Demand Response Opportunities in Industrial Refrigerated Warehouses in California

Industrial refrigerated warehouses that implemented energy efficiency measures and have centralized control systems can be excellent candidates for Automated Demand Response (Auto-DR) due to equipment synergies, and receptivity of facility managers to strategies that control energy costs without disrupting facility operations. Auto-DR utilizes OpenADR protocol for continuous and open communication signals over internet, allowing facilities to automate their Demand Response (DR). Refrigerated warehouses were selected for research because: They have significant power demand especially during utility peak periods; most processes are not sensitive to short-term (2-4 hours) lower power and DR activities are often not disruptive to facility operations; the number of processes is limited and well understood; and past experience with some DR strategies successful in commercial buildings may apply to refrigerated warehouses. This paper presents an overview of the potential for load sheds and shifts from baseline electricity use in response to DR events, along with physical configurations and operating characteristics of refrigerated warehouses. Analysis of data from two case studies and nine facilities in Pacific Gas and Electric territory, confirmed the DR abilities inherent to refrigerated warehouses but showed significant variation across facilities. Further, while load from California's refrigerated warehouses in 2008 was 360 MW with estimated DR potential of 45-90 MW, actual achieved was much less due to low participation. Efforts to overcome barriers to increased participation may include, improved marketing and recruitment of potential DR sites, better alignment and emphasis on financial benefits of participation, and use of Auto-DR to increase consistency of participation

Certifying Industrial Energy Efficiency Performance: AligningManagement, Measurement, and Practice to Create Market Value

More than fifteen years after the launch of programs in theU.K. and U.S., industry still offers one of the largest opportunities forenergy savings worldwide. The International Energy Agency (IEA) estimatesthe savings potential from cost-optimization of industrial motor-drivensystems alone at 7 percent of global electricity use. The U.S. Departmentof Energy (USDOE) Industrial Technologies Program estimates 7 percentsavings potential in total US industrial energy use through theapplication of proven best practice. Simple paybacks for these types ofprojects are frequently two years or less. The technology required toachieve these savings is widely available; the technical skills requiredto identify energy saving opportunities are known and transferable.Although programs like USDOE's Best Practices have been highlysuccessful, most plants, as supported by 2002 MECS data, remain eitherunaware or unmotivated to improve their energy efficiency--as evidencedby the 98 percent of US industrial facilities reporting to MECS say thatthey lack a full-time energy manager. With the renewed interest in energyefficiency worldwide and the emergence of carbon trading and newfinancial instruments such as white certificates1, there is a need tointroduce greater transparency into the way that industrial facilitiesidentify, develop, and document energy efficiency projects. Historically,industrial energy efficiency projects have been developed by plantengineers, frequently with assistance from consultants and/or supplierswith highly specialized technical skills. Under this scenario,implementation of energy efficiency improvements is dependent onindividuals. These individuals typically include "champions" within anindustrial facility or corporation, working in cooperation withconsultants or suppliers who have substantial knowledge based on years ofexperience. This approach is not easily understood by others without thisspecialized technical knowledge, penetrates the market fairly slowly, andhas no assurance of persistence, since champions may leave the company orbe reassigned after project completion.This paper presents an alternatescenario that builds on the body of expert knowledge concerning energymanagement best practices and the experience of industrial champions toengage industry in continuous energy efficiency improvement at thefacility rather than the individual level. Under this scenario,standardized methodologies for applying and validating energy managementbest practices in industrial facilities will be developed through aconsensus process involving both plant personnel and specializedconsultants and suppliers. The resulting protocols will describe aprocess or framework for conducting an energy savings assessment andverifying the results that will be transparent to policymakers, managers,and the financial community, and validated by a third-party organization.Additionally, a global dialogue is being initiated by the United NationsIndustrial Development Organization (UNIDO) concerning the development ofan international industrial energy management standard that would be ISOcompatible. The proposed scenario will combine the resulting standardwith the best practice protocols for specific energy systems (i.e.,steam, process heating, compressed air, pumping systems, etc.) to formthe foundation of a third party, performance-based certification programfor the overall industrial facility that is compatible with existingmanagement systems, including ISO 9001:2000, 14001:2004 and 6 Sigma. Thelong term goal of this voluntary, industry designed certification programis to develop a transparent, globally accepted system for validatingenergy efficiency projects and management practices. This system wouldcreate a verified record of energy savings with potential market valuethat could be recognized among sectors and countries

Going with the flow: Life cycle costing for industrial pumping systems

Industries worldwide depend upon pumping systems for theirdaily operation. These systems account for nearly 20 percent of theworld's industrial electrical energy demand and range from 25-50 percentof the energy usage in certain industrial plant operations. Purchasedecisions for a pump and its related system components are typicallybased upon a low bid, rather than the cost to operate the system over itslifetime. Additionally, plant facilities personnel are typically focussedon maintaining existing pumping system reliability rather than optimizingthe systems for best energy efficiency. To ensure the lowest energy andmaintenance costs, equipment life, and other benefits, the systemcomponents must be carefully matched to each other, and remain sothroughout their working lives. Life Cycle Cost (LCC) analysis is a toolthat can help companies minimize costs and maximize energy efficiency formany types of systems, including pumping systems. Increasing industryawareness of the total cost of pumping system ownership through lifecycle cost analysis is a goal of the US Department of Energy (DOE). Thispaper will discuss what DOE and its industry partners are doing to createthis awareness. A guide book, Pump Life Cycle Costs: A Guide to LCCAnalysis for Pumping Systems, developed by the Hydraulic Institute (HI)and Europump (two pump manufacturer trade associations) with DOEinvolvement, will be overviewed. This guide book is the result of thediligent efforts of many members of both associations, and has beenreviewed by a group of industrial end-users. The HI/Europump Guideprovides detailed guidance on the design and maintenance of pumpingsystems to minimize the cost of ownership, as well as LCC analysis. DOE,Hydraulic Institute, and other organizations' efforts to promote LCCanalysis, such as pump manufacturers adopting LCC analysis as a marketingstrategy, will be highlighted and a relevant case studyprovided

Energy efficiency improvements in Chinese compressed airsystems

Industrial compressed air systems use more than 9 percent ofall electricity used in China. Experience in China and elsewhere hasshown that these systems can be much more energy efficient when viewed asa whole system and rather than as isolated components.This paper presentsa summary and analysis of several compressed air system assessments.Through these assessments, typical compressed air management practices inChina are analyzed. Recommendations are made concerning immediate actionsthat China s enterprises can make to improve compressed air systemefficiency using best available technology and managementstrategies

Energy efficiency improvements in Chinese compressed air systems

Abstract Industrial compressed air systems use more than 9% of all electricity used in China. Experience in China and elsewhere has shown that these systems can be much more energy efficient when viewed as a whole system and rather than as isolated components. This paper presents a summary and analysis of several compressed air system assessments. Through these assessments, typical compressed air management practices in China are analyzed. Recommendations are made concerning immediate actions that China's enterprises can make to improve compressed air system efficiency using best available technology and management strategies. Current situation of industrial compressed air systems in China Compressed air is widely used in Chinese industry. In China, the electricity consumption of a compressed air system usually presents 10% to 40% [1] of the electricity use in an industrial facility or enterprise. With the increasing energy shortage and global warming effects, the Chinese government has emphasized the need to increase industrial energy efficiency. As a result, more attention is being paid to the energy savings potential from optimizing compressed air systems. A central focus of the UNIDO China Motor System Energy Conservation Program (2001Program ( -2005 included training motor system experts in the practice of conducting a compressed air system assessments and energy audits based on a system approach. For small-scale and middle-scale air compressor applications in Chinese industry, the share of reciprocating compressor is about 80%. For new compressed air systems, rotary screw compressor will typically be the first choice. But in an older factories, reciprocating compressors, often several decades old, are often still in use. Over time, energy efficiency decreases and the cost of maintaining these compressors increases as the valves and rings experience wear. In China, load/no load is the most common control method; with this type of control, it is very difficult to maintain a stable system pressure. Without adequate storage, variations in demand can lead to system pressure fluctuations and compressor cycling. If a compressor is unloaded time much of the time, the specific power consumption will high, resulting in wasted energy. China's economy is growing very rapidly, over 7% per annum. Because of the increase in economy, most enterprises in China are expanding their production and pursuing integrated economic benefits. To satisfy the increased compressed air demand brought about by increased productivity requirements, many enterprises have undertaken retrofits of their compressed air systems, such as increasing the compressors capacity, improving the system piping, etc. However, compressed air system management is largely confined to guaranteeing the compressed air supply for the production. In practice, system pressure is often higher than actually necessary, resulting in inefficient operations. While many enterprises understand that efficient operation of compressors requires avoiding "discharge, emissions

Opportunities for Energy Efficiency and Demand Response in the California Cement Industry

This study examines the characteristics of cement plants and their ability to shed or shift load to participate in demand response (DR). Relevant factors investigated include the various equipment and processes used to make cement, the operational limitations cement plants are subject to, and the quantities and sources of energy used in the cement-making process. Opportunities for energy efficiency improvements are also reviewed. The results suggest that cement plants are good candidates for DR participation. The cement industry consumes over 400 trillion Btu of energy annually in the United States, and consumes over 150 MW of electricity in California alone. The chemical reactions required to make cement occur only in the cement kiln, and intermediate products are routinely stored between processing stages without negative effects. Cement plants also operate continuously for months at a time between shutdowns, allowing flexibility in operational scheduling. In addition, several examples of cement plants altering their electricity consumption based on utility incentives are discussed. Further study is needed to determine the practical potential for automated demand response (Auto-DR) and to investigate the magnitude and shape of achievable sheds and shifts

Automated Demand Response Opportunities in Wastewater Treatment Facilities

Wastewater treatment is an energy intensive process which, together with water treatment, comprises about three percent of U.S. annual energy use. Yet, since wastewater treatment facilities are often peripheral to major electricity-using industries, they are frequently an overlooked area for automated demand response opportunities. Demand response is a set of actions taken to reduce electric loads when contingencies, such as emergencies or congestion, occur that threaten supply-demand balance, and/or market conditions occur that raise electric supply costs. Demand response programs are designed to improve the reliability of the electric grid and to lower the use of electricity during peak times to reduce the total system costs. Open automated demand response is a set of continuous, open communication signals and systems provided over the Internet to allow facilities to automate their demand response activities without the need for manual actions. Automated demand response strategies can be implemented as an enhanced use of upgraded equipment and facility control strategies installed as energy efficiency measures. Conversely, installation of controls to support automated demand response may result in improved energy efficiency through real-time access to operational data. This paper argues that the implementation of energy efficiency opportunities in wastewater treatment facilities creates a base for achieving successful demand reductions. This paper characterizes energy use and the state of demand response readiness in wastewater treatment facilities and outlines automated demand response opportunities

Assessing the Control Systems Capacity for Demand Response in California Industries

California's electricity markets are moving toward dynamic pricing models, such as real-time pricing, within the next few years, which could have a significant impact on an industrial facility's cost of energy use during the times of peak use. Adequate controls and automated systems that provide industrial facility managers real-time energy use and cost information are necessary for successful implementation of a comprehensive electricity strategy; however, little is known about the current control capacity of California industries. To address this gap, Lawrence Berkeley National Laboratory, in close collaboration with California industrial trade associations, conducted a survey to determine the current state of controls technologies in California industries. This,study identifies sectors that have the technical capability to implement Demand Response (DR) and Automated Demand Response (Auto-DR). In an effort to assist policy makers and industry in meeting the challenges of real-time pricing, facility operational and organizational factors were taken into consideration to generate recommendations on which sectors Demand Response efforts should be focused. Analysis of the survey responses showed that while the vast majority of industrial facilities have semi- or fully automated control systems, participation in Demand Response programs is still low due to perceived barriers. The results also showed that the facilities that use continuous processes are good Demand Response candidates. When comparing facilities participating in Demand Response to those not participating, several similarities and differences emerged. Demand Response-participating facilities and non-participating facilities had similar timings of peak energy use, production processes, and participation in energy audits. Though the survey sample was smaller than anticipated, the results seemed to support our preliminary assumptions. Demonstrations of Auto-Demand Response in industrial facilities with good control capabilities are needed to dispel perceived barriers to participation and to investigate industrial subsectors suggested of having inherent Demand Response potential

Assessing the Control Systems Capacity for Demand Response in California Industries

California's electricity markets are moving toward dynamic pricing models, such as real-time pricing, within the next few years, which could have a significant impact on an industrial facility's cost of energy use during the times of peak use. Adequate controls and automated systems that provide industrial facility managers real-time energy use and cost information are necessary for successful implementation of a comprehensive electricity strategy; however, little is known about the current control capacity of California industries. To address this gap, Lawrence Berkeley National Laboratory, in close collaboration with California industrial trade associations, conducted a survey to determine the current state of controls technologies in California industries. This,study identifies sectors that have the technical capability to implement Demand Response (DR) and Automated Demand Response (Auto-DR). In an effort to assist policy makers and industry in meeting the challenges of real-time pricing, facility operational and organizational factors were taken into consideration to generate recommendations on which sectors Demand Response efforts should be focused. Analysis of the survey responses showed that while the vast majority of industrial facilities have semi- or fully automated control systems, participation in Demand Response programs is still low due to perceived barriers. The results also showed that the facilities that use continuous processes are good Demand Response candidates. When comparing facilities participating in Demand Response to those not participating, several similarities and differences emerged. Demand Response-participating facilities and non-participating facilities had similar timings of peak energy use, production processes, and participation in energy audits. Though the survey sample was smaller than anticipated, the results seemed to support our preliminary assumptions. Demonstrations of Auto-Demand Response in industrial facilities with good control capabilities are needed to dispel perceived barriers to participation and to investigate industrial subsectors suggested of having inherent Demand Response potential

Opportunities for Open Automated Demand Response in Wastewater Treatment Facilities in California - Phase II Report. San Luis Rey Wastewater Treatment Plant Case Study

This case study enhances the understanding of open automated demand response opportunities in municipal wastewater treatment facilities. The report summarizes the findings of a 100 day submetering project at the San Luis Rey Wastewater Treatment Plant, a municipal wastewater treatment facility in Oceanside, California. The report reveals that key energy-intensive equipment such as pumps and centrifuges can be targeted for large load reductions. Demand response tests on the effluent pumps resulted a 300 kW load reduction and tests on centrifuges resulted in a 40 kW load reduction. Although tests on the facility?s blowers resulted in peak period load reductions of 78 kW sharp, short-lived increases in the turbidity of the wastewater effluent were experienced within 24 hours of the test. The results of these tests, which were conducted on blowers without variable speed drive capability, would not be acceptable and warrant further study. This study finds that wastewater treatment facilities have significant open automated demand response potential. However, limiting factors to implementing demand response are the reaction of effluent turbidity to reduced aeration load, along with the cogeneration capabilities of municipal facilities, including existing power purchase agreements and utility receptiveness to purchasing electricity from cogeneration facilities