AEP Ohio s CEI - MAHLE Energy Savings. Presented By: Jim Krotkiewicz 1 MAHLE

Transcription

1 AEP Ohio s CEI - MAHLE Energy Savings Presented By: Jim Krotkiewicz 1

2 4 Year Impact Of AEP Ohio s CEI Program 2

3 Electric Bill Reduction Accumulated Savings Once the projects are completed and in place. They just start to snow ball year after year. Electric prices per kilowatt will more than likely increase every year. MAHLE Electric Bill Reduction: 2014 average electric bill was $191, average electric bill was $137,977. Monthly savings $53,304. Annual savings $639,648. The savings could have been zero, if we would have done nothing. It is important to maintain your projects year after year, because the pay backs can be huge. 3

4 Energy Savings History Received American Electric Power 2016 Energy Efficiency Champion Award. History of Program Success Cost avoidance savings of the 208,506 kwh equals $18, Cost avoidance savings of the 976,593 kwh equals $87, Cost avoidance savings of the 1,404,369 kwh equals $126, Cost avoidance savings of the 1,776,113 kwh equals $159, Projects. Continue Conversion to LED lighting. Wasted Heat Recovery. More Compressed Air reduction. Remove 3 x 75 HP Air Compressors Received Additional $54K Check for rebates and Incentives. 4

5 2014 Savings Projects We were new to the AEP Ohio s CEI program and started late in the year with some projects. Lets face it. we were still trying to grasp the idea of a company that you buy electric from is offering to pay you and train you to use less of their electric. We started by creating a weekend checklist for maintenance to shut off equipment and lights. Changed our compressed air shop usage in the north and south building from 105psi to 90psi. $12K annual savings. Setup the Virtual Plant to control the furnaces over the weekend to go into energy savings mode, which lowered the furnace temperatures while they were idle. Total of 208,506 kwh reduced in (Also, received $0.02 kwh saved incentive check $4,170.12) 5

6 2015 Savings Projects Modified weekend checklist for maintenance to shut off more equipment and more lights. Used quench oil to heat make up water for north line strip washers using a heat exchanger. $12K per year. Added auto shut-off to sample press. $4K annual savings. Added auto shut-off to fracture press. $4K annual savings. Started to convert 32 of the 1,000 watt metal halide lights in the north building to 400 watt LED. $16K annual savings. (Also, received incentive rebate check $7,719.30) Total of 976,593 kwh reduced in (Also, received $0.02 kwh saved incentive check $19,531.86) 6

7 2016 Savings Projects Modified weekend checklist for maintenance to shut off more equipment and more lights. Upgraded 12 metal halide lights to LED s in waste treat & north building. Saves $5,950 annually. (Also, received incentive rebate check $2,295.54) Installed 116 LED lights in south building. Each fixture saved $128 for an annually savings of $3,712. (Also, received incentive rebate check $2,265.54) Replaced two 100 HP motors with one 125 HP on NL rough mill chip vac. $20K annual savings. (Also, received incentive rebate check $10,375.07) Used quench oil to heat make up water for south line strip washers using a heat exchanger. $12K per year. (Also, received incentive rebate check $8, for installing the units) Tied air makeup units into virtual plant. Saves maintenance 1.5 man hours/day collecting readings. Tied in Chip Vac, Hammer Mill and Uni-wash to casting line to have auto shut-off when line is idle. $22K annual savings. Inserted new Spirocore technology into gas fired strip anneal. Calculated annual savings $9K. Installed auto shut-off for Strip Anneal 40 HP Jet Cooler Fan, when idle. $15K annual savings. Total of 1,776,113 kwh reduced in (Also, received $0.02 kwh saved incentive check $31,545.06) 7

8 2017 Savings Projects Shut off compressed air to all equipment on the weekends. $11K annual savings. Install solenoid valves on compressed air line air knives, so equipment has no air supplied to them when they are sitting idle. $114K annual savings. Air leak surveys and what was done to fix them on energy savings reductions. $10K annual savings. Automatic shut off of chip collection systems on finish mills #1 and #2. $8K annual savings. Heating the 70 F nitrogen with our torch systems wasted heat. Heating nitrogen to 583 F which reduces heat load on the electric bronzing furnace. $6K annual savings. Peak demand reduction by shutting off north dump stand furnace when both casting line melting furnaces go into high power. $17K annual savings. Peak demand reduction of dump stands and holding stands, when the north dump stand goes into high power. We shut down our holding stands. $17K annual savings. North building peak demand drop due to eliminating three (3) 75 horsepower air compressors. Project finished in December Working with ENERNOC to do a 1 hour shutdown per year during summer peak demand months. $120K potential incentive payback. Total of 854,964 kwh reduced in (Also, received $0.02 kwh saved incentive check $17,099.38) 8

9 Testimony Of AEP Ohio Every question that we have asked.. no matter how technical or complex, they have answered them completely with data and possibly solutions. The seminars that they host are very good and informative. You would pay a least $500 a day for this training elsewhere. Many ideas come from these seminars. They will help with any difficulties that you have implementing them. They completed an energy survey of our entire facility. It is one of the best technical papers that I have read in my 38 years of engineering, and I have ready plenty of papers. The AEP Ohio staff is extremely competent in their field. 9

10 Compressed Air AEP Ohio did a seminar on compressed air. The data and literature that was supplied to the group was outstanding. Everyone knows that compressed air is the most expensive form of energy to use, but when you do studies on before and after a project is completed. The calculated cost savings is just shocking!!! Air compressor maintenance cost and electrical usage are huge. Ways to reduce compressed air usage: Do air leak detection and fix the air leaks. ¼ diameter air leak costs $9,839 per year. Replace high pressure air blow offs with low pressure blowers and low pressure blow off knives. Replace pneumatic systems with hydraulic or electrical systems. Shut off all air lines to unused equipment on the weekends, even with no leaks. they still use air. We have been able to eliminate 3 x 75 HP air compressors by performing the above techniques. 10