Best Low and No-Cost Refrigerated Practices in Methods of Warehouse Energy Warehouse Reducing Refrigerated Efficiency

Energy Consumption
By Marcus Wilcox, President

Our Company
Offices in Oregon, Utah, and Washington Staff of 75 (incl. 45 Engineers) Industrial energy efficiency consulting Food processing, warehouses, pulp & paper, petrochemical, manufacturing Worked on 700 to 800 ammonia refrigeration systems (incl. 250 refrigerated warehouses) Services include: Energy Management (EM) program design and implementation Tune-ups (i.e., kaizen blitzes or retro-commissioning) Retrofit & new construction project assistance Design and management of utility energy efficiency programs A few of our corporate EM customers: Americold Sysco GCCAs Service Partner for Energy Management

2011 Cascade Energy, Inc.

Slide 1

Typical PRW Energy Use & Cost

Typical Annual Energy Use
3,000,000 to 30,000,000+ kWh/yr
(Average U.S. Home = 10,000 kWh/yr)

Some natural gas

Average rate of 4 to 16/kWh

Annual cost of $100k to $5 million /yr

2011 Cascade Energy, Inc.

Slide 2

Energy Management Pyramid

2011 Cascade Energy, Inc.

Slide 3

The ROI Sweet Spot

2011 Cascade Energy, Inc.

Slide 4

Successfully Driving Action

Establish corporate commitment & goals Implement a fair performance measurement

Roll out training

Push out best practices Pursue the quick, easy and low cost Carefully invest in retrofits Include efficiency in construction or EOL replacement Invest in innovation, pilots, research, etc. Continuous improvement (there is no finish line)

2011 Cascade Energy, Inc.

Slide 5

Breakdown of PRW Energy Use

Refrigeration (60%) Warehouse Lighting (20%) Battery Charging (10%) Miscellaneous (10%)
Dock & Freezer Doors (Heaters & Blowers) Freezer Floor Heating Offices (Lighting, HVAC, Plug Loads) Exterior / Parking Lot Lighting Truck Shops Dry Warehouse HVAC

2011 Cascade Energy, Inc.

Slide 6

Refrigeration (60% of Energy)

Most PRW facilities utilize ammonia refrigeration
Engineered and built-up Hybrid ammonia/CO2 is now available

Some utilize air-cooled packaged systems

R-404a, 507, 134, 22, etc.

Blast freezing and process loads can increase refrigeration percentage dramatically

2011 Cascade Energy, Inc.

Slide 7

Typical Ammonia System Equipment

Warehouse Evaporators

Blast Freezing

Screw Compressors

Reciprocating Compressors

Rotary Vane Compressors Condensers

2011 Cascade Energy, Inc.

Slide 8

Typical Packaged System Components

Recip., Scroll or Discus Compressors

Condenser Fans

Electric Defrost

Pressure or Temperature Switches

Evaporator Fans

Time Clocks

2011 Cascade Energy, Inc.

Slide 9

Pursuing Low & No-Cost Opportunities

Interviewing Larry King Investigation Sherlock Holmes Typical Activities

Measuring Repair Tuning Improving Practices Improving Schedules Collaborating with Trade Allies

2011 Cascade Energy, Inc.

Slide 10

The Interview Process

2011 Cascade Energy, Inc.

Slide 11

The Investigation Process

12

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Slide 12

Is Regular Cleaning Occurring?

13

Cleanliness = Energy Efficiency

14

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Slide 14

There are Dumb Experts Out There

2011 Cascade Energy, Inc.

Slide 15

Are Control Components Working?

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Slide 16

Have There Been Bad Upgrades

2011 Cascade Energy, Inc.

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Fix Problems RIGHT NOW

2011 Cascade Energy, Inc.

Slide 18

Are Condensers in Good Shape?

2011 Cascade Energy, Inc.

Slide 19

Is Water Treatment Working Well?

20

2011 Cascade Energy, Inc.

Slide 20

Is Water Flowing?

2011 Cascade Energy, Inc.

Slide 21

Are Fans Performing?

22

2011 Cascade Energy, Inc.

Slide 22

Is Periodic Maintenance Occurring?

23

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Slide 23

Is Equipment Turned On?

2011 Cascade Energy, Inc.

Slide 24

Do You Have Good Information?

2011 Cascade Energy, Inc.

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25

Are Control Set Points Optimum?

2011 Cascade Energy, Inc.

Slide 26

Are Frequency Drives Optimized?

2011 Cascade Energy, Inc.

Slide 27

Lighting (20% of Energy)

Ensure motion sensors are functioning and tuned
Install automated controls Target appropriate light levels

Current technologies
Metal Halide T8 and T5 Fluorescent LED

2011 Cascade Energy, Inc.

Slide 28

Battery Charging (10% of Energy)

Unfortunately, it is the Wild Wild West There are no guidelines for rating efficiency What matters?
Energy into the charger vs. energy out of battery
a.k.a., round trip efficiency

Idle power draw Impact on peak demand Ability to facilitate or cooperate in demand management

2011 Cascade Energy, Inc.

Slide 29

Are Your Chargers Setting Your Peak Demand?

Charger Current vs Main Meter Power
1,800 500

1,600

450

1,400

400 350

300 1,000 250 800 200 600 150 400 Chargers 100

Battery Chargers (Amps)

1,200

Main Meter

Main Pulse Meter (kW)

Main Meter Chargers

200

50

Tue-11/11

Wed-11/12

Thu-11/13

Fri-11/14

Sat-11/15

Sun-11/16 Date

Mon-11/17

Tue-11/18

Wed-11/19

Thu-11/20

Fri-11/21

2011 Cascade Energy, Inc.

Slide 30

Traditional Technology
Relatively slow High maintenance Susceptible to damage Extremely high heating requirements in freezer applications

Radiant heaters Heated blowers In some cases, 5% to 15% of total facility energy use!

2011 Cascade Energy, Inc.

Slide 31

Modern Roll-Up Doors

Less infiltration
High speed Self-healing Fewer sealing edges to leak

Insulated Minimal to no heating requirement

2011 Cascade Energy, Inc.

Slide 32

Recirculatory Air Curtains

Appropriate for some applications
Safety considerations Productivity considerations

Consider fan energy use Consider air heating energy

Avoid electric if possible Avoid hot gas with high ammonia pressure requirement

Consider hybrid configuration

Mated to fast or bi-parting door, VFD on fans, heating disabled, advanced controls

2011 Cascade Energy, Inc.

Slide 33

Miscellaneous Loads
Freezer Floor Heating Offices (Lighting, HVAC, Plug Loads) Exterior / Parking Lot Lighting Truck Shops Dry Warehouse HVAC

2011 Cascade Energy, Inc.

Slide 34

Avoid Magic Technologies

Avoid equivalent of fuel line magnets There are no magic solutions that connect to your electrical system
Dont mistake power quality for demand or energy savings Avoid products that claim to trick your electric meter

Correcting quality (e.g., transients, harmonics) may be helpful, but does not save energy

Correcting Power Factor reduces cost, not energy

Other than lighting and battery charging, it is all about shaft horsepower

2011 Cascade Energy, Inc.

Slide 35

Sysco Case Study

110 food distribution centers (DCs)
Freezers, coolers, dock, and dry warehouse space

Aggressive goals:
10% after 1st year 25% after 3rd year Another 5% by 6th year

Rolled out program in March, 2006

Four-Prong approach

Announced by corporate management Managed by project engineering group

Corporate goal and commitment Energy Information Systems Tune-ups at every DC in 18 months Retrofits and highefficiency new construction

2011 Cascade Energy, Inc.

Slide 36

Established Benchmarking System

Cubic feet weighted by freezer, cooler/dock, and dry as well as average wet bulb for a normalized Efficiency Factor Entire company can be benchmarked
Rank within company Rank within benchmark group Rank within region

This report is seen across company. Requires monthly collection of 500+ utility bills

2011 Cascade Energy, Inc.

Slide 37

Sample Tune-Up Performance

2011 Cascade Energy, Inc.

Slide 38

Baseline Companywide Performance

Energy Use vs Facility Size - June Utility Bills

2005

kWh/day
-

2,000

4,000

6,000 Weighted Cubic Feet

8,000

10,000

12,000

2011 Cascade Energy, Inc.

Slide 39

Performance After Tune-Ups

Energy Use vs Facility Size - June Utility Bills

2005 2007

kWh/day
-

2,000

4,000

6,000 Weighted Cubic Feet

8,000

10,000

12,000

2011 Cascade Energy, Inc.

Slide 40

Most Recent Performance

Energy Use vs Facility Size - June Utility Bills

2005 2007

kWh/day

2010

2,000

4,000

6,000 Weighted Cubic Feet

8,000

10,000

12,000

2011 Cascade Energy, Inc.

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Year to Year Performance

Total Broadline Energy Intensity

kWh/day/1000 weighted ft3

2004 2005 2006 2007 2008 2009 2010

ar

ay

Fe b

Ju l

Au g

Ja n

Ap r

Ju n

Se p

ov N

ct

ec

2011 Cascade Energy, Inc.

Slide 42

Closing Questions
Do you have energy policy & goals? Do you accurately and fairly track energy performance? Is Energy Management a topic & priority for executive team? Is there executive support and funding to meet energy goals? Do you have an Energy Champion in place? How will you vet investment opportunities? How are you going to achieve real, substantial, sustainable savings?

2011 Cascade Energy, Inc.

Slide 43

Thank You

Marcus Wilcox, President, P.E. Cascade Energy, Inc. Marcus.Wilcox@CascadeEnergy.com

2011 Cascade Energy, Inc.

Slide 44