Workshop GG Energy Savings Champions Best Practices & Case - - PDF document

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Workshop GG Energy Savings Champions Best Practices & Case - - PDF document

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Workshop GG Energy Savings Champions Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Medium-Sized Companies Wednesday, February 20, 2019 2 p.m. to 3:15 p.m. Biographical Information Angela

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Workshop GG

Energy Savings Champions— Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Medium-Sized Companies

Wednesday, February 20, 2019 2 p.m. to 3:15 p.m.

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Biographical Information Angela M. Rybalt, Outreach Manager, Energy Efficiency Programs, AEP Ohio 700 Morrison Road, A:8.910.6902, Gahanna, OH 43230 614-883-6902 amrybalt@aep.com

  • Mrs. Rybalt is the Outreach Manager for the Solution Provider Network and the Bid4efficiency

Program for the AEP Ohio Energy Efficiency Programs. Angie’s responsibilities include Outreach and Education for the AEP Ohio Business Incentives across multiple sectors of architects, engineers, contractors, energy professionals and end users. Much of her time is spent effectively delivering energy efficiency solutions to Solution Providers, justifying ROI calculations and assisting with the overall sales process to gain energy efficiency incentives. Her key strengths include turnkey understanding of the sales process surrounding energy efficiency amongst different customer segments while utilizing national and local energy efficiency initiatives and incentives to implement projects. Mrs. Rybalt currently serves on the board of the local chapter of Association of Energy Engineers and has a BA in Business from The Ohio State University. Jeff Woolley, EHS Engineer American Fine Sinter, 957 N. Maule Rd., Tiffin Ohio 44883 419-443-8880 ext. 203 Fax 419-443-8881 jwoolley@afsus.com Jeff started his “EHS” career in the hazardous waste remediation field predominately as a field sample technician in various locations through the U.S. Other duties included field and fixed base lab analyst from the corporate office in Findlay, Ohio. From there he progressed through the heavy equipment rental and large commercial bakery industries before ending up in his present role in the production of automotive internal engine parts. Throughout his career his varied roles have always center primarily on safety and environmental compliance with other roles as needed. His current role in EHS at American Fine Sinter centers primarily on overall safety and environmental compliance secondary roles include ISO 14001 and guiding AFS’s future energy strategies. Jeff is a graduate of Bowling Green State University. Robert Moots, Senior Cost Planning / Purchasing, Weastec, Inc. 1600 N. High St., Hillsboro, OH 45133-8259 937-763-5790 robert.moots@weastec.com Robert has spent over 30 years at Weastec, Inc. in Hillsboro and among his responsibilities are: global strategic sourcing, VA/VE improvements, purchasing management, lean management & efficiency, risk management/analysis, quality metrics & improvements, TS16949-Certified, contract management, cost control, continuous improvement of operations, asset management and control and ISO-14001-2015 Certifications.

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American Fine Sinter

Tiffin, Ohio * Over $87,000 in Incentives *

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AFS Background

Tier 1 supplier for Toyota – internal engine parts 2003 >Started production 2013 >Added 23,000 sq.ft. addition 2015 >Added 109,000 sq.ft. “Plant 2” With the expansions came new equipment, including 5 new furnaces, presses, air compressors and team members

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AFS Background

  • Tier 1 supplier for Toyota – internal engine

parts

  • Parts start off as powdered metal and are

formed onto “shape” using a press

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AFS Background

  • Tier 1 supplier for Toyota – internal engine

parts

  • Parts start off as powdered metal and formed
  • nto “shape” of parts then hardened (sintered)
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AFS Background

  • Tier 1 supplier for Toyota – internal engine

parts

  • Parts start off as powdered metal and are

formed onto “shape” using a press

  • Sintering process (hardening) uses a

hydrogen/nitrogen atmosphere in an electric furnace to heat parts to over 1,100C

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AFS Background

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AFS Background

  • Tier 1 supplier for Toyota – internal engine

parts

  • Parts start off as powdered metal and are

formed onto “shape” using a press

  • Sintering process (hardening) uses a

hydrogen/nitrogen atmosphere in an electric furnace to heat parts to over 1,100C

  • Machined, inspected and shipped
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AFS Background

SINTERING requires quartz resistance heating – gasses are used for atmospheric conditioning

2018 power consumption over 14,000,000 kWh

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CAPITAL PROJECT

2010

  • Lighting Project – 458W Metal Halide lights

removed from the high bays and replaced with 225W T-5 HO 6-fluorescent light fixtures 190K+ kWh reduction/ $6,580 Incentive

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CAPITAL PROJECT

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2013/14 new expansion- 33k sq. ft.

  • Lighting Plant 1

36K+ kWh reduction/ $1,591 Incentive

  • VFD Chilled water pump

13K+ kWh reduction/ $1,350 Incentive

  • VFD Air compressor

173K+ kWh reduction/ $10,000 Incentive

CAPITAL PROJECT

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2015 new plant expansion- 100k+ sq. ft.

  • Interior/ Exterior Lighting Plant 2

547K+ kWh reduction/ $23,394 Incentive

  • VFD Air compressor

173K+ kWh reduction/ $9,000 Incentive

CAPITAL PROJECT

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2016

  • VFD Process motor

105K+ kWh reduction/ $4,800 Incentive

  • VFD Chilled water pump

13K+ kWh reduction/ $1,800 Incentive

CAPITAL PROJECT

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2017

  • Custom AC units

173K+ kWh reduction/ $12,153 Incentive

  • VFD Process motor

105K+ kWh reduction/ $4,800 Incentive

  • VFD Chilled water pump

13K+ kWh reduction/ $1,800 Incentive

CAPITAL PROJECT

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2018

  • HVAC unit replacement, 3 units -only

incentivized on single smaller unit 171 kWh reduction/ $105

  • Custom Servo Press

285K+ kWh reduction/ $15,012 Incentive

  • Another Servo Press in process under

different program

CAPITAL PROJECT

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  • No loss condensate drain

4.7K+ kWh reduction/ $50 Incentive

  • LED Lighting- exit, emergency

1.9K+ kWh reduction/ $86 Incentive

BACKGROUND PROJECTS

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BACKGROUND PROJECTS

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  • No loss condensate drain

4.7K+ kWh reduction/ $50 Incentive

  • LED Lighting- exit, emergency

1.9K+ kWh reduction/ $86 Incentive

  • Glass door Refig./ Freezers

16K+ kWh reduction/ $1,475 Incentive

  • HVAC unit

171+ kWh reduction/ $105 Incentive

BACKGROUND PROJECTS

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Summary

Capital projects 1,707,155 kWh reduction $86,167 Incentive Background Projects 19,615 kWh reduction $1,716 Incentive

Year Over Year $avings

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METHODS TO ACHIEVE

  • Know what projects are on the

horizon

  • Get AEP involved early
  • Eligibility
  • What is
  • What program
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METHODS TO ACHIEVE

  • Get AEP involved early
  • Your Requirements/ documentation
  • Invoices
  • Spec. Sheets
  • Schedules
  • Contractors - especially capital projects

Think Outside the Box- look at everything

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Weastec

2-8-2019

Weastec Environmental /Energy Savings Project Results w/ AEP Support Boilers, HVAC, LED, Water and Air Compressor Improvements

Cost Planning / Purchasing

  • Sr. Mgr Robert Moots
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Weastec Over View Weastec Inc. is a Distribution Facility Located in Hillsboro, Ohio Our facility consists of: Plant Area of ~ 100,000 sq/ft Office Area of ~ 25,000 sq/ft Total Space of ~ 125,000 sq/ft In 2014 Weastec needed to reduce our overall Electrical Expenses, as well as other costs of our building being 25 yrs old, because it was becoming a Major Factor in our Overhead Cost. Weastec laid out a 3-yr plan for Building Improvements and Upgrades to our “Existing” Systems that were either outdated, and/or were Non-efficient within our operations. The following is a History of what was changed, and the results of those changes that have occurred with the help of AEP Ohio and their Business Incentive Program, that helped Weastec make the Decision to do the necessary changes.

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Weastec Over View

Computerized Controls of HVAC System

  • Better Control of Air Environments
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for better Control of Air Environments

By adding HVAC Software, and VAV Boxes to our HVAC System, Wtec can control Temperatures better in all areas

  • f the Facility, and program our System

for Daily use as well as Shutdowns, Weekends, and Holidays.

FY Cost Down Attribution: -$24,310

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Weastec Over View

Summer Mo. Timing

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Weastec Over View

Efficiency Improvement

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Weastec Over View

Robert

Input: 6 Units @ 375,000 Btu's

(110 Kw)

Total: 2,250,000 BTU's

(660 Kw)

Current Efficiency: BTU In > Out = 60%

Output:

2,250,000 Btu @60% = 1,350,000 BTU

(396 Kw)

(111,427 Cu Mtr) 675,000 BTU's (198 Kw) 675,000 BTU's (198 Kw) 1,125,000 BTU (330 KW) 1,125,000 BTU

#4 #5

Yearly Natural Gas Usage = 3,935,000 cf

Yearly Natural Gas Cost = $30,845

¥2,714,360

#6

Current Heating / Boilers Configuration

(330 KW)

#1 #2 #3

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Weastec Over View

Better efficiency of Heating

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Weastec Over View

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Weastec Over View

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Weastec Over View

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Weastec Over View

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Weastec Over View

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Weastec Over View

Air Compressor Project

  • >25 yr old Overhead Airlines
  • Unaware Lines were Plugged and Leaking:
  • Only 40% Efficient
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Weastec Over View

2017 CY Project Completion Target

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Weastec Over View

Forklift Battery - Timer Project

  • Added Timers to Forklift Charging to reduce Peak hours usage
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Weastec Over View

Forklift Battery – Charging Timers

Weastec added Timers on the Forklift Battery Charging Stations, programmed to Activate after the “Peak” hours of 6:00 pm to reduce our “PJM” factor, reducing Electrical Cost from the “Peak-Demand” Costing from Electric Companies. Timer Program Panel Timer connected to Fuse Panel Battery Chargers connected to Panel

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Weastec Over View

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Weastec Over View

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Weastec Over View

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Weastec Over View - Awards

Weastec Awarded AEP Energy Efficiency Champion 1 of only 20 Companies in Ohio to Receive - 2018

AEP Business Incentives Multi Year Participation Award Weastec goes 100% LED Facility AEP Energy Check Awarded

SHARP Award - 1 of only 28 Companies in Ohio to be Awarded to this Prestige

Achieved ISO 14001:2015 August 2018

Weastec was featured in a 2018 Major Magazine Article written and published by AEP – Distribution ~ 50,000

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Weastec Over View

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Weastec Over View

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Weastec Over View

OSHA Impact

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Weastec Over View

Environmental Management System

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Weastec Over View

Additional Benefits

Seen from Weastec’s Energy and Environmental Improvements

  • Corporate Insurance Reductions
  • Corporate Tax Reductions
  • GHG Reductions
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Weastec Over View - Commercial Insurance

2018 2017 2013 2014 2015 2016

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Weastec Over View

Dept of Energy Tax Incentives

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Weastec Over View

Greenhouse Gas Reductions

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Weastec Over View

Add’l (Energy Reduction) Tax Deductible Totals

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Weastec Over View

Thank you for your time in reviewing this Presentation, and allowing me to brag on Weastec and it’s Projects ! Robert Moots

  • Sr. Mgr

Cost Planning/Purchasing