Workshop GG Energy Savings Champions— Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Medium-Sized Companies Wednesday, February 20, 2019 2 p.m. to 3:15 p.m.
Biographical Information Angela M. Rybalt, Outreach Manager, Energy Efficiency Programs, AEP Ohio 700 Morrison Road, A:8.910.6902, Gahanna, OH 43230 614-883-6902 amrybalt@aep.com Mrs. Rybalt is the Outreach Manager for the Solution Provider Network and the Bid4efficiency Program for the AEP Ohio Energy Efficiency Programs. Angie’s responsibilities include Outreach and Education for the AEP Ohio Business Incentives across multiple sectors of architects, engineers, contractors, energy professionals and end users. Much of her time is spent effectively delivering energy efficiency solutions to Solution Providers, justifying ROI calculations and assisting with the overall sales process to gain energy efficiency incentives. Her key strengths include turnkey understanding of the sales process surrounding energy efficiency amongst different customer segments while utilizing national and local energy efficiency initiatives and incentives to implement projects. Mrs. Rybalt currently serves on the board of the local chapter of Association of Energy Engineers and has a BA in Business from The Ohio State University. Jeff Woolley, EHS Engineer American Fine Sinter, 957 N. Maule Rd., Tiffin Ohio 44883 419-443-8880 ext. 203 Fax 419-443-8881 jwoolley@afsus.com Jeff started his “EHS” career in the hazardous waste remediation field predominately as a field sample technician in various locations through the U.S. Other duties included field and fixed base lab analyst from the corporate office in Findlay, Ohio. From there he progressed through the heavy equipment rental and large commercial bakery industries before ending up in his present role in the production of automotive internal engine parts. Throughout his career his varied roles have always center primarily on safety and environmental compliance with other roles as needed. His current role in EHS at American Fine Sinter centers primarily on overall safety and environmental compliance secondary roles include ISO 14001 and guiding AFS’s future energy strategies. Jeff is a graduate of Bowling Green State University. Robert Moots, Senior Cost Planning / Purchasing, Weastec, Inc. 1600 N. High St., Hillsboro, OH 45133-8259 937-763-5790 robert.moots@weastec.com Robert has spent over 30 years at Weastec, Inc. in Hillsboro and among his responsibilities are: global strategic sourcing, VA/VE improvements, purchasing management, lean management & efficiency, risk management/analysis, quality metrics & improvements, TS16949-Certified, contract management, cost control, continuous improvement of operations, asset management and control and ISO-14001-2015 Certifications.
American Fine Sinter Tiffin, Ohio * Over $87,000 in Incentives *
AFS Background Tier 1 supplier for Toyota – internal engine parts 2003 >Started production 2013 >Added 23,000 sq.ft. addition 2015 >Added 109,000 sq.ft. “Plant 2” With the expansions came new equipment, including 5 new furnaces, presses, air compressors and team members
AFS Background • Tier 1 supplier for Toyota – internal engine parts • Parts start off as powdered metal and are formed onto “shape” using a press
AFS Background • Tier 1 supplier for Toyota – internal engine parts • Parts start off as powdered metal and formed onto “shape” of parts then hardened (sintered)
AFS Background • Tier 1 supplier for Toyota – internal engine parts • Parts start off as powdered metal and are formed onto “shape” using a press • Sintering process (hardening) uses a hydrogen/nitrogen atmosphere in an electric furnace to heat parts to over 1,100C
AFS Background
AFS Background • Tier 1 supplier for Toyota – internal engine parts • Parts start off as powdered metal and are formed onto “shape” using a press • Sintering process (hardening) uses a hydrogen/nitrogen atmosphere in an electric furnace to heat parts to over 1,100C • Machined, inspected and shipped
AFS Background SINTERING requires quartz resistance heating – gasses are used for atmospheric conditioning 2018 power consumption over 14,000,000 kWh
CAPITAL PROJECT 2010 • Lighting Project – 458W Metal Halide lights removed from the high bays and replaced with 225W T-5 HO 6-fluorescent light fixtures 190K+ kWh reduction/ $6,580 Incentive
CAPITAL PROJECT
CAPITAL PROJECT 2013/14 new expansion- 33k sq. ft. • Lighting Plant 1 36K+ kWh reduction/ $1,591 Incentive • VFD Chilled water pump 13K+ kWh reduction/ $1,350 Incentive • VFD Air compressor 173K+ kWh reduction/ $10,000 Incentive
CAPITAL PROJECT 2015 new plant expansion- 100k+ sq. ft. • Interior/ Exterior Lighting Plant 2 547K+ kWh reduction/ $23,394 Incentive • VFD Air compressor 173K+ kWh reduction/ $9,000 Incentive
CAPITAL PROJECT 2016 • VFD Process motor 105K+ kWh reduction/ $4,800 Incentive • VFD Chilled water pump 13K+ kWh reduction/ $1,800 Incentive
CAPITAL PROJECT 2017 • Custom AC units 173K+ kWh reduction/ $12,153 Incentive • VFD Process motor 105K+ kWh reduction/ $4,800 Incentive • VFD Chilled water pump 13K+ kWh reduction/ $1,800 Incentive
CAPITAL PROJECT 2018 • HVAC unit replacement, 3 units -only incentivized on single smaller unit 171 kWh reduction/ $105 • Custom Servo Press 285K+ kWh reduction/ $15,012 Incentive • Another Servo Press in process under different program
BACKGROUND PROJECTS • No loss condensate drain 4.7K+ kWh reduction/ $50 Incentive • LED Lighting- exit, emergency 1.9K+ kWh reduction/ $86 Incentive
BACKGROUND PROJECTS
BACKGROUND PROJECTS • No loss condensate drain 4.7K+ kWh reduction/ $50 Incentive • LED Lighting- exit, emergency 1.9K+ kWh reduction/ $86 Incentive • Glass door Refig./ Freezers 16K+ kWh reduction/ $1,475 Incentive • HVAC unit 171+ kWh reduction/ $105 Incentive
Summary Capital projects 1,707,155 kWh reduction $86,167 Incentive Background Projects 19,615 kWh reduction $1,716 Incentive Year Over Year $avings
METHODS TO ACHIEVE • Know what projects are on the horizon • Get AEP involved early • Eligibility o What is o What program
METHODS TO ACHIEVE • Get AEP involved early • Your Requirements/ documentation o Invoices o Spec. Sheets o Schedules • Contractors - especially capital projects Think Outside the Box - look at everything
Weastec Weastec Environmental /Energy Savings Project Results w/ AEP Support Boilers, HVAC, LED, Water and Air Compressor Improvements Cost Planning / Purchasing 2-8-2019 Sr. Mgr Robert Moots
Weastec Over View Weastec Inc. is a Distribution Facility Located in Hillsboro, Ohio Our facility consists of: Plant Area of ~ 100,000 sq/ft Office Area of ~ 25,000 sq/ft Total Space of ~ 125,000 sq/ft In 2014 Weastec needed to reduce our overall Electrical Expenses, as well as other costs of our building being 25 yrs old, because it was becoming a Major Factor in our Overhead Cost. Weastec laid out a 3-yr plan for Building Improvements and Upgrades to our “Existing” Systems that were either outdated, and/or were Non-efficient within our operations. The following is a History of what was changed, and the results of those changes that have occurred with the help of AEP Ohio and their Business Incentive Program, that helped Weastec make the Decision to do the necessary changes.
Weastec Over View Computerized Controls of HVAC System - Better Control of Air Environments
for better Control of Air Environments By adding HVAC Software, and VAV Boxes to our HVAC System, Wtec can control Temperatures better in all areas of the Facility, and program our System for Daily use as well as Shutdowns, Weekends, and Holidays. FY Cost Down Attribution: -$24,310
Weastec Over View Summer Mo. Timing
Weastec Over View Efficiency Improvement
Weastec Over View Robert Current Heating / Boilers Configuration 1,125,000 BTU 675,000 BTU's #1 #2 #3 (330 KW) (198 Kw) 1,125,000 BTU 675,000 BTU's #4 #5 #6 (330 KW) (198 Kw) Input: 6 Units @ 375,000 Btu's Total: 2,250,000 BTU's (110 Kw) (660 Kw) Current Efficiency: BTU In > Out = 60% Output: 2,250,000 Btu @60% = 1,350,000 BTU (396 Kw) Yearly Natural Gas Usage = 3,935,000 cf (111,427 Cu Mtr) Yearly Natural Gas Cost = $30,845 ¥2,714,360
Weastec Over View Better efficiency of Heating
Weastec Over View
Weastec Over View
Weastec Over View
Weastec Over View
Weastec Over View
Weastec Over View Air Compressor Project - >25 yr old Overhead Airlines - Unaware Lines were Plugged and Leaking: - Only 40% Efficient
Weastec Over View 2017 CY Project Completion Target
Weastec Over View Forklift Battery - Timer Project - Added Timers to Forklift Charging to reduce Peak hours usage
Weastec Over View Forklift Battery – Charging Timers Weastec added Timers on the Forklift Battery Charging Stations, p rogrammed to Activate after the “Peak” hours of 6:00 pm to reduce our “PJM” factor, reducing Electrical Cost from the “Peak - Demand” Costing from Electric Companies. Timer Program Panel Timer connected to Fuse Panel Battery Chargers connected to Panel
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