. Labor costs were
conservatively estimated at one hour per sensor installation with a typical electrician’s wage of
$50 per hour and one hour per skylight for glass panes with a typical maintenance wage of $15
per hour.
Cost Summary
Item
Units Cost/Unit Total
Photo Sensors/Timers
15
$20
$300
Glass Panes
360
$2
$720
Electrician
15
$50
$750
Installation
15
$15
$225
Total
$1,995
Incentive Summary
Energy Trust cash incentives are available to help pay for implementation of energy saving
measures if they save at least 10% of the energy used in a system. Incentives can be anticipated
to equal the minimum of 25% of total project cost, $0.12 per kWh saved, or $1 per therm saved.
CI
Where,
TES
TC
=
=
=
=
=
ETO Cash Incentive
Minimum of
TES x $0.12
Minimum of
6,574 x $0.12
Minimum of
$789
$499
=
=
Total Energy Savings
6,574 kWh
=
=
Applicable Implementation Cost
$1,995
or
or
or
0.25 x TC
0.25 x $1,995
$499
You may also be eligible for the Oregon Business Energy Tax Credit. If a project reduces system
energy use by at least 10%, the incentive can be expected to equal 35% of project costs after
applying other incentives. However the tax credit accrues over a 5 year period (10%, 10%, 5%,
5%, and 5%), or over one year for projects with implementation costs of less than $20,000. The
Oregon Department of Energy also allows “pass through” of a onetime lump value, which is
25.5% of project costs over $20,000 and 30.5% of project costs under $20,000. As this is a
reasonable estimate for the 35% tax credit’s net present value, we will use 30.5% as the value of
the tax credit in our analysis and estimate of the “payback” period.
32
BTC
=
=
=
=
Business Energy Tax Credit
(TC – CI) x 0.305
($1,995 – $499) x 0.305
$456
The following table summarizes implementation costs before and after incentives.
Incentive Summary
Description
Pre-incentive Cost
Energy Trust Incentives
Business Energy Tax Credit
Total after Incentives
Cost
$1,995
($499)
($456)
$1,040
Savings will pay for implementation costs in 2.5 years after incentives.
33
Install Photo Sensor/Timer Units
Report Number:
PLANT DATA
Building:
Area:
Lamp Replacement Time:
Ballast Replacement Time:
Fixture Replacement Time:
M emorial Union
2nd Floor Hallways
1/6 hours
1/2 hours
1
hours
Existing
$4.75 /kW-mo.
$0.04640 /kWh
$15.00 /hour
$50.00 /hour
Proposed
Savings
4 Ft T8 Elec.
15
8,760
100%
3
1
$62.95
4 Ft T8 Elec.
15
4,064
100%
3
1
$62.95
0
4,696
0%
0
0
$0.00
F32-1
4 Ft T8 C.T.
45
20,000
$1.94
32
2,710
44%
$38.24
$49.08
F32-1
4 Ft T8 C.T.
45
20,000
$1.94
32
2,710
20%
$17.74
$22.77
0
0
$0.00
0
0
0
$20.50
$26.31
T32-5
4 Ft F32T8
15
75,000
$42.65
0%
93
12%
$74.72
$43.80
T32-5
4 Ft F32T8
15
75,000
$42.65
0%
93
5%
$34.67
$20.32
0
0
$0.00
0
0
0
$40.06
$23.48
FIXTURES
FIXTURE CODE
Description:
Quantity:
Operating Hours:
Output Factor:
Lamps per Fixture:
Ballasts per Fixture:
Fixture Cost:
2001
Incremental Demand Cost:
Incremental Energy Cost:
Recommended Foot-candles:
M aintenance Labor Rate:
Electrician Labor Rate:
OFT8-2
Units
OFT8-2
hours
LAMPS
LAM P CODE
Description:
Quantity:
Life:
Lamp Cost:
Watts per Lamp:
Lumens:
Replacement Fraction:
Annual Lamp Replacement Cost:
Annual M aintenance Labor Cost:
hours
watts
BALLASTS
BALLAST CODE
Description:
Quantity:
Life:
Ballast Cost:
Ballast Factor:
Input Watts:
Replacement Fraction:
Annual Ballast Replacement Cost:
Annual M aintenance Labor Cost:
hours
watts
POWER AND ENERGY
Power:
Energy Use:
1.4
12,264
1.4
5,690
0.0
6,574
kW
kWh
LIGHT LEVEL CHECK
Total Lumens:
Foot-candles:
Lighting Efficiency:
121,950
0
0.0
121,950
0
0.0
0
0
0 Lum./W
ANNUAL OPERATING COST
Demand Cost:
Energy Cost:
M aintenance M aterial Cost:
M aintenance Labor Cost:
Total Operating Cost:
$80
$569
$113
$93
$855
34
$80
$264
$52
$43
$439
$0.00
$305.00
$60.55
$49.79
$415.34
AR No. 6
Halogen Lights
Calculation Methodology
Recommendation
Replace Halogen fixtures in the ballroom with Compact Fluorescent fixtures. This will reduce
energy usage in this area by 58%.
Assessment Recommendation Summary
Energy
Energy
Cost
Implementation Payback
(MMBtu)
39.7
(kWh)*
12,650
Savings
$483
Cost
$4,860
(years)
10.1
*1 kWh = 3,410 Btu
Estimated Incentive Summary
ETO
BETC2
Net
Net Payback
Incentive
Tax Credit
Cost
(years)
$1,215
$1,112
$2,533
5.2
1
Energy Trust of Oregon Incentive
2
Oregon Department of Energy Business Energy Tax Credit
1
Data Collected Summary
The following data was collected during our visit
• 45 recessed cans
• 1 Halogen T4 E11 fixture per recessed can
Assumptions
• The lights operate 1,340 hrs annually
Savings Analysis
Energy and maintenance cost savings for installing motion sensors and replacing metal halide
lights are calculated using the “Replace Halogen Fixtures with Compact Fluorescents”
spreadsheet that follows this calculation summary. Lighting spreadsheet terminology is described
in Appendix C.
35
Energy savings are estimated using power, current fixture wattages, and proposed fixture
wattages, and operating hours. Energy cost savings are estimated with an incremental energy
cost of $0.0464/ kWh.
ES
=
=
=
=
Energy Cost Savings
(CE – PE) x EC
(21,762 kWh – 9,112 kWh) x $0.0464/ kWh
$587
CE
=
=
Current Energy Consumption
21,762 kWh
PE
=
=
Proposed Energy Consumption
9,112 kWh
EC
=
=
Energy Cost
$0.0464/ kWh
Where,
Installing compact fluorescent fixtures will also lead to a decrease in fixture maintenance labor
costs by extending the life of lamps. Annual labor savings are $56. However, the increased cost
of lamps will increase material costs by $160 annually, totaling $104 of annual increased
maintenance costs. Total annual cost savings are summarized in the following Savings Summary
table:
Savings Summary
Source
Energy Use
Maintenance Material
Maintenance Labor
Total
Energy
Quantity Units MMBtu
12,650 kWh
39.7
39.7
Cost
$
$587
($160)
$56
$483
Cost Analysis
The cost of replacing the halogen fixtures with Compact Fluorescent fixtures is based on the cost
of material and installation per fixture. There are a total of 45 fixtures that need replaced. We
estimate that it will take an electrician one hour to install each fixture at a wage of $50 per hr.
36
The costs are summarized in the table below:
Item
150 Watt Mogul CFL
Mogul Base Socket Assembly
Electrician
Total
Cost Summary
Quantity
Units
45
Lamps
45
Fixtures
45
Hours
Cost/Unit
$46
$12
$50
Total Cost
$2,070
$540
$2,250
$4,860
Incentive Summary
Energy Trust cash incentives are available to help pay for implementation of energy saving
measures if they save at least 10% of the energy used in a system. In this case, the 10% savings
is met. Incentives can be anticipated to equal the minimum of 25% of total project cost, $0.12 per
kWh saved, or $1 per therm saved.
CI
Where,
TES
TC
=
=
=
=
=
ETO Cash Incentive
Minimum of
TES x $0.12
Minimum of
12,650 x $0.12
Minimum of
$1,518
$1,215
=
=
Total Energy Savings
12,650 kWh
=
=
Total Implementation Cost
$4,860
or
or
or
0.25 x TC
0.25 x $4,860
$1,215
You may also be eligible for the Oregon Business Energy Tax Credit. If a project reduces system
energy use by at least 10%, the incentive can be expected to equal 35% of project costs after
applying other incentives. However, the tax credit accrues over a 5 year period (10%, 10%, 5%,
5%, and 5%), or over one year for projects with implementation costs of less than $20,000. The
Oregon Department of Energy also allows “pass through” of a onetime lump value, which is
25.5% of project costs over $20,000 and 30.5% of project costs under $20,000. As this is a
reasonable estimate of the net present value of the 35% tax credit, we will use 30.5% as the value
of the tax credit in our analysis and estimate of the “payback” period.
BTC
=
=
=
=
Business Energy Tax Credit
(TC – CI) x 0.305
($4,860 – $1,215) x 0.305
$1,112
37
The following table summarizes implementation costs before and after incentives.
Incentive Summary
Description
Pre-incentive Cost
Energy Trust Incentives
Business Energy Tax Credit
Total after Incentives
Cost
$4,860
($1,215)
($1,112)
$2,533
Savings will pay for implementation costs in 5.2 years after incentives.
38
Replace Halogen Fixtures with Compact Fluorescents
PLANT DATA
Building:
Area:
Lamp Replacement Time:
Ballast Replacement Time:
Fixture Replacement Time:
Memorial Union
Ballroom
1/6 hours
1/2 hours
1
hours
Report Number:
Incremental Energy Cost:
2001
$0.04640 /kWh
Maintenance Labor Rate:
Electrician Labor Rate:
$15.00 /hour
$50.00 /hour
FIXTURES
Existing
Proposed
FIXTURE CODE
Description:
Quantity:
Operating Hours:
Output Factor:
Lamps per Fixture:
Fixture Cost:
HF450
CF150
450 Watt Halogens
45
1,340
80%
1
$0.00
150 Watt CF
45
1,340
100%
1
$11.95
0
0
-20%
0
($11.95)
H450
450 Watt Halogens
45
2,000
$6.19
450
8,000
67%
$186.63
$75.07
C150
150 Watt Compact Fluor
45
8,000
$46.06
150
8,000
17%
$347.18
$18.77
0
(6,000)
($39.87)
300
0
1
($160.55)
$56.31
Savings
Units
hours
LAMPS
LAMP CODE
Description:
Quantity:
Life:
Lamp Cost:
Watts per Lamp:
Lumens:
Replacement Fraction:
Annual Lamp Replacement Cost:
Annual Maintenance Labor Cost:
hours
watts
POWER AND ENERGY
Power:
Energy Use:
20.3
21,762
6.8
9,112
13.5
12,650
$1,010
$187
$75
$1,272
$423
$347
$19
$789
$587.00
($160.55)
$56.31
$482.76
kW
kWh
ANNUAL OPERATING COST
Energy Cost:
Maintenance Material Cost:
Maintenance Labor Cost:
Total Operating Cost:
IMPLEMENTATION COST
Materials:
Labor:
Total Implementation Cost:
$2,610
$2,250
$4,860
SIMPLE PAYBACK
10.1
39
years
40
APPENDIX A
UTILITIES
A.1 Energy Definitions
An essential component of any energy management program is tracking energy. When utility
bills are received, we record energy use and cost in a spreadsheet and get the appropriate graphs.
A separate spreadsheet may be required for each type of energy used, such as oil, gas, or
electricity. A combination might be merited when both gas and oils are used interchangeably in a
boiler. In such a case we suggest using a common energy unit for a cost-benefit analysis that can
represent most fuel options: the Btu.
We have prepared a utility spreadsheet analysis based on the information provided by you or
your utility companies. The worksheets are in section A.3, Energy, Waste, and Production
Accounting. They show how energy is used and help identify potential energy savings.
We use specific terminology and calculations in analyzing and discussing your energy, water,
and waste expenses. Energy related terms and calculations are detailed below followed by those
for waste and water.
Electricity Definitions:
Average Energy Cost. The total amount billed for 12 months of energy, divided by the total
number of energy units. Each energy type (oil, gas, electricity, propane, etc.) has its own average
energy cost. The average cost per energy unit includes the fees, taxes and unit cost.
Average Energy Cost = (Total Billed $) ÷ (Total Energy Units)
Average Load Factor. The ratio of annual electrical energy use divided by the average kilowatts
(kW) and the hours in a year.
Average Load Factor = (Total kWh) ÷ (Average kW x 8,760 hrs)
Average Load Factor expresses how well a given electrical system uses power. A higher load
factor yields lower average energy cost.
An example of how load factor applies: A large air compressor has high electric demand for
small periods of time and is not a large energy user. It will usually have low load factor and
relatively high demand charges. A smaller air compressor that runs for longer periods of time at
higher part load efficiency will have higher load factor and lower demand charges.
Basic Charge. The fee a utility company can charge each month to cover their administrative,
facility, or other fixed costs. Some companies have higher energy or power rates that compensate
for no or low basic charge.
Energy. The time-rate of work expressed in kWh for electric energy. The common unit is
million Btu (MMBtu). For a more complete description, see Power.
Energy = Work ÷ Time = (Force x Distance) ÷ Time
41
Incremental Demand Cost. It is the price charged by your utility company for the capacity to
meet your power needs at any given time. Peak demand is the highest demand level required
over a set period of time and is calculated by continuously monitoring demand levels. Demand is
usually billed based on peak power, but charges such as facility charges and other fees billed per
kW are also included in the incremental demand cost. If your utility company has stepped
demand cost rates, the step with the greatest demand is considered in the incremental demand
cost. If your utility company bills one set rate for all power needs, this value is used as the
incremental demand cost.
Incremental Energy Cost (Electricity). It is cost of a unit of energy, from current use. This
cost is usually taken from your utility rate schedule. When all large meters are on the same rate
schedule, the incremental energy cost is the cost from the highest energy tier, or tail block. To
further clarify this method: if a company is charged $0.05/kWh up to 100,000 kWh, and
$0.03/kWh over 100,000 kWh and they are consistently buying over 100,000 kWh each month,
any energy savings will be calculated using the $0.03/kWh cost.
If your facility has multiple meters on different rate schedules or tariffs, the incremental cost is
calculated by adding electrical energy costs and dividing by the total electrical energy use.
Incremental Energy Cost = (Total kWh $) ÷ (Total kWh)
Minimum Charge. The least amount billed by a utility at the end of the billing period.
Power (and Energy). The rate at which energy is used, expressed as the amount of energy use
per unit time, and commonly measured in units of watts and horsepower. Power is the term used
to describe the capacity the utility company must provide to serve its customers. Power is
specified three ways: real, reactive and total power. The following triangle gives the relationship
between the three.
Total Power (kVA)
Reactive Power (kVAR)
Ө
Real Power (kW)
Real power is the time average of the instantaneous product of voltage and current (watts).
Apparent power is the product of rms (root mean square) volts and rms amps (volt-amps).
Demand. The highest electrical power required by the customer, generally averaged over 15
minute cycling intervals for each month. Demand is usually billed by kW unit.
42
Kilovolt Amperes (kVA). Kilovolt amperes are a measure of the power available before
accounting for power factor. See the triangle on the previous page. Power is sometimes billed by
kVA.
Reactive Power. Reactive power is measured in units of kVAR. Reactive power produces
magnetic fields in devices such as motors, transformers, and lighting ballasts that allow work to
be done and electrical energy to be used. Kilo Volt Amperes Reactive (kVAR) could occur in an
electrical circuit where voltage and current flow are not perfectly synchronized. Electric motors
and other devices that use coils of wire to produce magnetic fields usually cause this
misalignment of three-phase power. Out-of-phase current flow causes more electrical current to
flow in the circuit than is required to supply real power. kVAR is a measure of this additional
reactive power.
High kVAR can reduce the capacity of lines and transformers to supply kilowatts of real power
and therefore cause additional expenses for the electrical service provider. Electric rates may
include charges for kVAR that exceed a normal level. These charges allow the supplying utility
to recover some of the additional expenses caused by high KVAR conditions, and also
encourages customers to correct this problem.
Power Factor. The ratio of real power to total power. Power factor is the cosine of angle θ
between total power and real power on the power triangle.
PF = cos θ = kW ÷ kVA
Disadvantages of Low Power Factor
•
Increases costs for suppliers because more current has to be transmitted requiring greater
distribution capacity. This higher cost is directly billed to customers who are metered for
reactive power.
•
Overloads generators, transformers and distribution lines within the plant, resulting in
increased voltage drops and power losses. All of which represents waste, inefficiency and
wear on electrical equipment.
•
Reduces available capacity of transformers, circuit breakers and cables, whose capacity
depends on the total current. Available capacity falls linearly as the power factor decreases.
Low Power Factor Charges
Most utilities penalize customers whose power factor is below a set level, typically in the range
of 95% - 97%, or kVAR greater than 40% of kW. Improving power factor may reduce both
energy and power costs, however these are generally much less than savings from real power
penalties enforced by electrical utilities. Energy savings are also difficult to quantify. Therefore
in our recommendations, only power factor penalty avoidance savings are included.
43
Improving Power Factor
The most practical and economical power factor improvement device is the capacitor. All
inductive loads produce inductive reactive power current (lags voltage by a phase angle of 90°).
Capacitors, on the other hand, produce capacitive reactive power, which is the opposite of
inductive reactive power (current leads…). Current peak occurs before voltage by a phase angle
of 90°. By careful selection of capacitance required, it is possible to totally cancel out the
inductive reactive power, but in practice it is seldom feasible to correct beyond your utilities’
penalty level (~95% for kVA meters).
Improving power factor results in:
•
Reduced utility penalty charges.
•
Improved plant efficiency.
•
Additional equipment on the same line.
•
Reduced overloading of cables, transformers, and switchgear.
•
Improved voltage regulation due to reduced line voltage drops and improved starting torque
of motors.
Power Factor Penalty
Utility companies generally calculate monthly power factor two ways. One way is based on
meters of reactive energy and real energy.
Monthly PF = cos [tan-1 (kVARh ÷ kWh)]
The second method is based on reactive power and real power.
Monthly PF = cos [tan-1 (kVAR ÷ kW)]
Power Factor is often abbreviated as “PF”. Also see the Power Factor definition below.
Cost Calculations
Annual operating expenses include both demand and energy costs. Demand cost (DC) is
calculated as the highest peak demand (D) multiplied by your incremental demand charge and
the number of operating months per year:
DC
=
D x demand rate ($/kW·mo) x 12 mo/yr
Energy cost (EC) is energy multiplied by your incremental electric rate:
EC
=
E x energy rate ($/kWh)
44
Natural Gas Definitions:
Rate Schedules. (Or tariffs) specify billing procedures and set forth costs for each service
offered. The state public utility commission approves public utility tariffs. For example: an
electric utility company will set a price or schedule of prices for power and energy and specify
basic and PF charges. A natural gas utility will specify cost to supply or transport gas and include
costs such as price per therm, basic charge, minimum charges and other costs. Current rate
schedules can often be found online at the utility company’s website. If you think your facility
belongs in a different rate schedule, your utility representative can help you best.
Tariff. Another term for rate schedule.
Therm. The unit generally used for natural gas (1 therm = 100,000 Btu), but sometimes it is
measured in MMBtu.
Commodity Rate. The component of the billing rate that represents the company’s annual
weighted average commodity cost of natural gas.
Transportation. The movement of customer-owned natural gas from the pipeline receipt
point(s).
Waste and Water Definitions:
Average Disposal Cost. The average cost per pickup or ton of waste or other scrap material.
This cost is calculated using all of the annual expenses to get a representative cost per unit of
disposal.
Average Disposal Cost / Ton = (Total Disposal $) ÷ (Total tons removed)
Average Disposal Cost / Pickup = (Total Disposal $) ÷ (Total number of pickups)
BOD Charge. Charge levied by the sewer/water treatment utility to cover extra costs for high
strength wastewater. High strength wastewater requires more intensive treatment by the utility
and extra processing due to very low oxygen levels. BOD, biochemical oxygen demand, is a
measure of how much oxygen will be used to microbiologically degrade the organic matter in the
wastewater stream. State agencies such as a Department of Environmental Quality set BOD and
other regulations that wastewater treatment facilities must meet to discharge treated water into
nearby waterways. Your treatment facility may have ideas that could help lower the strength of
your wastewater.
Box Rental Charge. The fee imposed by the waste or recycling utility to cover costs of their
receiving containers.
Disposal Cost. Incurred by the waste utility for disposing of your waste in a landfill or other
facility. These charges increase when hazardous materials are present in the waste.
Pickup Costs. The cost charged by the waste utility for each pickup of waste or recycling. This
charge is usually applied when the utility is working on an “on call” basis. Pickup costs can also
be a flat rate for a certain number of pickups per month.
45
A.2. Energy Conversions
An essential component of any energy management program is a continuing account of energy
use and its cost. This can be done best by keeping up-to-date graphs of energy consumption and
costs on a monthly basis. When utility bills are received, we recommend that energy use be
immediately plotted on a graph. A separate graph will be required for each type of energy used,
such as oil, gas, or electricity. A combination will be necessary, for example, when both gas and
oil are used interchangeably in a boiler. A single energy unit should be used to express the
heating values of the various fuel sources so that a meaningful comparison of fuel types and fuel
combinations can be made. The energy unit used in this report is the Btu, British Thermal Unit,
or million Btu's (MMBtu). The Btu conversion factors and other common nomenclature are:
Energy Unit
Energy Equivalent
1 kWh
1 MWh
1 cubic foot of natural gas
1 gallon of No. 2 oil (diesel)
1 gallon of No. 6 oil
1 gallon of gasoline
1 gallon of propane
1 pound of dry wood
1 bone dry ton of wood (BDT)
1 unit of wood sawdust (2,244 dry pounds)
1 unit of wood shavings (1,395 dry pounds)
1 unit of locally supplied steam (1 pound)
1 ton of coal
1 MWh
1 therm
1 MMBtu
1 kilowatt
1 horsepower (electric)
1 horsepower (boiler)
1 ton of refrigeration
3,413
3,413,000
1,030
140,000
152,000
128,000
91,600
8,600
17,200,000
19,300,000
12,000,000
954
28,000,000
1,000
100,000
1,000,000
Btu
Btu
Btu
Btu
Btu
Btu
Btu
Btu
Btu
Btu
Btu
Btu
Btu
kWh
Btu
Btu
3,413
2,546
33,478
12,000
Btu/hr
Btu/hr
Btu/hr
Btu/hr
8.33
7.48
1,000
200
pounds
gallons
gallons
ft3
Unit Equivalent
1 gallon of water
1 cubic foot of water
1 kgal
1 unit wood fuel
The value of graphs can best be understood by examining those plotted for your company in the
Energy Summary. Energy use and costs are presented in the following tables and graphs. From
these figures, trends and irregularities in energy usage and costs can be detected and the relative
merits of energy conservation can be assessed.
46
A.3. Energy, Waste, and Production Accounting
Energy Use
Combined Meters / Utilities
Month
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
Totals
Avg/Mo
Electricity
kWh
Total $
154,680
$7,177
189,440
$8,790
163,320
$7,578
172,240
$7,992
173,280
$8,040
141,600
$6,570
147,240
$6,832
181,040
$8,400
153,600
$7,127
160,680
$7,456
170,480
$7,910
164,960
$7,654
1,972,560
$91,527
164,380
$7,627
Steam
Gas
Therms
455
528
301
1,276
1,351
821
569
1,239
1,145
954
1,287
964
10,890
907
$
$511
$594
$339
$1,434
$1,519
$923
$640
$1,393
$1,287
$1,072
$1,447
$1,083
$12,244
$1,020
lbs
22,100
7,500
16,400
201,500
367,100
751,500
992,700
873,000
334,500
343,600
82,000
75,600
4067500
338958
$
$431
$146
$320
$3,929
$7,158
$14,654
$19,358
$17,024
$6,523
$6,700
$1,599
$1,474
$79,316
$6,610
Totals
MMBtu
$
594
$8,119
707
$9,530
603
$8,237
908
$13,355
1,077
$16,718
1,282
$22,148
1,506
$26,830
1,575
$26,816
958
$14,937
972
$15,228
789
$10,956
731
$10,212
11,702 $183,087
975
$15,257
Combined Utility Summary
Electricity
Incremental Energy Cost
Average Energy Cost
$0.04640 /kWh
$0.04640 /kWh
Incremental Steam Cost
Steam Energy Cost
Natural Gas
Incremental gas Cost
Average Gas Cost
$0.01950 /kWh
$0.01950 /kWh
Steam
1.1243 /therm
1.1243 /therm
$11.24 /MMBtu
47
Electricity Use
Month
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
Totals
Avg/Mo
kWh
154,680
189,440
163,320
172,240
173,280
141,600
147,240
181,040
153,600
160,680
170,480
164,960
1,972,560
164,380
kWh$
$7,177
$8,790
$7,578
$7,992
$8,040
$6,570
$6,832
$8,400
$7,127
$7,456
$7,910
$7,654
$91,527
$7,627
Total $
$7,177
$8,790
$7,578
$7,992
$8,040
$6,570
$6,832
$8,400
$7,127
$7,456
$7,910
$7,654
$91,527
$7,627
Electric Utility Summary
Energy Cost
Average Electricity Cos
48
$0.04640 /kWh
$0.04640 /kWh
Natural Gas Use
Month
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
Totals
Avg./Mo
Therms
455
528
301
1,276
1,351
821
569
1,239
1,145
954
1,287
964
10,890
907
Therm$
$511
$594
$339
$1,434
$1,519
$923
$640
$1,393
$1,287
$1,072
$1,447
$1,083
$12,244
$1,020
MMBtu
45
53
30
128
135
82
57
124
114
95
129
96
1,089
91
Natural Gas Utility Summary
Natural Gas Cost
Average Energy Cost
$1.12430 /therm
$1.12 /therm
$11.24 /MMBtu
49
Total$
$511
$594
$339
$1,434
$1,519
$923
$640
$1,393
$1,287
$1,072
$1,447
$1,083
$12,244
$1,020
Steam Use
Month
lbs
Jul-07
22,100
Aug-07
7,500
Sep-07
16,400
Oct-07 201,500
Nov-07 367,100
Dec-07 751,500
Jan-08 992,700
Feb-08 873,000
Mar-08 334,500
Apr-08 343,600
May-08
82,000
Jun-08
75,600
Totals
4,045,400
Avg./Mo
367,764
Steam $
$431
$146
$320
$3,929
$7,158
$14,654
$19,358
$17,024
$6,523
$6,700
$1,599
$1,474
$79,316
$6,610
MMBtu
21
7
16
192
350
717
947
833
319
328
78
72
3880
323
Total $
$431
$146
$320
$3,929
$7,158
$14,654
$19,358
$17,024
$6,523
$6,700
$1,599
$1,474
$79,316
$6,610
Steam Summary
Steam Cost
Average Steam Cost
$0.0195 / lb
$0.01961 / lb
$20 /MMBtu
50
51
52
53
54
A.4. ENERGY USE SUMMARY & ENERGY ACCOUNTING
END USE SUMMARY
Average Electricity Cost
Average Natural Gas Cost
Average Steam Cost
$0.04640 /kWh
$1.12430 /therm
$0.01950 /lb
ELECTRICITY
MMBtu
ENERGY %
1,454
21.6%
616
9.1%
2,202
32.7%
116
1.7%
849
12.6%
523
7.8%
152
2.3%
544
8.1%
275
4.1%
6,732
100.0%
COST
COST%
$19,769
21.6%
$8,373
9.1%
$29,943
32.7%
$1,573
1.7%
$11,544
12.6%
$7,113
7.8%
$2,073
2.3%
$7,398
8.1%
$3,742
4.1%
$91,527 100.0%
UNIT
therm
therm
therm
MMBtu
ENERGY %
950
87.2%
139
12.8%
1,089
100.0%
COST
COST%
$10,681
87.2%
$1,563
12.8%
$12,244 100.0%
HVAC
Dishwasher
Miscellaneous
TOTALS
USE
UNIT
2,929,681 lbs
100,000 lbs
1,037,819 lbs
4,067,500 lbs
MMBtu
ENERGY %
2,795
72.0%
95
2.5%
990
25.5%
3,880
100.0%
COST
COST%
$57,129
72.0%
$1,950
2.5%
$20,237
25.5%
$79,316 100.0%
ELECTRICITY
NATURAL GAS
STEAM
TOTALS
FUEL SUMMARY
USE
UNIT
MMBtu
ENERGY %
1,972,560 kWh
6,732
57.5%
10,890 therm
1,089
9.3%
4,067,500 lbs
3,880
33.2%
11,702
100.0%
COST
COST%
$91,527
50.0%
$12,244
6.7%
$79,316
43.3%
$183,087 100.0%
Lighting
BkStore EquipRoom
Bowling Chiller Room
Bowling Compressor Room
Bowling Air-handling Room
Ballroom Maintenance
Rooftop
Miscellaneous Motors
Miscellaneous
TOTALS
USE
UNIT
426,052 kWh
180,456 kWh
645,321 kWh
33,903 kWh
248,784 kWh
153,300 kWh
44,676 kWh
159,432 kWh
80,636 kWh
1,972,560 kWh
NATURAL GAS
Ovens
Miscellaneous
TOTALS
USE
9,500
1,390
10,890
STEAM
55
56
57
58
APPENDIX B
MOTORS
B.1. Motor Worksheet Definitions
The motor worksheet uses information obtained during the on-site visit to calculate electric
motor energy use, as well as energy and cost savings for efficiency improvements. Motor
worksheet information is also used for a variety of AR's, including refrigeration, air compressors,
and turning off equipment. In addition, the information contained in the worksheet aids in
determining an accurate plant energy breakdown. The worksheet calculation methods and
symbols are described as follows:
B.2. Motor Inventory (Nameplate)
The Motor Inventory contains the manufacturer, horsepower, volts, amps and revolutions per
minute (rpm), that are read directly from each motor nameplate. Standard NEMA values are used
to estimate full load efficiency and power factor.
Identification Number (ID#). An identification number is assigned to each motor.
Manufacturer. The manufacturer of the motor.
Horsepower (Hp). Nameplate horsepower.
Volts. Rated voltage for the motor. If the motor can be wired for more than one voltage, the
voltage closest to the operating voltage is entered.
Amps. The rated full-load amperage of the motor corresponding to the voltage listed above.
RPM. Rated full-load RPM.
Power Factor (PF). The motor power factor at full load. Power factor is primarily taken from
General Electric publications GEP-500H (11/90) and GEP-1087J (1/92). See section B.9 Motor
Performance Table for data and other sources.
Efficiency (EFF). The present motor efficiency at full load. Motor efficiencies for standard and
energy-efficient motors are also taken from General Electric publications GEP-500H (11/90) and
GEP-1087J (1/92). See section B.9 Motor Performance Table.
Type. The type of motor is described in the table at the bottom of the inventory page. The
purpose is to identify standard 900, 1200, 1800, and 3600 rpm motors (Type = 1) that could be
replaced with energy-efficient motors.
59
B.3. Motor Applications (Measured Operating Conditions)
The Motor Applications page contains application-specific information. The same motor may be
used in several applications. This information is used to calculate the annual energy consumption
of each application.
Application Number (#). A number is assigned to each application described in this section.
Area. A brief description of the location of the motor application.
Identification Number (ID#). The identification number of the motor used in the application.
The worksheet looks up the nameplate information for each motor application in section B.2
Motor Inventory.
Use. Each use, such as refrigeration, is given a separate code. This allows the energy use and
operating cost for each end use to be summarized in section B.7 Motor Use Summary.
Description. A brief description of the motor application.
Quantity (Qty). The number of motors in each application of the same horsepower and type.
Horsepower (Hp). The horsepower of the motor(s) used in this application is looked up in
section B.2 Motor Inventory, based on the motor ID#.
Total Horsepower (Hptot). The total horsepower used in the application is the product of the
quantity of motors and the motor horsepower.
Power Factor (PF). For motors with no power factor correction, the operating power factor of
the motor is approximated by the following equation to account for part-load conditions:
PF
=
Nameplate PF x {0.728 + [0.4932 / (FLA%)] - [0.2249 / (FLA%)2]}
The power factor correction, enclosed in ({}) brackets, has a minimum allowable value of 0.3
and a maximum value of 1.0 when FLA% is 90% or greater in the worksheet, and is shown as a
curve in section B.10. If the motor has been corrected for power factor (PFC = "C"), or the motor
is a synchronous type, 0.95 power factor is used.
Power Factor Correction (PFC). If a motor has power factor correction capacitors and the
amperage has been measured ahead of the capacitors, a "C" is input.
Drive (DRV). All motors with standard V-belt drives (b) are considered for replacement with
High Torque Drive (HTD) belts and sheaves. HTD Replacements are summarized in Section
B.5.
Volts. Measured operating voltage.
60
Amps. Measured operating amperage.
Use Factor (UF). Use Factor is the percentage of the annual operating hours the motor is
actually running.
Percent Full Load Amps (FLA%). The measured operating amperage divided by the motor
nameplate full load amps.
Efficiency (EFF). Present motor efficiency (η0) is looked up in section B.2 Motor Inventory,
based on the motor ID#.
Demand. The operating power (D) of the motor in kilowatts (kW). If the operating amperage is
known, the following equation is used:
D
=
Qty x Volts x Amps x PF x 1.73 / 1,000
If operating amperage is not known, the motor load factor (LF) is estimated depending on motor
application at your plant. Motor load was either modeled after similar applications at your plant
or derived from averaged application specific data of over 160 previous audits. The operating
power is found from
D
=
Qty x LF x (0.746 kW/Hp) x Hp / η0
Load Factor (LF). The operating input power divided by the motor nameplate full-load input
power, which is found from
LF
=
(D x η0) / [Hp x (0.746 kW/Hp)]
Hours. The annual motor operating hours (H) are entered in section B.7 Motor Use Summary for
each use.
Energy. The annual energy consumption (E) of the motor in kilowatt-hours (kWh) is calculated
by:
E
=
D x H x UF
B.4. Motor Use Summary
The Motor Use Summary summarizes motor power and energy requirements by end use.
B.5. Economics
The Economics Table summarizes the electrical energy and demand costs, payback criterion, and
motor lifetime.
61
Energy Cost. The electrical energy charge ($/kWh) is taken from your rate schedule. If the
energy charge varies seasonally, the average cost is used.
Demand Cost. The demand charge ($/kW-Month) is taken from your rate schedule. If the
demand charge varies seasonally, the average cost is used.
Payback Criterion. Standard motors that are candidates for replacement with energy-efficient
motors are listed in section B.3 Motor Efficiency. Motors for which the payback is less than this
criterion are included in the total at the bottom of the table and included in the Energy Efficient
Motors AR.
B.6. Motor Performance Table
The Motor Performance Table contains general motor information used in the worksheet. For
each motor horsepower, efficiency, motor cost, and power factor for both standard and efficient
motors are listed. Information is primarily taken for totally enclosed fan cooled (TEFC) motors
from General Electric publications GEP-500H (11/90) and GEP-1087J (1/92). Larger motors that
are not available in TEFC configuration are Open Drip Proof (ODP), and are shown in italics.
For motors not found in the General Electric publications, the values for efficiency, motor cost,
and power factor were taken as averaged values of several motor manufacturers from Motor
Master, a database available from Washington State Energy Office. These sections are indicated
by shading.
B.7. Power Factor
Power factor is graphed as a function of operating amperage (FLA%). The curve approximates
motor performance data taken from General Electric publication #GEP-500G (3/87). The graph
is used to calculate power factor in section B.2 Motor Applications.
62
B.2. Motor Inventory (Nameplate)*
#
Description
1 Pump
2 Pump
3 Air Compressor
4 Exhaust Fan
5 Fan
6 Pump
7 Pump
8 Pump
9 Pump
10 Pump
11 Pump
12 Pump
13 Pump
14 Air Compressor
15 Fan
16 Air Compressor
17 Pump
18 Pump
19 Pump
20 HRU-1 Supply
21 HRU-2 Supply
22 F2
23 F7
24 Exhaust Fan
25 HRU-1 Exhaust
26 HRU-2 Return
27 Chiller Compressor
28 Refrigerated Panel
29 Panda Cooler
30 Freezer Panel
31 MU Walk In
32 Lounge Blower
33 Ballroom Blower
34 Panda Freezer
35 Fan
36 Fan
37 Chiller
38 Chiller
39 Bowling AHU
Hp Volts Amps RPM
0.5
208
2.6 1800
0.5
208
2.6 1800
0.75
208
3.9 1800
0.75
208
3.9 1800
1
208
4.7 1800
1.5
208
5.7 1800
1.5
208
5.7 1800
1.5
208
5.7 1800
1.5
208
5.7 1800
1.5
208
5.7 1800
1.5
208
5.7 1800
1.5
208
5.7 1800
1.5
208
5.7 1800
3
208
10.9 1800
3
208
10.9 1800
5
208
16.6 1800
5
208
16.6 1800
5
208
16.6 1800
5
208
16.6 1800
5
208
16.6 1800
5
208
16.6 1800
7.5
208
27.0 1800
7.5
208
27.0 1800
7.5
208
27.0 1800
7.5
208
27.0 1800
7.5
208
27.0 1800
10
208
34.1 1800
10
208
34.1 1800
15
208
48.9 1800
15
208
48.9 1800
15
208
20.0 1800
15
208
52.0 1180
15
208
48.9 1800
20
208
65.0 1800
25
208
80.9 1800
25
208
80.9 1800
35
208
129.0 1800
40
208
129.0 1800
5
460
6.4 1800
+ Type Code
1=Standard Efficiency
2=High Efficiency
C=Composite
DC=Direct Current
RPM=Not 900, 1200, 1800, or 3600 RPM
V=Standard V-belt
*Note: Some Nameplate Data May Be Estimated
PF%
63%
63%
60%
60%
70%
79%
79%
79%
79%
79%
79%
79%
79%
78%
78%
78%
78%
78%
78%
78%
78%
82%
82%
82%
82%
82%
74%
74%
82%
82%
82%
80%
82%
83%
86%
86%
86%
83%
78%
TS=Two Speed
F=Fractional Horsepower
G=Gear Motor
H=Hermetic
ASD=Adjustable Speed Drive
63
EFF%
72%
72%
76%
76%
77%
84%
84%
84%
84%
84%
84%
84%
84%
83%
83%
88%
88%
88%
88%
88%
88%
86%
86%
86%
86%
86%
90%
90%
91%
91%
91%
88%
91%
91%
92%
92%
90%
93%
88%
Frame
Type+
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
284T
1
1
1
1
1
1
1
1
HD=Heavy Duty
O=Oversize (>500hp)
SY=Synchronous
U=Unknown
SP=Single Phase
B.3. Motor Applications (Measured Operating Conditions)
#
1
2
6
7
16
22
23
27
8
9
17
18
19
28
29
30
31
34
37
38
3
10
11
12
13
14
15
35
36
5
32
33
4
24
20
21
39
25
26
Area
BkStore EquipRoom
BkStore EquipRoom
BkStore EquipRoom
BkStore EquipRoom
BkStore EquipRoom
BkStore EquipRoom
BkStore EquipRoom
Miscellaneous
Bowling Chiller Room
Bowling Chiller Room
Bowling Chiller Room
Bowling Chiller Room
Bowling Chiller Room
Bowling Chiller Room
Bowling Chiller Room
Bowling Chiller Room
Bowling Chiller Room
Bowling Chiller Room
BkStore EquipRoom
Bowling Chiller Room
Bowling Compressor Room
Bowling Compressor Room
Bowling Compressor Room
Bowling Compressor Room
Bowling Compressor Room
Bowling Compressor Room
Bowling Compressor Room
Bowling Air-handling Room
Bowling Air-handling Room
Elevator Fan Room
Ballroom Maintenance
Ballroom Maintenance
Rooftop
Rooftop
Miscellaneous
Miscellaneous
Miscellaneous
Miscellaneous
Miscellaneous
Use
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
4
4
5
6
6
7
7
8
8
8
8
8
Description
Pump
Pump
Pump
Pump
AirCompressor
F2
F7
Chiller Compressor
Pump
Pump
Pump
Pump
Pump
Referigerated Panel
Panda Cooler
Freezer Panel
MU Walk In
Panda Freezer
Chiller
Chiller
Air Compressor
Pump
Pump
Pump
Pump
Air Compressor
Fan
Fan
Fan
Fan
Lounge Blower
Ballroom Blower
Exhaust Fan
Exhaust Fan
HRU-1 Supply
HRU-2 Supply
Bowling AHU
HRU-1 Exhaust
HRU-2 Return
Qty Hp Hptot PF% DRV
0 0.5
0 63.0% D
0 0.5
0 63.0% D
0 1.5
0 79.0% D
0 1.5
0 79.0% D
0
5
0 78.0% F
1 7.5
7.5 82.0% F
1 7.5
7.5 82.0% F
1 10
10 74.0% D
0 1.5
0 79.0% D
0 1.5
0 79.0% D
0
5
0 78.0% D
1
5
5 78.0% D
1
5
5 78.0% D
1 10
10 74.0% D
1 15
15 82.0% D
1 15
15 82.0% D
1 15
15 82.0% D
1 20
20 83.0% D
1 35
35 86.0% D
1 40
40 83.0% D
0 0.75
0 60.0% F
0 1.5
0 79.0% D
0 1.5
0 79.0% D
0 1.5
0 79.0% D
0 1.5
0 79.0% D
0
3
0 78.0% F
0
3
0 78.0% F
1 25
25 86.0% F
1 25
25 86.0% F
0
1
0 70.0% F
1 15
15 80.0% F
1 15
15 82.0% F
0 0.75
0 60.0% F
1 7.5
7.5 82.0% F
1
5
5 78.0%
1
5
5 78.0%
1
5
5 78.0%
1 7.5
7.5 82.0%
1 7.5
7.5 82.0%
64
UF%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
80%
80%
80%
80%
80%
66%
66%
10%
60%
60%
40%
40%
40%
66%
100%
100%
0%
100%
100%
100%
100%
100%
100%
100%
100%
100%
EFF%
72.0%
72.0%
84.0%
84.0%
87.5%
86.0%
86.0%
89.5%
84.0%
84.0%
87.5%
87.5%
87.5%
89.5%
91.0%
91.0%
91.0%
91.0%
90.0%
93.0%
76.0%
84.0%
84.0%
84.0%
84.0%
83.0%
83.0%
91.7%
91.7%
77.0%
88.0%
91.0%
76.0%
86.0%
87.5%
87.5%
87.5%
86.0%
86.0%
Demand
kW
0.4
0.4
0.9
0.9
3.0
4.6
4.6
5.8
0.9
0.9
3.0
3.0
3.0
5.8
8.6
8.6
8.6
11.5
20.3
22.5
0.5
0.9
0.9
0.9
0.9
1.9
1.9
14.2
14.2
0.7
8.9
8.6
0.5
4.6
3.0
3.0
3.0
4.6
4.6
Energy
LF Hours kWh
70% 8,760
3,504
70% 8,760
3,504
70% 8,760
7,884
70% 8,760
7,884
70% 8,760 26,280
70% 8,760 40,296
70% 8,760 40,296
70% 8,760 50,808
70% 8,760
7,884
70% 8,760
7,884
70% 8,760 26,280
70% 8,760 26,280
70% 8,760 26,280
70% 7,008 40,646
70% 7,008 60,269
70% 7,008 60,269
70% 7,008 60,269
70% 7,008 80,592
70% 5,810 117,943
70% 5,810 130,725
70%
876
438
70% 5,256
4,730
70% 5,256
4,730
70% 3,504
3,154
70% 3,504
3,154
70% 3,504
6,658
70% 5,810 11,039
70% 8,760 124,392
70% 8,760 124,392
70%
0
0
70% 8,760 77,964
70% 8,760 75,336
70% 8,760
4,380
70% 8,760 40,296
70% 8,760 26,280
70% 8,760 26,280
70% 8,760 26,280
70% 8,760 40,296
70% 8,760 40,296
B.4. Motor Use Summary
Use
1
2
3
4
5
6
7
8
Total
Area
Bk. Store Equipment Room
Bowling Chiller Room
Bowling Compressor Room
Bowling Air-handling Room
Elevator Fan Room
Ballroom Maintenance
Rooftop
Miscellaneous
Hours Qty Hp
8,760
8 34
8,760
12 168
8,760
7 13
8,760
2 50
8,760
1
1
8,760
2 30
8,760
2
8
8,760
5 30
39 334
kW
20.6
96.7
7.9
28.4
0.7
17.5
5.1
18.2
195
kWh
kWh%
180,456 12.3%
645,321 44.0%
33,903
2.3%
248,784 17.0%
0
0.0%
153,300 10.5%
44,676
3.0%
159,432 10.9%
1,465,872 100.0%
B.5. Economics
Energy Cost:
Motor Payback Criterion:
High Torque Drive Payback Criterion:
$0.0464 /kWh
10 years
10 years
65
B.6 Motor Performance Table
900 RPM
Horsepower
(HP)
1
1.5
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
250
300
350
400
450
500
Standard
69.4
73.0
76.4
79.3
82.0
82.8
85.4
85.8
88.0
87.8
87.5
89.5
88.5
91.0
90.2
91.7
92.4
92.4
94.1
94.5
94.5
93.6
93.6
93.6
Motor Efficiency
Efficient
75.5
80.0
85.5
86.5
85.5
86.5
91.0
91.0
91.7
91.7
93.6
93.0
93.6
93.6
94.1
94.1
94.5
94.5
95.0
95.0
95.0
95.0
95.0
95.0
Increase
6.1
7.0
9.1
7.2
3.5
3.7
5.6
5.2
3.7
3.9
6.1
3.5
5.1
2.6
3.9
2.4
2.1
2.1
0.9
0.5
0.5
1.4
1.4
1.4
Standard
$283
$343
$459
$597
$824
$1,049
$1,243
$1,633
$1,968
$2,331
$2,746
$3,401
$4,052
$4,699
$6,258
$7,907
$9,193
$10,371
13443.0
15370.0
17411.0
10493.0
11692.0
12622.0
1200 RPM
Motor
Cost
Efficient
$359
$434
$581
$755
$1,043
$1,327
$1,573
$2,067
$2,491
$2,950
$3,475
$4,305
$5,128
$5,947
$7,920
$10,007
$11,635
$13,126
15989.0
18213.0
20633.0
12922.0
14251.0
15593.0
Increase
$76
$91
$122
$158
$219
$278
$330
$434
$523
$619
$729
$904
$1,076
$1,248
$1,662
$2,100
$2,442
$2,755
2546.0
2843.0
3222.0
2429.0
2559.0
2971.0
Power Factor
Standard
Efficient
59.5
62.0
62.0
61.7
54.0
61.7
62.5
66.4
60.0
67.3
62.0
69.3
78.0
77.2
78.0
75.5
77.5
78.6
78.0
78.3
80.0
76.5
80.0
75.5
76.5
84.0
80.5
83.5
80.0
85.0
78.5
84.0
78.0
82.5
77.5
82.5
86.5
87.0
86.5
84.0
87.0
84.0
81.0
80.5
81.5
84.0
81.0
84.5
Standard
75.5
75.5
80.0
85.5
84.0
86.8
87.5
88.5
90.2
88.5
89.5
89.5
91.0
91.0
91.0
92.4
92.4
93.0
94.1
94.3
95.0
95.0
95.0
94.5
94.5
Motor Efficiency
Efficient
82.1
87.5
87.5
89.5
89.5
91.7
91.7
91.7
92.4
92.4
93.0
93.6
93.6
94.1
95.0
95.0
95.0
95.8
95.4
95.4
95.4
95.8
95.8
96.2
96.2
Increase
6.6
12.0
7.5
4.0
5.5
4.9
4.2
3.2
2.2
3.9
3.5
4.1
2.6
3.1
4.0
2.6
2.6
2.8
1.3
1.1
0.4
0.8
0.8
1.7
1.7
1800 RPM
Horsepower
(HP)
1
1.5
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
250
300
350
400
450
500
Standard
72.0
77.0
80.0
82.5
84.0
86.5
87.5
87.5
89.5
90.2
91.0
90.2
91.7
91.7
91.7
91.7
92.4
93.0
94.1
93.6
94.1
94.5
94.5
95.0
94.5
Motor Efficiency
Efficient
84.3
85.4
85.2
89.5
90.2
91.7
91.7
92.4
93.0
93.6
93.6
94.1
94.1
95.0
95.4
95.4
95.4
95.8
95.8
96.2
95.8
95.8
95.8
95.8
95.8
*Sources:
Unless otherwise noted, all data is from General
publications GEP-500H (11/90), and GEP-1087J
(1/92).
Increase
12.3
8.4
5.2
7.0
6.2
5.2
4.2
4.9
3.5
3.4
2.6
3.9
2.4
3.3
3.7
3.7
3.0
2.8
1.7
2.6
1.7
1.3
1.3
0.8
1.3
Standard
$191
$209
$219
$197
$229
$329
$409
$541
$683
$820
$996
$1,280
$1,658
$2,489
$3,182
$3,837
$4,950
$6,021
$7,285
$8,157
10084.0
11574.0
13528.0
17016.0
10019.0
Standard
$241
$193
$213
$283
$407
$550
$701
$946
$1,150
$1,396
$1,704
$2,229
$2,603
$3,008
$3,615
$5,088
$6,191
$6,818
$9,524
12140.0
14380.0
16692.0
18960.0
11465.0
12626.0
Motor Cost
Efficient
$302
$253
$280
$373
$548
$740
$869
$1,153
$1,403
$1,703
$1,952
$2,770
$3,232
$3,826
$4,575
$6,405
$7,371
$8,606
$11,733
14386.0
17042.0
19780.0
22470.0
14119.0
15549.0
Increase
$61
$60
$67
$90
$141
$190
$168
$207
$253
$307
$248
$541
$629
$818
$960
$1,317
$1,180
$1,788
$2,209
2246.0
2662.0
3088.0
3510.0
2654.0
2923.0
Power Factor
Standard
Efficient
60.5
65.9
77.5
72.0
74.5
74.0
74.5
75.5
78.5
76.0
88.0
72.0
84.5
71.5
82.5
76.5
85.5
76.0
83.5
81.0
82.5
83.5
83.5
85.5
87.0
85.5
81.0
85.5
79.0
86.0
82.5
89.0
84.5
88.5
87.9
86.0
87.8
86.5
85.0
89.0
88.5
89.5
89.0
89.0
89.5
87.5
87.5
87.0
87.0
88.0
Increase
$17
$193
$129
$64
$79
$102
$114
$165
$122
$166
$267
$330
$298
$224
$660
$576
$679
$1,145
$1,837
$3,037
2185.0
4638.0
2331.0
3458.0
2535.0
Power Factor
Standard
Efficient
81.6
81.8
86.0
82.4
87.5
89.9
81.0
87.0
82.0
88.0
82.0
88.5
83.5
88.5
83.0
88.5
90.0
90.0
90.5
91.0
91.5
91.0
85.5
92.0
85.0
92.0
90.0
92.0
91.5
92.0
89.0
91.5
92.5
93.5
92.0
93.5
93.9
94.0
92.5
89.5
92.0
93.0
93.0
93.0
93.0
93.5
93.5
93.0
90.0
93.0
3600 RPM
Motor Cost
Efficient
$237
$262
$274
$262
$299
$431
$520
$695
$845
$1,028
$1,216
$1,560
$1,921
$2,856
$3,680
$4,517
$6,354
$7,415
$8,913
$11,181
12257.0
14068.0
16113.0
19023.0
12339.0
Increase
$46
$53
$55
$65
$70
$102
$111
$154
$162
$208
$220
$280
$263
$367
$498
$680
$1,404
$1,394
$1,628
$3,024
2173.0
2494.0
2585.0
2007.0
2320.0
Power Factor
Standard
Efficient
72.9
76.0
74.2
78.5
78.5
86.5
79.0
80.0
84.0
83.0
83.0
82.5
85.0
81.0
83.0
81.5
84.5
82.0
85.0
83.5
83.0
83.0
80.0
87.5
85.5
86.5
82.5
85.5
83.5
84.5
87.0
85.0
84.5
89.0
86.5
88.0
89.5
90.0
88.5
83.0
90.0
84.0
90.5
90.5
91.0
91.0
91.0
91.0
89.0
90.0
Standard
74.0
80.0
81.5
82.5
84.0
86.5
87.5
87.5
87.5
88.5
89.5
88.5
89.5
89.5
91.0
90.2
91.0
91.7
93.0
93.0
91.0
91.7
91.7
93.0
94.1
Motor Efficiency
Efficient
77.4
84.0
85.2
88.5
89.5
91.7
91.7
91.7
92.4
92.4
92.4
93.6
93.0
94.1
94.5
94.1
94.5
94.5
95.0
95.4
95.4
95.4
95.4
95.4
95.4
Price From Motor Master, Washington State Energy Office.
Efficiency From Motor Master, Washington State Energy Office.
Averaged Data.
66
Increase
3.4
4.0
3.7
6.0
5.5
5.2
4.2
4.2
4.9
3.9
2.9
5.1
3.5
4.6
3.5
3.9
3.5
2.8
2.0
2.4
4.4
3.7
3.7
2.4
1.3
Standard
256.0
$149
$173
$203
$251
$329
$395
$533
$719
$883
$974
$1,278
$1,772
$2,594
$3,089
$4,167
$5,809
$6,958
$8,695
$10,246
13351.0
15335.0
17948.0
18692.0
10947.0
Motor Cost
Efficient
273.0
342.0
302.0
$267
$330
$431
$509
$698
$841
$1,049
$1,241
$1,608
$2,070
$2,818
$3,749
$4,743
$6,488
$8,103
$10,532
$13,283
15536.0
19973.0
20279.0
22150.0
13482.0
Open Drip Proof (ODP)
Totaly Enclosed Fan Cooled
(TEFC)
67
APPENDIX C
LIGHTING
C.1 Lighting Worksheet Definitions
The following lighting inventory and any lighting worksheets contained in the report use
information obtained during the on-site visit to determine any potential energy savings related to
lighting improvements. In all cases the value in the Savings column is the existing value less the
proposed value. The terminology and calculations are described as follows:
PLANT
Building. A description of the building if the plant includes several buildings.
Area: The lighting calculations may refer to a specific location within the building.
Recommended Footcandles. The recommended footcandle levels come from the Illuminating
Engineering Society (IES) Lighting Handbook.
Average Demand Cost (D$). The demand cost ($/kW-month) is taken from the appropriate rate
schedule of your utility. Winter and summer rates are averaged, if necessary.
Average Energy Cost (E$). The energy cost ($/kWh) is taken from the appropriate rate
schedule of your utility for the least expensive energy block. Winter and summer rates are
averaged, if necessary.
Labor Cost ($/H). The cost of labor is estimated for operating and installation cost calculations.
FIXTURES
Description (FID). Fixture type, size, manufacturer, or catalog number may be included here.
Quantity (F#). The number of fixtures in the area recorded during the site visit.
Operating Hours (H). The number of hours which the lighting fixtures operate each year.
Use Factor (UF). The fraction of fixtures that are used multiplied by the fraction of operating
hours (H) that the lights are on.
Lamps/Fixture (L/F). The number of lamps in each fixture.
Ballasts/Fixture (B/F). The number of ballasts in each discharge fixture.
68
Cost (FC). The cost of the existing and proposed fixtures can be compared when modifying or
replacing fixtures.
LAMPS
Description (LID). Lamp type, size, manufacturer, or catalog number may be included here.
Quantity (L#). The number of lamps can be calculated from the number of fixtures and the
number of lamps per fixture:
L#
=
F# x L/F
Life (LL). Lamp life is defined as the number of operating hours after which half the original
lamps will fail. The life recorded here is based on 3 operating hours per start. This provides a
more conservative estimate of lamp life than using longer hours per start.
Replacement Fraction (Lf). The fraction of lamps that normally can be expected to burn out
during a year can be calculated from the operating hours, the use factor, and the lamp life:
Lf
=
H x UF / LL
Watts / Lamp (W/L). The rated lamp power does not include any ballast power, which is
included in the Ballasts section.
Lumens (LM). Lamp output is measured in lumens. Lumens are averaged over lamp life
because lamp output decreases with time.
Cost (C/L). The retail cost per lamp is entered here.
BALLASTS
This section applies only to discharge lamps with ballasts. This section will be blank for
incandescent lamps.
Description (BID). Additional information such as type, size, manufacturer, or catalog number
may be included here.
Quantity (B#). The number of ballasts can be calculated from the number of fixtures and the
number of ballasts per fixture:
B#
=
F# x B/F
69
Life (BL). Ballast life is determined from manufacturer's data. A life of 87,600 hours for a
standard ballast and 131,400 hours for an efficient ballast is used in the calculations.
Replacement Fraction (Bf). The fraction of ballasts normally expected to burn out during a
year can be calculated from the operating hours, the use factor, and the ballast life:
Bf
=
H x UF / BL
Input Watts (IW). Ballast catalogs specify ballast input watts that include lamp power. The
input wattage varies for different combinations of lamps and ballasts.
Cost (BC). The retail ballast cost is entered here.
POWER AND ENERGY
Total Power (P). For incandescent lamps total power is the product of the number of lamps and
the watts per lamp.
P
=
L# x W/L
(Incandescent Lamps)
For discharge lamps total power is the product of the ballast input watts and the number of
ballasts:
P
=
B# x IW
(Discharge Lamps)
Energy Use (E). The annual energy use is the product of the total power, the use factor, and the
annual operating hours:
E
=
P x UF x H / (1,000 watts/kilowatt)
LIGHT LEVEL CHECK
Total Lumens (TLM). The existing and proposed lumen levels are summed for all lamps.
TLM
=
L# x LM
Footcandles (FC). Light is measured in units of footcandles. The existing footcandle level
(FC0) is measured, while the proposed level (FC1) is determined from the ratio of the proposed
total lumens (TLM1) to existing total lumens (TLM0) times the existing footcandle level.
FC1
=
FC0 x (TLM1 / TLM0)
The proposed footcandle level can then be compared to both the existing and the recommended
levels to determine if there will be adequate light for the work space.
70
Lumens / Watt (LM/W). The total lamp output in lumens divided by the total power is a
measure of lighting efficiency.
LM/W
=
TLM / P
ANNUAL OPERATING COST
Power Cost (PC). The annual demand cost is the total power times the average monthly demand
cost from the worksheet times 12 months per year:
PC
=
P x D$ x 12 months/year
Energy Cost (EC). The annual energy cost is the energy use times the electricity cost from your
utility rate schedule:
EC
=
E x E$
Lamp O&M Cost (LOM). Operation and maintenance costs are the sum of lamp and labor
costs for replacing the fraction of lamps (L# x Lf) that burn out each year.
LOM
=
L# x Lf x [LC + (0.166 hours x $/H)]
We assume that two people can replace a lamp and clean the fixture and lens in about five
minutes (0.166 man-hours/lamp), replacing lamps as they burn out.
Ballast O&M Cost (BOM). Operation and maintenance costs are the sum of ballast (BC) and
labor costs ($/H) for replacing the fraction of ballasts (B# x Bf) that burn out each year.
BOM
=
B# x Bf x [BC + (0.5 hours x $/H)]
We assume that one person can replace a ballast in about thirty minutes (0.5 man-hours/ballast),
replacing ballasts as they burn out.
Total Operating Cost (OC). The sum of the annual power and energy costs and lamp and
ballast O&M costs.
OC
=
PC + EC + LOM + BOM
71
IMPLEMENTATION COST
The implementation costs depend on whether refixturing, group relamping, or spot replacing of
lamps and ballasts is recommended.
Refixturing
Materials: The cost is the cost per fixture (C/F) times the number of fixtures (F#) plus the
lamp cost (LC) times the number of lamps (L#).
M$
=
F# x (C/F) + L# x C/L
Labor: The labor cost includes the removal of the existing fixtures and the installation of the
recommended fixtures.
Group Relamping
Materials: When replacing all lamps at one time (group relamping), the cost of materials can
be found from
M$
=
L# x C/L
Labor: We estimate the labor cost for group relamping to be one half the cost of replacing
each lamp as it burns out. We assume that two people can replace two lamps and clean the
fixture and lens in about 5 minutes (0.083 man-hours/lamp, H/L). Because relamping does
not require a licensed electrician, the labor rate for relamping is often lower than the labor
rate for fixture replacement. To calculate the total labor cost for group lamp replacement we
calculate the labor cost of group replacing all of the lamps.
L$GROUP
=
L# x H/L x $/H
Spot Replacement of Lamps & Ballasts
Materials: When replacing lamps only as they burn out (spot relamping), we use the cost
difference (LC1 - LC0) between standard and energy-efficient lamps for all lamps.
M$
=
L# x (LC1 - LC0)
When replacing ballasts only as they burn out (spot reballasting), we use the cost difference
(BC1 - BC0) between standard and energy-efficient ballasts for all ballasts.
M$
=
B# x (BC1 - BC0)
Labor: There is no additional labor cost.
72
Total Cost (IC). Total implementation cost is the sum of materials and labor cost
IC
=
M$ + L$
SIMPLE PAYBACK.
The simple payback (SP) is calculated on each lighting worksheet.
SP
=
IC / OC
73
C.2 LIGHTING INVENTORY & ENERGY CONSUMPTION
CODE
Area
Description
101 Java Stop
HF20
101 Java Stop
102 Office
102A Presidents Office
102A Presidents Office
103 Office
103A Vestibule
104A Work Area
104A WorkArea
104B Office
104B Office
104C Office
105 Meeting Room 105 Meeting Room 105 Meeting Room 105Meeting Room 106 Meeting Room
106 Meeting Room
106 Meeting Room
106 Meeting Room
106A Custodial
106A Custodial
108 Catering
108 Catering
109A Banquet Room
109A Banquet Room
109B Banquet Room
109B Banquet Room
109C Banquet Room
109C Banquet Room
109D Banquet Room
109D Banquet Room
109E Banquet Room
109E Banquet Room
110 Meeting 110 Meeting 111 Office 111 Office 111A Office Manager
112 Office 112A Office
112B Office
112C Vault
112D Office
115 Student Lounge
115 Student Lounge
115 Student Lounge
115 Student Lounge
115A Music Room
115A Music Room
115A Music Room
115B Quiet Room
115B Quiet Room
115B Quiet Room
116 Womens Restroom
116 Womens Restroom
20 Shop Office
201 Storage
203 Meeting Room
203 Meeting Room
204 Office
207 Meeting Room
207 Meeting Room
208 Meeting Room
208 Meeting Room
20A Shop
210 Meeting Room
CF13
OFT8‐1
OFT8‐1
IF60
CF9
OFT8‐1
IF60
OFT8‐1
OFT8‐1
IF60
OFT8‐1
CF9
CF9
CF9
CF13
CF13
IF60
CF9
IF60
IF60
OFT8‐1
OFT8‐1
OFT8‐4
CF9
OFT8‐1
OFT8‐1
CF9
OFT8‐1
CF9
CF9
OFT8‐1
CF9
OFT8‐1
HF20
OFT8‐1
OFT8‐1
IF60
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
IF60
CF9
IF60
IF60
IF60
IF60
IF60
OFT8‐1
IF60
IF60
WLT8‐1
WLT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
IF60
OFT8‐1
OFT8‐1
IF60
HF20
OFT8‐1
OFT8‐1
OFT8‐1
20 Watt Halogens
13 Watt CF
4 Ft T8 Elec.
4 Ft T8 Elec.
60 Watt Incand.
9 Watt CF
4 Ft T8 Elec.
60 Watt Incand.
4 Ft T8 Elec.
4 Ft T8 Elec.
60 Watt Incand.
4 Ft T8 Elec.
9 Watt CF
9 Watt CF
9 Watt CF
13 Watt CF
13 Watt CF
60 Watt Incand.
9 Watt CF
60 Watt Incand.
60 Watt Incand.
4 Ft T8 Elec.
4 Ft T8 Elec.
U‐Bent T8 Elec.
9 Watt CF
4 Ft T8 Elec.
4 Ft T8 Elec.
9 Watt CF
4 Ft T8 Elec.
9 Watt CF
9 Watt CF
4 Ft T8 Elec.
9 Watt CF
4 Ft T8 Elec.
20 Watt Halogens
4 Ft T8 Elec.
4 Ft T8 Elec.
60 Watt Incand.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
60 Watt Incand.
9 Watt CF
60 Watt Incand.
60 Watt Incand.
60 Watt Incand.
60 Watt Incand.
60 Watt Incand.
4 Ft T8 Elec.
60 Watt Incand.
60 Watt Incand.
4 Ft Elec. Wet/Dust
4 Ft Elec. Wet/Dust
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
60 Watt Incand.
4 Ft T8 Elec.
4 Ft T8 Elec.
60 Watt Incand.
20 Watt Halogens
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
FC
10
10
74
Qty
Fixtures
25
9
6
6
1
4
4
2
20
4
1
6
4
5
12
6
6
1
4
2
1
1
4
8
12
18
6
4
6
4
4
6
12
18
6
8
4
1
8
20
7
8
4
12
8
11
32
21
4
16
2
1
18
9
4
28
30
4
48
1
8
12
1
4
48
66
8
Lamps/
Fixture
Ballasts/
Fixture
1
1
2
2
1
1
2
1
2
2
1
2
1
1
1
1
1
1
1
1
1
2
2
2
1
2
2
1
2
1
1
2
1
2
1
2
2
1
2
2
2
2
2
2
1
1
1
1
1
1
1
2
1
1
2
2
2
2
2
1
2
2
1
1
2
2
2
Watts/
Lamp
0
0
1
1
0
0
1
0
1
1
0
1
0
0
0
0
0
0
0
0
0
1
1
1
0
1
1
0
1
0
0
1
0
1
0
1
1
0
1
1
1
1
1
1
0
0
0
0
0
0
0
1
0
0
1
1
1
1
1
0
1
1
0
0
1
1
1
20
13
32
32
60
9
32
60
32
32
60
32
9
9
9
13
13
60
9
60
60
32
32
32
9
32
32
9
32
9
9
32
9
32
20
32
32
60
32
32
32
32
32
32
60
9
60
60
60
60
60
32
60
60
32
32
32
32
32
60
32
32
60
20
32
32
32
Input
Watts
0
0
62
62
0
0
62
0
62
62
0
62
0
0
0
0
0
0
0
0
0
62
62
62
0
62
62
0
62
0
0
62
0
62
0
62
62
0
62
62
62
62
62
62
0
0
0
0
0
0
0
62
0
0
62
62
62
62
62
0
62
62
0
0
62
62
62
Output
Factor
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
Hr/Yr
5,100
5,100
3,060
3,060
3,060
3,060
5,100
2,040
2,040
3,060
3,060
3,060
3,060
3,060
3,060
3,060
3,060
3,060
3,060
3,060
1,275
1,275
3,060
3,060
1,275
1,275
1,275
1,275
1,275
1,275
1,275
1,275
1,275
1,275
3,060
3,060
3,060
3,060
3,060
3,060
3,060
3,060
1,275
3,060
5,100
5,100
5,100
5,100
3,060
3,060
3,060
5,100
5,100
5,100
5,100
5,100
3,060
1,275
3,060
3,060
3,060
3,060
3,060
3,060
3,060
5,100
3,060
kW
kWh
0.5
0.1
0.4
0.4
0.1
0
0.2
0.1
1.2
0.2
0.1
0.4
0
0
0.1
0.1
0.1
0.1
0
0.1
0.1
0.1
0.2
0.5
0.1
1.1
0.4
0
0.4
0
0
0.4
0.1
1.1
0.1
0.5
0.2
0.1
0.5
1.2
0.4
0.5
0.2
0.7
0.5
0.1
1.9
1.3
0.2
1
0.1
0.1
1.1
0.5
0.2
1.7
1.9
0.2
3
0.1
0.5
0.7
0.1
0.1
3
4.1
0.5
2,550
510
1,224
1,224
306
0
1,020
204
2,448
612
306
1,224
0
0
306
306
306
306
0
306
128
128
612
1,530
128
1,403
510
0
510
0
0
510
128
1,403
306
1,530
612
306
1,530
3,672
1,224
1,530
255
2,142
2,550
510
9,690
6,630
612
3,060
306
510
5,610
2,550
1,020
8,670
5,814
255
9,180
306
1,530
2,142
306
306
9,180
20,910
1,530
211 Meeting Room
211 Meeting Room
211 Meeting Room
212 Meeting Room
213 Meeting Room
214 Office
214 Office
215 Office
217 Office
218 Office
219 Womens Restroom
22 Womens Restroom
22 Womens Restroom
220A Custodial Closet
222 Council Room
222 Council Room
222 Council Room
226 Womens Restroom
226 Womens Restroom
23B Storage Closet
24 Storage, Ballroom Stage
24A Light Storage, Ballroom Stage
24B Storage Ballrom Stage
24C Storage, Custodial, Ballroom
24D, Storage, Custodial Ballroom
27C Storage
28 Storage
28A Storage
28B Storage Closet
28D Stoarge
29 West Ballroom
29A Piano Practice Room
29B Piano Practice Room
29C Piano Practice Room
30 Kitchen
31 Hall From Loading Dock
31B Custodial Supervisor Office
31C Freezer
31D Cooler
32 Storage
32 Storage
32A Mechanical Room
34 Storage
35 Lounge
35 Lounge
36 Locker
37 Storage
38 Closet
H10 Hall, Jefferson Entry
H109 Hall, Banquet Rooms
H109 Hall, Banquet Rooms
H11 Hall, Bookstore to Ballroom
H11 Hall, Bookstore to Ballroom
H112 Hall, MU Business Office
H12 Hall, to Rec Center
H14 West Ballroom Exit
H201 Balcony
V10, Vestibule, ATM, Jefferson Entry
V116 Vestibule, Vending/Womens Restroom
Bookstore Lower
Bookstore Lower
Bookstore Upper
Bookstore Upper
Bookstore To Mu
Mesanine Hallway and Lounge
Bites
Mesanine Hallway
Mesanine Lounge
Commons
Commons
Commons
Ballroom
2nd floor Hallway
Totals for Lighting Inventory
CF13
OFT8‐1
CF13
CF9
OFT8‐1
IF60
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
WLT8‐1
CF13
OFT8‐1
IF40
OFT8‐1
CF13
CF13
OFT8‐1
CF13
OFT8‐1
OFT8‐1
CF13
OFT8‐1
OFT8‐1
OFT8‐1
CF13
OFT8‐1
CF13
CF13
CF13
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
CF13
CF13
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
OFT8‐1
CF13
OFT8‐1
CF13
CF13
OFT8‐1
CF13
CF18
OFT8‐1
OFT8‐4
OFT8‐1
OFT8‐1
OFT8‐1
CF13
OFT8‐1
OFT8‐1
OFT8‐2
OFT8‐1
OFT8‐4
OFT8‐1
CF9
CF13‐2
OFT8‐1
CF9
CF9
CF13‐2
CF13‐3
CF13
HF450
OFT8‐1
13 Watt CF
4 Ft T8 Elec.
13 Watt CF
9 Watt CF
4 Ft T8 Elec.
60 Watt Incand.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft Elec. Wet/Dust
13 Watt CF
4 Ft T8 Elec.
40 Watt Incand.
4 Ft T8 Elec.
13 Watt CF
13 Watt CF
4 Ft T8 Elec.
13 Watt CF
4 Ft T8 Elec.
4 Ft T8 Elec.
13 Watt CF
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
13 Watt CF
4 Ft T8 Elec.
13 Watt CF
13 Watt CF
13 Watt CF
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
13 Watt CF
13 Watt CF
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
13 Watt CF
4 Ft T8 Elec.
13 Watt CF
13 Watt CF
4 Ft T8 Elec.
13 Watt CF
18 Watt CF
4 Ft T8 Elec.
U‐Bent T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
13 Watt CF
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
4 Ft T8 Elec.
U‐Bent T8 Elec.
4 Ft T8 Elec.
9 Watt CF
13 Watt CF
4 Ft T8 Elec.
9 Watt CF
9 Watt CF
13 Watt CF
13 Watt CF
13 Watt CF
450 Watt Halogens
4 Ft T8 Elec.
80
65
65
65
15
85
15
15
15
15
15
15
15
12
48
9
8
36
1
8
18
8
8
4
4
16
1
21
6
14
2
1
2
3
5
1
1
1
4
29
1
1
1
27
6
6
4
30
48
4
4
1
4
36
6
6
8
4
10
1
1
8
4
6
6
10
2
14
6
2
16
2
140
12
46
108
4
14
19
164
19
29
59
40
45
15
1
2
1
1
2
1
2
2
2
2
2
1
2
1
2
1
1
2
1
2
2
1
2
2
2
1
2
1
1
1
2
2
2
2
2
2
2
1
1
2
2
2
2
2
1
2
1
1
2
1
1
2
2
2
2
2
1
2
2
3
2
2
2
1
8
2
1
1
8
2
1
1
2
0
1
0
0
1
0
1
1
1
1
1
0
1
0
1
0
0
1
0
1
1
0
1
1
1
0
1
0
0
0
1
1
1
1
1
1
1
0
0
1
1
1
1
1
0
1
0
0
1
0
0
1
1
1
1
1
0
1
1
1
1
1
1
0
0
1
0
0
0
0
0
0
1
13
32
13
9
32
60
32
32
32
32
32
13
32
40
32
13
13
32
13
32
32
13
32
32
32
13
32
13
13
13
32
32
32
32
32
32
32
13
13
32
32
32
32
32
13
32
13
13
32
13
18
32
32
32
32
32
13
32
32
32
32
32
32
9
13
32
9
9
13
13
13
450
32
0
62
0
0
62
0
62
62
62
62
62
0
62
0
62
0
0
62
0
62
62
0
62
62
62
0
62
0
0
0
62
62
62
62
62
62
62
0
0
62
62
62
62
62
0
62
0
0
62
0
0
62
62
62
62
62
0
62
62
93
62
62
62
0
0
62
0
0
0
0
0
0
62
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
3,060
3,060
3,060
3,060
3,060
3,060
3,060
3,060
3,060
3,060
5,100
5,100
5,100
1,275
3,060
3,060
3,060
5,100
5,100
1,275
1,275
1,275
1,275
1,275
1,275
1,275
1,275
1,275
1,275
1,275
1,340
1,340
1,340
1,340
5,100
5,100
3,060
1,275
1,275
1,275
1,275
1,275
1,275
5,100
5,100
5,100
1,275
1,275
8,000
8,000
8,000
8,000
8,000
8,000
8,000
8,000
5,100
5,100
5,100
3,160
3,160
3,160
3,160
3,160
5,100
3,160
5,100
5,100
5,100
5,100
5,100
1,340
8,760
0.2
3
0.1
0.1
2.2
0.1
0.5
1.1
0.5
0.5
0.2
0.1
1
0
1.3
0.1
0.2
0.1
0
0.1
0.2
0.1
0.1
0.1
0.1
0.1
1.8
0
0
0
1.7
0.4
0.4
0.2
1.9
3
0.2
0.1
0
0.2
2.2
0.4
0.4
0.5
0.1
0.6
0
0
0.5
0.1
0.1
0.4
0.6
0.1
0.9
0.4
0
1
0.1
13
0.7
2.9
6.7
0
1.2
1.5
0.2
3
1.5
0.5
20.3
0.9
118.3
75
612
9,180
306
306
6,732
306
1,530
3,366
1,530
1,530
1,020
510
5,100
0
3,978
306
612
510
0
128
255
128
128
128
128
128
2,295
0
0
0
2,278
536
536
268
9,690
15,300
612
128
0
255
2,805
510
510
2,550
510
3,060
0
0
4,000
800
800
3,200
4,800
800
7,200
3,200
0
5,100
510
41,080
2,212
9,164
21,172
0
0
3,792
7,650
1,020
15,300
7,650
2,550
27,202
7,884
381,268
APPENDIX D
REFRIGERATION
D.1 REFRIGERATION WORKSHEET DEFINITIONS
The refrigeration worksheet uses data gathered during the on-site visit and local weather data to
estimate the energy savings due to reducing condensing pressure. The worksheet calculation
methods and symbols are described as follows:
EXISTING OPERATING CONDITIONS (e)
Minimum Existing Condensing Temperature (Tme). The condenser fans cycle on and off to
maintain a minimum condensing temperature. The minimum existing condensing temperature is
the average of the fan cut-in and fan cut-out temperatures. When system load or low ambient
temperatures permit, the condensing temperature drops. A pressure switch maintains the
minimum condensing temperature and pressure by turning the condenser fans off, reducing the
condensing capacity, and causing the condensing temperature to rise. The same pressure switch
also turns the fans back on when the condensing temperature rises. During periods of high
system load or high ambient temperatures, the condensing temperature may stay above the fan
shut off point.
Temperature Difference (DTe). With the condenser fans on, the condensing temperature floats
at an average temperature difference above the ambient temperature.
Compressor Energy (ECe). The annual energy consumption of the high-stage compressors,
calculated in Appendix A.3: Motor Applications Table.
Condenser Fan Horsepower (HPe). The total condenser fan horsepower of the system.
Fan Power (FPe). The actual power used by the condenser fans, taking motor load and
efficiency into consideration.
Annual Operating Hours (OH). Annual operating hours of refrigeration system.
PROPOSED OPERATING CONDITIONS (p)
Minimum Proposed Condensing Temperature (Tmp). Same as the definition for the existing
conditions, except that the fan cut-in and fan-cut out points have been reduced. The condensing
capacity may have been increased if needed to reduce the condensing temperature. The
minimum proposed condensing temperature is 50°F for reciprocating compressors and screw.
76
compressors without liquid injection cooling. The minimum pressure is 125 psig for screw
compressors with liquid injection cooling, and 93 psig with liquid injection booster pumps.
Temperature Difference (DTe). Same as the definition for the existing conditions, except that
the temperature difference may be reduced if condenser capacity or fan use is increased.
Compressor Energy (ECp). The annual energy consumption of the high-stage compressors
with reduced condensing temperature.
BIN CALCULATION
Long term (30-year average) local weather data is commonly available in a "bin" format. A
temperature bin is a five degree range of dry bulb temperatures. Bin weather data consists of the
average number of hours per year that the temperature was within each 5-degree range. The
middle temperature of each bin is defined as the dry bulb temperature for that bin. For example,
the temperature bin between 45°F and 49°F is listed as the average dry bulb temperature of 47°F.
Dry Bulb Temperature (Tdb). The dry bulb temperature for each bin is used for air-cooled
condensers.
Wet Bulb Temperature (Twb). The mean coincident wet bulb temperature for the
corresponding bin is used for wet or evaporative condensers.
Hours (H). The annual hours of occurrence for the bin temperature.
Existing (Tce) and Proposed (Tcp) Condensing Temperature. We assume the existing
condensing temperature floats above the ambient wet or dry bulb temperature while maintaining
the existing minimum condensing temperature. Resetting fan pressure switches will allow the
proposed condensing temperature to float above the wet or dry bulb temperature with a new
proposed minimum condensing temperature. The actual condensing temperatures are therefore:
Tce = Larger [Tme, T + DTe]
Tcp = Larger [Tmp, T + DTp]
where,
T = Twb, Wet Bulb for wet or evaporative condensers
or
T = Tdb, Dry Bulb for air cooled condensers
Degree-Hour Savings (DHS). The Degree-Hour Savings reflects the decrease in condensing
temperature multiplied by the number of hours for each bin temperature in the worksheet. The
Degree-Hour Savings is calculated when the proposed condensing temperature is less than the
existing condensing temperature:
DHS = (Tce - Tcp) x H
77
Energy Savings Percent (E%). Energy savings will occur due to reduced running time,
increased capacity, and reduced compressor power. Savings of 1% in compressor energy per
degree drop in condensing temperature are possible. The energy savings percent of the total
annual compressor energy for each bin temperature can be found from:
E% = DHS / HT
Where,
HT = Total annual bin hours: 8,760 hr annually
Compressor Energy Savings (CES). The compressor energy savings for each bin temperature
can be calculated by:
CE = ECe x E%
Fan Energy Increase (FEI). Reducing the minimum condensing temperature will increase the
condenser fan energy consumption. We assume that the fans will operate at full load during
periods when the condensing temperature is above the minimum condensing temperature. When
the condensing temperature reaches its minimum setpoint, a decrease in the dry or wet bulb
temperature results in fan cycling to maintain the minimum condensing temperature. The fan
energy increase for each bin temperature can be found from:
FE = FP x H x (OH / HT) x [ DTp / (Tcp-T) – DTe / (Tce-T)]
ENERGY AND COST SAVINGS
Total Energy Savings (ES). The compressor energy savings minus the fan energy increase.
ES = CE - FE
Total Cost Savings (CS). The total annual cost savings resulting from multiplying the total
annual energy savings by the cost of electricity (E$):
CS = ES x E$
Implementation Cost (IC). There is no implementation cost to reduce the pressure switch
settings. If there are no pressure switches, these cost about $75 each to install. The cost of liquid
pumps for screw compressors with liquid injection to ensure adequate compressor cooling or
other systems will be approximately $3,000 each. Hy-Save pumps for freon systems cost
approximately $1,200 each. The cost of increasing evaporative condenser capacity is estimated
at $75/ton.
Simple Payback (PB). The simple payback is calculated as:
PB = IC / CS
78