TLFeBOOK ENERGY MANAGEMENT HANDBOOK SIXTH EDITION Eric Angevine School of Architecture Oklahoma State University Stillwater, OK Bradley Bracher Oklahoma City, OK Barney Burroughs Indoor Air Quality Consultant Alpharetta, GA Barney L. Capehart Industrial Engineering University of Florida Gainesville, FL Clint Christenson Industrial Engineering Oklahoma State University Stillwater, OK David E. Claridge Mechanical Engineering Department Texas A&M University College Station, Texas William E. Cratty Ventana Corporation Bethal, CT Charles Culp Energy Systems Laboratory Texas A&M University College Station, Texas Steve Doty Colorado Springs Utilities Colorado Springs, CO Keith Elder Coffman Engineers, Inc. Seattle, WA John L. Fetters, CEM, CLEP Effective Lighting Solutions, Inc. Columbus, Ohio Carol Freedenthal, CEO Jofree Corporation, Houston, TX GSA Energy Consultants Arlington, VA Richard Wakefi eld Lynda White Jairo Gutiemez Dale A. Gustavson Consultant Orange, CA Jeff Haberl Energy Systems Laboratory Texas A&M University College Station, Texas Michael R. Harrison, Manager Engineering & Technical Services Johns-Mansfi eld Corporation Denver, CO Russell L. Heiserman School of Technology Oklahoma State University Stillwater, OK William J. Kennedy, Jr. Industrial Engineering Clemson University Clemson, SC John M. Kovacik, Retired GE Industrial & Power System Sales Schenectady, NY Mingsheng Liu Architectural Engineering University of Nebraska Lincoln, NB Konstantin Lobodovsky Motor Manager Penn Valley, CA Tom Lunneberg CTG Energetics, Inc. Irvine, CA William Mashburn Virginia Polytechnic Institute and State University Blacksburg, VA Javier Mont Johnson Controls Chesterfi eld, MO George Owens Energy and Engineering Solutions Columbia, MD Les Pace Lektron Lighting Tulsa, OK Jerald D. Parker, Retired Mechanical & Aerospace Engineering Oklahoma State University Stillwater, OK S.A. Parker Pacifi c Northwest National Laboratory Richland, WA David Pratt Industrial Enginneering and Management Oklahoma State University Stillwater, OK Wesley M. Rohrer Mechanical Engineering University of Pittsburgh Pittsburgh, PA Philip S. Schmidt Department of Mechanical Engineering University of Texas Austin, TX R. B. Scollon Manager, Energy Conservation Allied Chemical Corporation Morristown, NJ R. D. Smith Manager, Energy Generation & Feed Stocks Allied Chemical Corporation Morristown, NJ Mark B. Spiller Gainesville Regional Utilities Gainesville, FL Nick Stecky NJS Associates, LLC Albert Thumann Association of Energy Engineers Atlanta, GA W.D. Turner Mechanical Engineering Department Texas A&M University College Station, Texas Alfred R. Williams Ventana Corporation Bethel, CT Larry C. Witte Department of Mechanical Engineering University of Houston Houston, TX Jorge Wong Kcomt General Electric, Evansville, IN Eric Woodroof Johnson Controls, Santa Barbara, CA EDITORIAL BOARD EDITOR ASSOCIATE EDITOR Wayne C. Turner Steve Doty School of Industrial Engineering and Management Colorado Springs Utilities Oklahoma State University Colorado Springs, Colorado Stillwater, Oklahoma CONTRIBUTORS ENERGY MANAGEMENT HANDBOOK SIXTH EDITION BY WAYNE C. TURNER SCHOOL OF INDUSTRIAL ENGINEERING AND MANAGEMENT OKLAHOMA STATE UNIVERSITY AND STEVE DOTY COLORADO SPRINGS UTILITIES COLORADO SPRINGS, COLORADO iv Library of Congress Cataloging-in-Publication Data Turner, Wayne C., 1942- Energy management handbook / by Wayne C. Turner & Steve Doty. 6th ed. p. cm. Includes bibliographical references and index. ISBN: 0-88173-542-6 (print) — 0-88173-543-4 (electronic) 1. Power resources Handbooks, manuals, etc. 2. Energy conservation Handbooks, manuals, etc. I. Doty, Steve. II. Title. TJ163.2.T87 2006 658.2'6 dc22 2006041263 Energy management handbook / by Wayne C. Turner & Steve Doty ©2007 by The Fairmont Press, Inc. All rights reserved. No part of this publica- tion may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage and retrieval system, without permission in writing from the publisher. Published by The Fairmont Press, Inc. 700 Indian Trail Lilburn, GA 30047 tel: 770-925-9388; fax: 770-381-9865 http://www.fairmontpress.com Distributed by Taylor & Francis Ltd. 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487, USA E-mail: orders@crcpress.com Distributed by Taylor & Francis Ltd. 23-25 Blades Court Deodar Road London SW15 2NU, UK E-mail: uk.tandf@thomsonpublishingservices.co.uk Printed in the United States of America 10 9 8 7 6 5 4 3 2 1 0-88173-542-6 (The Fairmont Press, Inc.) 0-8493-8234-3 (Taylor & Francis Ltd.) While every effort is made to provide dependable information, the publisher, authors, and editors cannot be held responsible for any errors or omissions. v CONTENTS Chapter Page 1 Introduction 1 Background 1 The Value of Energy Management 2 The Energy Management Profession 3 Some Suggested Principles of Energy Management 5 2 Effective Energy Management 9 Introduction 9 Energy Management Program 9 Organizational Structure 10 Energy Policy 13 Planning 13 Audit Planning 14 Educational Planning 15 Strategic Planning 16 Reporting 16 Ownership 17 Summary 17 3 Energy Auditing 23 Introduction 23 Energy Auditing Services 23 Basic Components of an Energy Audit 23 Specialized Audit Tools 33 Industrial Audits 34 Commercial Audits 36 Residential Audits 37 Indoor Air Quality 37 4 Economic Analysis 41 Objective 41 Introduction 41 General Characteristics of Capital Investments 42 Sources of Funds 43 Tax Considerations 44 Time Value of Money Concepts 46 Project Measures of Worth 54 Economic Analysis 58 Special Problems 64 Summary and Additional Example Applications 69 vi 5 Boilers and Fired Systems 87 Introduction 87 Analysis of Boilers and Fired Systems 87 Key Elements for Maximum Effi ciency 89 Fuel Considerations 116 Direct Contact Technology for Hot Water Production 122 6 Steam and Condensate Systems 125 Introduction 125 Thermal Properties of Steam 126 Estimating Steam Usage and its Value 133 Steam Traps and Their Application 139 Condensate Recovery 147 7 Cogeneration 155 Introduction 155 Cogeneration System Design and Analysis 157 Computer Programs 174 U.S. Cogeneration Legislation: PURPA 176 Evaluating Cogeneration Opportunities: Case Examples 178 8 Waste-Heat Recovery 193 Introduction 193 Waste-Heat Survey 201 Waste-Heat Exchangers 207 Commercial Options in Waste-Heat-Recovery Equipment 211 Economics of Waste-Heat Recovery 218 9 Building Envelope 221 Introduction 221 Principles of Envelope Analysis 223 Metal Elements in Envelope Components 225 Roofs 230 Floors 233 Fenestration 234 Infi ltration 237 Summarizing Envelope Performance with the Building Load Coeffi cient 239 Thermal “Weight” 240 Envelope Analysis for Existing Buildings 240 Envelope Analysis for New Buildings 245 Updated Envelope Standards for New and Existing Construction 245 Additional Reading 246 10 HVAC Systems 247 Introduction 247 Surveying Existing Conditions 247 Human Thermal Comfort 248 HVAC System Types 249 Energy Conservation Opportunities 259 Cooling Equipment 269 Domestic Hot Water 271 Estimating HVAC Energy Consumption 272 vii 11 Electric Energy Management 273 Introduction 273 Power Supply 273 Effects of Unbalanced Voltages on the Performance of Motors 274 Effect of Performance-General 274 Motor 275 Glossary of Frequently Occurring Motor Terms 275 Power Factor 279 Handy Electrical Formulas & Rules of Thumb 281 Electric motor Operating Loads 281 Determining Electric Motor Operating Loads 282 Power Meter 282 Slip Measurement 282 Amperage Readings 284 Electric Motor Effi ciency 284 Comparing Motors 286 Sensitivity of Load to Motor RPM 290 Theoretical Power Consumption 291 Motor Effi ciency Management 294 Motors Are Like People 294 Motor Performance Management Process 294 How to Start MPMP 295 Nameplate Glossary 298 12 Energy Management Control Systems 315 Energy Management Systems 315 Justifi cation of EMCSs 321 Systems Integration 326 13 Lighting 353 Introduction 353 Lighting Fundamentals 353 Process to Improve Lighting Effi ciency 367 Maintenance 368 New Technologies & Products 370 Special Considerations 379 Daylighting 383 Common Retrofi ts 385 Schematics 390 Glossary 397 14 Energy Systems Maintenance 401 Developing the Maintenance Program 401 Detailed Maintenance Procedures 413 Materials Handling Maintenance 421 Truck Operation and Maintenance 423 Measuring Instruments 426 Saving Energy Dollars in Materials Handling and Storage 430 Recent Developments 433 15 Industrial Insulation 437 Fundamentals of Thermal Insulation Design Theory 437 viii Insulation Materials 439 Insulation Selection .443 Insulation Thickness Determination 448 Insulation Economics 461 16 Use of Alternative Energy 471 Introduction 471 Solar Energy 471 Wind Energy 484 Refuse-Derived Fuel .489 Fuel Cells 493 17 Indoor Air Quality 497 Introduction and Background 497 What is the Current Situation 499 Solutions and Prevention of IAQ Problems .500 18 Electric and Gas Utility Rates for Commercial and Industrial Consumers 507 Introduction 507 Utility Costs .507 Rate Structures 508 Innovative Rate Type 509 Calculation of a Monthly Bill 510 Conducting a Load Study 513 Effects of Deregulation on Customer Rates 516 19 Thermal Energy Storage 519 Introduction 519 Storage Systems 521 Storage Mediums 523 System Capacity 526 Economic Summary 532 20 Codes Standards & Legislation 539 The Energy Policy Act of 1992 539 State Codes 540 Model Energy Code 541 Federal Energy Effi ciency Requirements 541 Indoor Air Quality Standards 542 Regulations & Standards Impacting CFCs 543 Regulatory and Legislative Issues Impacting Air Quality 544 Regulatory and Legislative Issues Impacting Cogeneration & Power 545 Opportunities in the Spot Market 546 The Climatic Change Action Plan 547 21 Natural Gas Purchasing 549 Preface 549 Introduction 550 Natural Gas as a Fuel 553 Buying Natural Gas 566 New Frontiers for the Gas Industry 575 ix 22 Control Systems 577 Introduction 577 Why Automatic Control? 577 Why Optimization? 578 Technology Classifi cations 578 Control Modes 580 Input/Output Devices 584 Valves and Dampers 586 Instrument Accuracy, Repeatability, and Drift 588 Basic Control Block Diagrams 589 Key Fundamentals of Successfully Applied Automataic Controls 590 Operations and Maintenance 592 Expected Life of Control Equipment 592 Basic Energy-saving Control Applications 594 Advanced Energy-saving Control Applications 594 Facilities Operations Control Applications 594 Control System Application Pitfalls to Avoid 601 Costs and Benefi ts of Automataic Control 601 Estimating Savings from Applied Automatic Control Systems 601 Conclusion and Further Study 605 Glossary of Terms 616 23 Energy Security and Reliability 621 Introduction 621 Risk Analysis Methods 624 Countermeasures 630 Economics of Energy Security and Reliability 632 Links to Energy Management 633 Impact of Utility Deregulation 634 24 Utility Deregulation and Energy System Outsourcing 637 Introduction 637 An Historical Perspective of the Electric Power Industry 637 The Transmission System and The Federal Regulatory Commission's (FERC) Role in Promoting Competition in Wholesale Power 638 Stranded Costs 639 Status of State Electric Industry Restructuring Activity 640 Trading Energy—Marketers and Brokers 640 The Impact of Retail Wheeling 640 The Ten-Step Program to Successful Utility Deregulation 641 Aggregation 643 In-house vs. Outsourcing Energy Services 643 25 Financing Energy Management Projects 649 Introduction 649 Financial Arrangements: A Simple Example 649 Financial Arrangements: Details and Terminology 652 Applying Financial Arrangements: A Case Study 653 "Pros" & "Cons" of Each Financial Arrangement 664 Characteristics that Infl uence which Financial Arrangement is Best 665 Incorporating Strategic Issues when Selecting Financial Arrangements 666 [...]... Washington, D.C., 19 99 2 Energy User News, Jan 14 , 19 80 3 JOHN G WINGER et al., Outlook for Energy in the United States 8 ENERGY MANAGEMENT HANDBOOK to 19 85, The Chase Manhattan Bank, New York, 19 72, p 52 4 DONELLA H MEADOWS et al., The Limits to Growth, Universe Books, New York, 19 72, pp 15 3 -15 4 5 JIMMY E CARTER, July 15 , 19 79, “Address to the Nation,” Washington Post, July 16 , 19 79, p A14 6 Monthly Energy Review,... Jan 19 80, U.S Department of Energy, Washington, D.C., p 16 7 Monthly Energy Review, Jan 19 80, U.S Department of Energy, Washington D.C., p 8; Statistical Abstract of the United States, U.S Government Printing Office, Washington, D.C., 19 79, Table 14 09; Energy User News, Jan 20, 19 80, p 14 8 American Association for the Advancement of Science, “U.S Energy Demand: Some Low Energy Futures,” Science, Apr 14 ,... University Press, Pittsburgh, Pa., 19 79 11 U.S Congress Office of Technology Assessment (OTA) Energy Efficiency in the Federal Government: Government by Good Example? OTA-E-492, U.S Government Printing Office, Washington D.C., May 19 91 12 U.S Air Force DOD Energy Manager’s Handbook Volume 1: Installation Energy Management Washington D.C., April 19 93 CHAPTER 2 EFFECTIVE ENERGY MANAGEMENT WILLIAM H MASHBURN,... 19 78 ————————————————————————— Dollar Expenditure Percent of Percent of Function (billions) Expenditure Total Btu ————————————————————————— Machine drive 19 35 12 Feedstocks 16 29 35 Process steam 7 13 23 Direct heat 4 7 13 Indirect heat 4 7 13 Electrolysis 4 7 3 Space conditioning and lighting 1 1 1 ––– ––– ––– Total 55 10 0 10 0 ————————————————————————— Source: Technical Appendix, The Least-Cost Energy. .. about 70 percent of the sulfur dioxide emissions from stationary sources CH4 + 2 O2 = CO2 + 2 H2O (12 + 4 *1) +2(2 *16 ) = (12 + 2 *16 ) + 2(2 *1 +16 ) (1. 1) Thus, 16 pounds of methane produces 44 pounds of carbon dioxide; or 2.75 pounds of carbon dioxide is produced for each pound of methane burned Energy management reduces the load on power plants as fewer kilowatt hours of electricity are needed If a plant... program, but will identify areas of concentration for reducing energy 2 .11 .4 Training With the committee involvement, develop a training plan for the first year 18 ENERGY MANAGEMENT HANDBOOK 2 .11 .5 Audits Again with the committee involvement, develop an auditing plan for the first year I 2 .11 .6 Reporting Develop a simple reporting system II 2 .11 .7 Schedule From the above information develop a schedule of... support to energy service company support Energy management skills are extremely important in this rapidly expanding field, and even critical to those companies that are in the business of identifying energy savings and providing a guarantee of the savings results • • • • Building/Facility Energy Manager Utility Energy Analyst Federal Energy Analyst Consulting Energy Engineer Figure 1. 2 Typical Energy Management. .. Set up an Energy Management Plan Establish energy records Identify outside assistance Assess future energy needs Identify financing sources Make energy recommendations Implement recommendations ENERGY MANAGEMENT PROGRAM President Policy VP VP VP Audit Plan Energy Manager Coordinator Coordinator Educational Plan Coordinator Reporting System Employees Figure 2 .1 Strategic Plan EFFECTIVE ENERGY MANAGEMENT. .. balance of payments by reducing costs of imported energy — Need to minimize the effects of a potential limited energy supply interruption None of these concerns can be satisfactorily met without having an energy efficient economy Energy management plays a key role in helping move toward this energy efficient economy 1. 3 THE ENERGY MANAGEMENT PROFESSION Energy management skills are important to people in many... the impact that Energy Management Handbook has had for those we serve The book is an official reference and preparatory text for AEE’s Certified Energy Manager (CEM) program, the most widely recognized professional credential in the energy management field, having certified more than 6,000 professionals since its inception in 19 81 In addition numerous large corporations have selected Energy Management Handbook . omissions. v CONTENTS Chapter Page 1 Introduction 1 Background 1 The Value of Energy Management 2 The Energy Management Profession 3 Some Suggested Principles of Energy Management 5 2 Effective Energy Management. Introduction 9 Energy Management Program 9 Organizational Structure 10 Energy Policy 13 Planning 13 Audit Planning 14 Educational Planning 15 Strategic Planning 16 Reporting 16 Ownership 17 Summary. emissions from stationary sources. CH 4 + 2 O 2 = CO 2 + 2 H 2 O (12 + 4 *1) +2(2 *16 ) = (12 + 2 *16 ) + 2(2 *1 +16 ) (1. 1) Thus, 16 pounds of methane produces 44 pounds of carbon dioxide; or 2.75