Water/Wastewater Conference May 9, 2018 Delaware, Ohio AEP Ohio - - PowerPoint PPT Presentation
Water/Wastewater Conference May 9, 2018 Delaware, Ohio AEP Ohio Energy Efficiency Programs Bid4efficiency Continuous Energy Improvement (CEI) Combined Heat & Power /Waste Energy Recovery Data Center Efficient Products for
1970 1980 Today
Safety
Quality Lean
Energy
Environment Sustainability
Six Sigma
1990 Early 1900’s
Planning
Energy Plan Master Calendar Team Reports Assessment
Management Involvement
Assign Executive Sponsor Assign Energy Champion Energy Policy & Goals Form Energy Team
Employee Engagement
Events Employee Ideas Communications Training
Improvement Process
Opportunity Register Prioritizing Projects Energy Scans Energy Audits
Measurement
Baseline Data MT&R Model Analysis Communications
Energy Team
CEI Integrates Organizational Change & Improvement Methodologies
Build a Foundation Measure Implement Sustain
Organization Change Management Methodology (ADKAR)
Awareness Desire Knowledge Reinforcement Ability
Continuous Energy Improvement (CEI)
Define Measure Analyze Control Improve
Lean Six Sigma Methodology
Understand the need to change & current state Set goals based on current performance to achieve future state Determine solution based on data to achieve future state Sustain improvements, behaviors, skills &
Implement solution & train skills required for future state
Methodology Connection
http://www.slideshare.net/optimaltransformation/dmaic-adkar-change-management-homogeneity
Cumulative sum of differences (CUSUM)
6
What if You Could See Energy Waste?
Can you afford to continue to waste 5%, 10% , 15% of your energy?
Cohorts 1-8 98 Companies 106 GWh Cohorts 9-10 24 Alumni 25 GWh Cohorts 11-12 20 Companies 2018 Finish
118 Total Participants
THE SIX ENERGY WASTES AND O&M ENERGY EFFICIENCY MEASURES FOR WWTP’S PRESENTATION BY MARK FARRELL – AEP OHIO CEI PROGRAM
practices at WWTP’s.
to lowest energy use.
systems, they are repeated, so that each system has a complete list.
important ideas applicable to the entire plant.
– Equipment, motors, heating, cooling, and lighting left on during non-productive time or inactive periods
– Turn equipment off or dial it back to minimum levels
Examples
spaces
equipment
Equipment
are off for the season
during cool weather
– Equipment or lights left on during periods of non-use – Equipment operating 24/7
– Weekends, nights, breaks, and seasonal downtimes are prime opportunities to save energy – Install automatic timers and sensors that will turn off equipment when not in use
– Any unplanned leakage of liquids, blower air, HVAC air, compressed air, heat, steam, or vacuum – The higher the pressure, flow, and temperature, the more $ wasted
– Fix /Repair
underground)
Digesters
and roof
– Piping: blower and compressed air, liquids, chemicals, etc. – Worn or leaky seals – Windows, doors, penetrations – Missing or poor insulation
– Look & listen for leaks – Adjust pump packing/seal water pressure and flow – Use quality insulation, seals, and other components – Use valves to isolate equipment when not in use
– Restriction or obstruction that occurs during air and liquid flow, or while moving or removing materials – Friction loss is proportional to pipe velocity squared
– Eliminate or minimize
Basket strainers Blower intake filters
Examples
60% open
diffusers
filters
bends
Throttled Blower Inlet Valve
– Clogged, dirty, or expired filters – Dirty or clogged diffusers, strainers, nozzles, or outlets – Fouled heat exchanger surfaces – Partially closed valves and dampers – Constrictions or tight bends
– Use SCADA System to monitor pressures, flows, valve positions – Systematic, regular cleaning and replacement – Size piping and duct systems properly
– Occurs when more efficient equipment and methods exist than are currently being used
– Run the most efficient equipment first when you have a choice – Preventative Maintenance is needed to run equipment in peak efficiency mode – Replace broken or worn out equipment and lighting with newer energy efficient models
Examples
BOD and SS removal is gravity
removal efficiency before Secondary Treatment System
– Use proper baffling and velocity control
Examples
choose most efficient pump
impeller (no more than 9%)
impeller clearances
smaller unit sized for average, rather than peak, condition
Example
running when one at higher speed will suffice
create larger bubbles which decrease O2 transfer efficiency: Flex membranes or pressure wash
probes, airflow pressure gauges & meters result in inefficient DO control system
tubes limit UV light
– Redundant equipment – Equipment requiring engineering analysis to determine best operating point– blowers, pumps, etc. – Old or worn equipment ready for replacement
– Proper Preventative Maintenance keeps equipment running at peak efficiency levels: Primary Clarifiers, AB diffusers, air filters, basket strainers, UV tubes, pump wear rings & impeller clearances
– Broken equipment, valves, switches, and controls – Improperly calibrated controls and gauges
– Repair/fix/replace – Clean/calibrate (regularly via PM scheduling)
draw in equipment:
– Bad bearing or partial plugging of pumps, mixers, and mechanical aerators – Heat at electrical connections
– Improperly placed or inoperable DO probes – Airflow pressure gauges and meters – Automatic control valves
actuators
– HOA valve in HAND position – Broken equipment – Stuck valves, switches or actuators – Broken sensors and gauges – Calibrated gauges, sensors (out of date or not calibrated)
– Excessive vibration, heat, noise, or amp draw indicate malfunction
– System requirements are out of balance with capabilities – System set points or operating parameters are out of synchronization with requirements
– Balance the system – Ensure that set points are accurate and adjusted for new
de-nitrification
Secondary Clarifiers, more digester heating and less digester detention time
methane production
– More agitation in aerated grit basins or aerated channels than needed to keep solids suspended – Extra Aeration Basins and Secondary Clarifiers on line – DO set-point higher than 2 PPM in Aeration basins and 0.2 PPM in Aerobic Digesters – Mean Cell Residence Time greater than 4–5 days if nitrification is not required
needed to remove scum
back after high pressure use
pumps
set:
– Simultaneous heating & cooling – Settings not programmed for unoccupied hours
– Systems set at peak or worst-case conditions – Systems in bypass, override, or manual mode – Systems throttled with partially closed valves or dampers – Set points not reviewed or updated on a regular basis
– Understand changes in your plant and reconfigure to adapt to the different requirements – Use SCADA System to observe trends and control systems