June 2006 - Energy Conservation
posted by Larry J Smith
Submitted by K L Petrocelly; RPA, CPE, CFM, PMP.
Like wood nymphs, sprites and poltergeists, "energy" is elusive and comes in many forms. Pinning it down to a singular essence would be like grouping all imaginary beings as the same. The reality is... just as leprechauns are elves, but all elves are not leprechauns; electricity is a form of energy but not all energy is electric. And no where is that truth more evident than in our energy intensive physical plants. There is potential energy in our fuel supplies, kinetic energy in our pipes and expended energy in the heat we're constantly transferring, supplying or dissipating with our machines, devices and lighting systems. And just as untold treasures await anyone with a clever enough plan to catch a leprechaun, so too will the conservation of energy pay dividends to the Facility Manager resourceful enough to engineer his operations.
Strictly speaking, Energy Engineering identifies potential areas of energy waste, assesses their impact on an organization's operational bottom line and prescribes cost-effective alternatives for dealing with them. In maintenance parlance that equates to making choices; such as, what fuel to use or how long to leave a system in service. For many of us the "energy crisis" is just a bad memory. Some of us only know of it from what we've read. Others say we're right in the middle of it as I write this. I'm not so old that I recall using ice in a box as a means for preserving perishable foodstuffs, but I do remember sitting in long lines at the service station on alternate days to get my gas tank filled, at four times what it had cost me the week before, in the 70's. In that same week, the National Geographic had published an article, replete with a photograph of a smiling Kuwaiti holding a Kool-aid picture filled with crude that warned of imminent oil shortages. It was also around that time that I learned of Einstein's hypothesis that "... energy can neither be created nor destroyed". That it can be wasted, he left us on our own to puzzle over. Reducing energy consumption is a lost art. It seems that even the best programs can get off track. Maybe we don't establish it as a high enough priority. Possibly we aren't providing the proper training for our personnel. Perhaps people just don't care when they aren't footing the bill. Do we only take conservation measures when we're afraid we're running out? I guess it all gets back to energy's elusive nature. Energy itself may be considered one of life's great mysteries but it doesn't take a shamus to figure out the consequences of over utilization of our limited resources. Where should we begin? How about...
THE BUILDING ENVELOPE
The perimeter walls and their roof assemblies comprise the shell (or envelope) of a building. I suppose most people choose the term envelope because it infers that this portion of the total structure envelopes the remainder inside. For all I care, you can call it the container and the lid, as long as you understand it's functionality. A building's shell (or envelope) provides a barrier between the unpredictable atmosphere outside and the controlled environment within. Properly designed and utilized, this barrier, which includes all of the buildings structural components (doors windows, roof, walls... etc.), can selectively filter out or allow in certain amounts of fresh air, light, heat and humidity to temper the buildings interior as desired. After recognizing energy's many faces (chemical, mechanical, thermal... etc.), it's the monitoring and control of that "heat" that gives the building engineer his most pause. A well designed and maintained envelope will: minimize heat losses and gains through proper insulation and control of sunlight; maintain the movement of water vapor and control condensation via good ventilation and humidity control; prevent inappropriate air infiltration and escape through engineered openings; and provide adequate venting of interior gasses with mechanical exhaust systems.
The care and repair of this barrier, replete with its windows and door assemblies, is a full time job. Normal maintenance of the structure and its components includes:
caulking of frames and thresholds
repair of leaks and cracks
exchange of dry insulation for saturated
removal of efflorescent salts
repair of locks and hardware
application of protective coatings
maintenance of roof flashing
replacement of exterior lighting
minimization of penetrations
proper ground level drainage
replacement and tinting of fenestration
tuckpointing of masonry
proper vent installation
weatherstripping entryways
removal of debris from roof drains
cleaning of windows and curtains
regular inspections and PM's
sealing of porous surfaces
waterproofing areas below ground
GENERAL CONSERVATION MEASURES
Essentially, there are two approaches to reducing energy consumption: one is pro-active, where we take the bull by the horns and wrestle it to the ground; the second is inactive, where we do nothing and the bull eventually dies and falls down with a thud. Granted, the first option is a lot more work but the alternative... Can you imagine the problems that would cause? Then there's the burial! Every plant should undergo a comprehensive audit, performed by a competent energy specialist which culminates in an established (enforced) conservation program. Until you can arrange that, here are some Heloise’s to get by on:
DAILY
switch off safety/security lights at daybreak
utilize lighting/heating/air-conditioning only as required
take advantage of daylighting situations in lieu of electric lighting
pre-adjust thermostats for comfort cooling/heating
set back thermostats later in the day prior to exiting
keep doors/windows closed; make use of Venetian blinds
ON WEEKENDS
turn off all but safety/security lighting
set back heating/cooling thermostat
check settings and accuracy of HVAC controls
de-energize water heaters and domestic water circulating pumps
SEASONALLY
prior to heating and cooling seasons; thoroughly test, inspect, and adjust all associated equipment and controls in accordance with manufacturer's recommendations
turn off heating in unoccupied spaces that won't be adversely affected by the lack of same
in hot weather, take advantage of night air to pre-cool the building
thoroughly winterize buildings and equipment in accordance with the dictates of the energy management program guidelines
adjust outdoor timers to accommodate the seasonal temperatures and hours of daylight
cover or remove window air conditioners at the onset of the heating season
EQUIPMENT OPERATION AND MAINTENANCE
Open that envelope up and you'll probably find a stack of bills from your local energy suppliers. You purchase natural gas for your boilers, electricity for your motors and lights, water for process and consumption, fuel oil for your generators, and gasoline for your vehicles and portapumps. If energy were a drug, you'd be a junkie. How much does it all cost? Do you care? Should you? What are you going to do to cut your dependency? Here are some general rules of thumb -- followed by a few system specific suggestions:
when replacing equipment; make sure it is properly sized for the load it is connected to
if it's not being used; turn it off!
when purchasing new, buy the more energy efficient model
lower outputs only to needed levels
avoid excessive demand charges by operating your equipment during "off peak" hours
lower settings to reduce consumption (temperature, pressure, speed ...)
don't overload, but eliminate partial loading; run at full capacity
keep all moving parts clean and well lubricated
adjust linkages/alignments and replace worn parts
automate manual controls; calibrate existing controls/devices
schedule equipment for overhaul/shut downs; perform internal inspections
utilize waste heat from processes to produce steam, preheat fluid or warm spaces
set controls on refrigeration equipment only as low as necessary
turn machines off when not in use; don't leave stand-by units energized unnecessarily
keep nozzles, intakes, drains and orifices unclogged and free flowing
install heat reclamation devices and eliminate hot water leaks/drips
reduce water temperatures in hot water systems to acceptable sanitation levels
turn off water heaters or circulating pumps when systems aren't being used
insulate ....insulate ...insulate!
ENERGY MANAGEMENT SYSTEMS
Want to improve your stock when it comes time to resell your properties? Tell the prospective buyer they come equipped with computerized energy management systems. Without getting into the subjects of energy audits, life cycle costing and rate of return analyses, it's conceded by most that a well conceived energy management program will provide a good return on investment (ROI), with payback periods of one to three years as the acceptable norm. But before you go running off to purchase yours, it might pay you to hire an expert to walk you through the process. A good analyst will be able to educate you on what's "state of the art" in the energy conservation field, analyze those parts of your systems you don't understand, estimate potential costs/savings, explain possible modifications and suggest computer hardware/software acquisitions. When you contract with one, make sure it's spelled out what specific services will be provided, what reports will be forthcoming (including audits) and how much your operation can reasonably expect to save, over what period of time. Once the audit is out of the way, an energy management system can be chosen which best matches your established needs. Any EMS worth its chips should be able to:
turn off lights in unoccupied areas
maintain partial lighting before and after "public" hours
schedule lighting operation by hour of day, and time-of-year
turn off a water heater when appropriate
eliminate hot water circulation when an area is unoccupied
maintain HVAC system start-up and set-back schedules
eliminate unnecessary HVAC use during unoccupied hours
monitor/control space temperatures/humidity
provide temperature/pressure read outs on selected equipment
Bear in mind that when you interrupt, modify or otherwise change your existing systems, you take the chance of affecting the productivity, health and comfort of the buildings machinery and occupants, as well as falling out of compliance with applicable codes/standards. Well guy (girl); my creative juices have all but been spent. Unlike that never ending battery commercial, my energy reserves aren't limitless. But don't let that rabbit fool you; he's just going ... and going ... and going to the bank. In the real world; if you don't monitor energy consumption, you can bank on your rabbit dying, then you can watch your operations go... go... go down the tubes. I've got enough drum left to pound out one last message... CONSERVE!