Water/Wastewater Conference May 9, 2018 Delaware, Ohio
AEP Ohio Energy Efficiency Programs • Bid4efficiency • Continuous Energy Improvement (CEI) • Combined Heat & Power /Waste Energy Recovery • Data Center • Efficient Products for Business • Emotor Rewind • Express Program • Process Efficiency (Custom Program) • New Construction • Self-Direct
Energy Management’s Time has Come Early Today 1970 1980 1990 1900’s Energy Quality Lean Six Sigma Safety Environment Sustainability Management Evolution
CEI Process Management Involvement Assign Executive Sponsor Assign Energy Champion Energy Policy & Goals Form Energy Team Employee Engagement Planning Events Energy Plan Employee Ideas Master Calendar Communications Team Reports Energy Training Assessment Team Measurement Improvement Process Baseline Data Opportunity Register MT&R Model Prioritizing Projects Analysis Energy Scans Communications Energy Audits
CEI Integrates Organizational Change & Improvement Methodologies Organization Change Continuous Energy Methodology Lean Six Sigma Management Methodology Improvement (CEI) Connection Methodology (ADKAR) Build a Understand the need to Awareness Define Foundation change & current state Set goals based on Desire Measure current performance to achieve future state Measure Determine solution Knowledge Analyze based on data to achieve future state Implement solution & Implement Ability Improve train skills required for future state Sustain improvements, Sustain Reinforcement Control behaviors, skills & outputs of new state http://www.slideshare.net/optimaltransformation/dmaic-adkar-change-management-homogeneity
6 Performance Tracking Using Energy Model Cumulative sum of differences (CUSUM)
What if You Could See Energy Waste? Can you afford to continue to waste 5%, 10% , 15% of your energy?
2017 CEI Results 118 Total Participants - Manufacturers Cohorts 9-10 Cohorts 11-12 Cohorts 1-8 24 Alumni 20 Companies - Hospitals 98 Companies 106 GWh 25 GWh 2018 Finish - Universities
THE SIX ENERGY WASTES AND O&M ENERGY EFFICIENCY MEASURES FOR WWTP’S PRESENTATION BY MARK FARRELL – AEP OHIO CEI PROGRAM
O&M Measure Checklist • Identify no cost or low cost energy savings through O&M practices at WWTP’s. • Organized by System in approximate order from highest to lowest energy use. • Start at the top of the list and work down. • Because some measures are common to multiple systems, they are repeated, so that each system has a complete list. • Review “ Other Measures ” on last page, which lists important ideas applicable to the entire plant. • Share and improve this checklist
WWTP System List • Blower aeration • Mechanical aeration • Mixing: secondary treatment and anaerobic digesters Pumping: lift stations, RAS, WAS, trickling filters • • Plant water system • Motor controls • Ultraviolet disinfection • Odor control Building HVAC • • Lighting • Laboratory • Compressed air
The 6 Energy Wastes of Wastewater Treatment Processes • Unnecessary running or idling • Leaks • Friction loss • Sub optimized efficiency • Malfunctions • System imbalance
1. Unnecessary Running or Idling • Definition – Equipment, motors, heating, cooling, and lighting left on during non-productive time or inactive periods • Action – Turn equipment off or dial it back to minimum levels
1. Unnecessary Running or Idling Examples • Outdoor lighting on during the day • Heating, cooling, lighting unoccupied spaces Fume hood, muffle furnace, & other lab • equipment • Shop air compressor • Bar Screen & Compactor conveyors • Sludge Thickening & Dewatering Equipment • VFD’s left on when blowers or pumps are off for the season Odor Control equipment: Turn off • during cool weather
1. Unnecessary Running or Idling • Audit Check Points – Equipment or lights left on during periods of non-use – Equipment operating 24/7 • Is it necessary? • Tips – Weekends, nights, breaks, and seasonal downtimes are prime opportunities to save energy – Install automatic timers and sensors that will turn off equipment when not in use
2. Leaks • Definition – Any unplanned leakage of liquids, blower air, HVAC air, compressed air, heat, steam, or vacuum – The higher the pressure, flow, and temperature, the more $ wasted • Action – Fix /Repair
2. Leaks - Examples • Water and air piping leaks (exposed and underground) • Boiling air in Aeration Basins and Aerobic Digesters • Pump packing and seal water • Equipment seals • Building seals at doors, windows, wall, and roof • Hot and cold HVAC ducting • Hot water for Anaerobic Digester
2. Leaks • Audit Check Points – Piping: blower and compressed air, liquids, chemicals, etc. – Worn or leaky seals – Windows, doors, penetrations – Missing or poor insulation • Tips – Look & listen for leaks – Adjust pump packing/seal water pressure and flow – Use quality insulation, seals, and other components – Use valves to isolate equipment when not in use
3. Friction Loss • Definition – Restriction or obstruction that occurs during air and liquid flow, or while moving or removing materials – Friction loss is proportional to pipe velocity squared • Action – Eliminate or minimize
3. Friction Loss - Examples Basket strainers Blower intake filters
3. Friction Loss – Water Examples • Partially closed isolation valves • Sticking check valves • Air in water piping, air release valves • Throttling valves less than 60% open • Partially plugged sludge & scum lines • Partially clogged spray nozzles • Undersized piping & tight bends
3. Friction Loss – Blower Examples Throttled Blower Inlet Valve • Blower discharge throttling • Control valves less than 60% open • Plugged aeration basin diffusers • Compacting media in bio- filters • Undersized piping & tight bends
3. Friction Loss • Audit Check Points – Clogged, dirty, or expired filters – Dirty or clogged diffusers, strainers, nozzles, or outlets – Fouled heat exchanger surfaces – Partially closed valves and dampers – Constrictions or tight bends • Tips – Use SCADA System to monitor pressures, flows, valve positions – Systematic, regular cleaning and replacement – Size piping and duct systems properly
4. Sub-Optimized Efficiency • Definition – Occurs when more efficient equipment and methods exist than are currently being used • Action – Run the most efficient equipment first when you have a choice – Preventative Maintenance is needed to run equipment in peak efficiency mode – Replace broken or worn out equipment and lighting with newer energy efficient models
4. Sub-Optimized Efficiency Examples • Primary Clarification • Lowest cost method for BOD and SS removal is gravity • Maximize Primary Clarifier removal efficiency before Secondary Treatment System • Level and clean weirs – Use proper baffling and velocity control
4. Sub-Optimized Efficiency Examples • Redundant equipment: choose most efficient pump or blower as the lead • Throttled pump: trim impeller (no more than 9%) • Pump wear rings and impeller clearances • Worn out over-sized pump or blower: replace with smaller unit sized for average, rather than peak, condition
4. Review Pump Curves
4. Sub-Optimized Efficiency Example • Two low-speed blowers or pumps running when one at higher speed will suffice • Fouled aeration basin diffusers create larger bubbles which decrease O2 transfer efficiency: Flex membranes or pressure wash • Fouled and un-calibrated DO probes, airflow pressure gauges & meters result in inefficient DO control system • UV Disinfection System: fouled tubes limit UV light
4. Sub-Optimized Efficiency • Audit Check Points – Redundant equipment – Equipment requiring engineering analysis to determine best operating point– blowers, pumps, etc. – Old or worn equipment ready for replacement • Tips – Proper Preventative Maintenance keeps equipment running at peak efficiency levels: Primary Clarifiers, AB diffusers, air filters, basket strainers, UV tubes, pump wear rings & impeller clearances
5. Malfunctions • Definition – Broken equipment, valves, switches, and controls – Improperly calibrated controls and gauges • Action – Repair/fix/replace – Clean/calibrate (regularly via PM scheduling)
5. Malfunctions- Examples • Excessive vibration, noise, heat, or amp draw in equipment: – Bad bearing or partial plugging of pumps, mixers, and mechanical aerators – Heat at electrical connections • Aeration Basin DO controls: – Improperly placed or inoperable DO probes – Airflow pressure gauges and meters – Automatic control valves • Stuck or broken valves, switches, or actuators • Lighting controls not working • Pump Gauges – calibrated?
5. Malfunctions • Audit Check Points – HOA valve in HAND position – Broken equipment – Stuck valves, switches or actuators – Broken sensors and gauges – Calibrated gauges, sensors (out of date or not calibrated) • Tips – Excessive vibration, heat, noise, or amp draw indicate malfunction
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