Michael Bellstedt Energy Efficiency Opportunities
Typical Energy Efficiency Opportuni3es in Winery Refrigera3on Systems Dr Michael Bellstedt, Ananth Arkal and Mick Calcoen Minus40 Pty Ltd Sydney
Wednesday, 26 September 12
Content
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different?
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis • Conclusions
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis • Conclusions
Wednesday, 26 September 12
Common energy savings strategies Variable head pressure control Compressor speed and staging control High efficiency motors on compressors and pumps Liquid refrigerant (condensate) sub-‐cooling Variable speed control of glycol pumps Mixing avoidance in glycol system/tanks
Wednesday, 26 September 12
Variable head pressure control / condenser fan speed control
Wednesday, 26 September 12
Variable head pressure control / condenser fan speed control • Head pressure setpoint depending on load and
ambient conditions
VSDs on condensers Temperature/Humidity sensor Wednesday, 26 September 12
Variable head pressure control / condenser fan speed control • Head pressure setpoint depending on load and
ambient conditions • Significant savings at: • Cool Ambient Conditions • Part Load
VSDs on condensers Temperature/Humidity sensor Wednesday, 26 September 12
Compressor speed and staging control
Wednesday, 26 September 12
Compressor speed and staging control • Unloading via Speed Control rather than Slide
Valve
Wednesday, 26 September 12
Compressor speed and staging control • Unloading via Speed Control rather than Slide
Valve • VSD’s on Compressors
Wednesday, 26 September 12
Compressor speed and staging control • Unloading via Speed Control rather than Slide
Valve • VSD’s on Compressors • Appropriate Control Logic
Wednesday, 26 September 12
Economisers on Screw compressors
Wednesday, 26 September 12
Economisers on Screw compressors • Sub-‐cooling receiver liquid
Economiser vessel Eco port connection Wednesday, 26 September 12
Economisers on Screw compressors • Sub-‐cooling receiver liquid • Improved efficiency (5-‐10%)
Economiser vessel Eco port connection Wednesday, 26 September 12
Economisers on Screw compressors • Sub-‐cooling receiver liquid • Improved efficiency (5-‐10%) • Increase in compressor capacity (3-‐8%)
Economiser vessel Eco port connection Wednesday, 26 September 12
Economisers on Screw compressors • Sub-‐cooling receiver liquid • Improved efficiency (5-‐10%) • Increase in compressor capacity (3-‐8%) • Needs VSD on compressor
Economiser vessel Eco port connection Wednesday, 26 September 12
High efficiency motors
Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
OLD Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
• Modern motors >95% efficient
NEW
OLD Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
• Modern motors >95% efficient • Savings up to 10% possible
NEW
OLD Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
• Modern motors >95% efficient • Savings up to 10% possible • 2-‐3% loss with every re-‐wind!!
NEW
OLD Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
• Modern motors >95% efficient • Savings up to 10% possible • 2-‐3% loss with every re-‐wind!! • Match with VSD NEW
OLD Wednesday, 26 September 12
Review of Mixing Arrangement • VSD’s on both primary and secondary brine pumps • Review of tank / brine circuits / control logic
Serves a double purpose:
Reduce pump motor power consumption Increase of compressor suction temperature
Wednesday, 26 September 12
Review of Mixing Arrangement • VSD’s on both primary and secondary brine pumps • Review of tank / brine circuits / control logic
Serves a double purpose:
Reduce pump motor power consumption Increase of compressor suction temperature
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis • Conclusions
Wednesday, 26 September 12
Load Profile of Food Manufacturer
Wednesday, 26 September 12
Load Profile of Food Manufacturer
Wednesday, 26 September 12
Load Profile of Food Manufacturer • Represents monitored
hourly load profile for 1 week
Wednesday, 26 September 12
Load Profile of Food Manufacturer • Represents monitored
hourly load profile for 1 week • Refrigeration Plant load is dominated by production variations
Wednesday, 26 September 12
Load Profile of Food Manufacturer • Represents monitored
hourly load profile for 1 week • Refrigeration Plant load is dominated by production variations • Weekend operation clearly distinctive from weekdays
Wednesday, 26 September 12
Load Profile of Food Manufacturer • Represents monitored
hourly load profile for 1 week • Refrigeration Plant load is dominated by production variations • Weekend operation clearly distinctive from weekdays As far as production stays constant throughout year, load profile will not vary much throughout the year. (Will be slightly elevated during summer.)
Wednesday, 26 September 12
Load Profile of Dairy
Wednesday, 26 September 12
Load Profile of Dairy 2 Weeks profile shows no distinct weekday/weekend operation
Wednesday, 26 September 12
Load Profile of Dairy 2 Weeks profile shows no distinct weekday/weekend operation
Wednesday, 26 September 12
Load Profile of Dairy 2 Weeks profile shows no distinct weekday/weekend operation Annual load profile influenced by varying production and heat infiltration
Wednesday, 26 September 12
Load Profile of Winery
Wednesday, 26 September 12
Load Profile of Winery • Distinctive peak
coinciding with vintage period and summer conditions
Wednesday, 26 September 12
Load Profile of Winery • Distinctive peak
coinciding with vintage period and summer conditions • Refrigeration plant at significant part load for long periods of the year
Wednesday, 26 September 12
Load Profile of Winery • Distinctive peak
coinciding with vintage period and summer conditions • Refrigeration plant at significant part load for long periods of the year • Profile dependent on vintage period, fermenting, cold stabilisation, weather conditions …
Wednesday, 26 September 12
Load Profile of Winery • Distinctive peak
coinciding with vintage period and summer conditions • Refrigeration plant at significant part load for long periods of the year • Profile dependent on vintage period, fermenting, cold stabilisation, weather conditions … • Possibility of having base load and peak load refrigeration plants
Wednesday, 26 September 12
Load Profile Comparison
Wednesday, 26 September 12
Load Profile Comparison
• Significant difference in load profile throughout the year, which heavily influences
viability of energy savings projects.
Wednesday, 26 September 12
Load Profile Comparison
• Significant difference in load profile throughout the year, which heavily influences
viability of energy savings projects. • The same investment in an abattoir/dairy/… might not result in the same returns for a winery.
Wednesday, 26 September 12
Load Profile Comparison
• Significant difference in load profile throughout the year, which heavily influences
viability of energy savings projects. • The same investment in an abattoir/dairy/… might not result in the same returns for a winery. • Different opportunities need to be carefully assessed when planning investments in refrigeration plant(s).
Wednesday, 26 September 12
Load Profile Comparison
• Significant difference in load profile throughout the year, which heavily influences
viability of energy savings projects. • The same investment in an abattoir/dairy/… might not result in the same returns for a winery. • Different opportunities need to be carefully assessed when planning investments in refrigeration plant(s). • If site has base and peak load refrigeration plant, special consideration must be given as to how plants are operated throughout the year and where capital is spent Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis • Conclusions
Wednesday, 26 September 12
The modelling approach
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Step 2: Develop a site-‐specific load profile
Will depend on production
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Step 2: Develop a site-‐specific load profile
Will depend on production
Step 3: Prepare a computer model of existing and upgraded plants
Calculates the annual power consumption
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Step 2: Develop a site-‐specific load profile
Will depend on production
Step 3: Prepare a computer model of existing and upgraded plants
Calculates the annual power consumption
Step 4: Run the model with current load profile and current ambient
Difference between existing and upgraded plants = savings Compare results to current site power use = baseline
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Step 2: Develop a site-‐specific load profile
Will depend on production
Step 3: Prepare a computer model of existing and upgraded plants
Calculates the annual power consumption
Step 4: Run the model with current load profile and current ambient
Difference between existing and upgraded plants = savings Compare results to current site power use = baseline
Step 5: In future, run same models with new load profile and ambient
Difference between existing and upgraded plants = savings Compare results to future power use
Wednesday, 26 September 12
Modeling to find savings
Wednesday, 26 September 12
Modeling to find savings System Load Profile Ambient Conditions
•
Wednesday, 26 September 12
System Model • • • •
Plant control logic Equipment etails Needs to cdonsider: Temperature levels Upgrade concepts
Establish Annual Energy Consumption
• Existing plant – Energy usage
Modeling to find savings System Load Profile Ambient Conditions
•
System Model • • • •
Plant control logic Equipment etails Needs to cdonsider: Temperature levels Upgrade concepts
Establish Annual Energy Consumption
• Existing plant – Energy usage
Compare Predicted Savings after Implementation with Project Cost
Wednesday, 26 September 12
Modeling to find savings System Load Profile Ambient Conditions
•
System Model • • • •
Plant control logic Equipment etails Needs to cdonsider: Temperature levels Upgrade concepts
Establish Annual Energy Consumption
• Existing plant – Energy usage
Compare Predicted Savings after Implementation with Project Cost Payback / Internal Rate of Return Wednesday, 26 September 12
Examples – Project Savings Project
Compressor VSD’s and Optimised Compressor Staging
Condenser Fan VSD’s and Variable Head Pressure Control
Brine Pump VSD’s and Mixing Avoidance
Wednesday, 26 September 12
Abattoir
Energy Savings [% of refrigeration plant] 8.08
Dairy
11.07
Winery A
1
Winery B
2.74
Abattoir
5.92
Dairy
8.89
Winery A
8.15
Winery B
4.98
Winery A
6.18
Winery B
4.45
Site
Establishing Plant Load Profile
Wednesday, 26 September 12
Establishing Plant Load Profile Problems:
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of:
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant • Site and plant power meter data
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant • Site and plant power meter data • Wine production data (crush data, vintage periods …)
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant • Site and plant power meter data • Wine production data (crush data, vintage periods …) • Interviewing site personnel
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant • Site and plant power meter data • Wine production data (crush data, vintage periods …) • Interviewing site personnel
Wednesday, 26 September 12
Average Refrigeration Plant Load Profile
Establishing Plant Load Profile Year 1
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to: Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables Disease
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables Disease other…
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables Disease other…
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables Disease other…
Need to acknowledge that Energy/Cost Savings will vary from year to year.
Wednesday, 26 September 12
Year 2
Year 3
Content • Typical Refrigeration Energy Savings
Opportunities • Business Case Analysis • Why are wineries different? • Conclusions
Wednesday, 26 September 12
Conclusions
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not Analysis difficult for wineries due to unique load profile
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not Analysis difficult for wineries due to unique load profile Transfer of recommendations valid for other industries (dairy,
meat, cold storage) to wineries is not recommended
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not Analysis difficult for wineries due to unique load profile Transfer of recommendations valid for other industries (dairy,
meat, cold storage) to wineries is not recommended Achieved energy savings will inevitably vary from year to year
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not Analysis difficult for wineries due to unique load profile Transfer of recommendations valid for other industries (dairy,
meat, cold storage) to wineries is not recommended Achieved energy savings will inevitably vary from year to year Modeling yields best results, but not always those that you
would like to see.
Wednesday, 26 September 12
Ques%ons?
Wednesday, 26 September 12
Wednesday, 26 September 12
Content
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different?
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis • Conclusions
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis • Conclusions
Wednesday, 26 September 12
Common energy savings strategies Variable head pressure control Compressor speed and staging control High efficiency motors on compressors and pumps Liquid refrigerant (condensate) sub-‐cooling Variable speed control of glycol pumps Mixing avoidance in glycol system/tanks
Wednesday, 26 September 12
Variable head pressure control / condenser fan speed control
Wednesday, 26 September 12
Variable head pressure control / condenser fan speed control • Head pressure setpoint depending on load and
ambient conditions
VSDs on condensers Temperature/Humidity sensor Wednesday, 26 September 12
Variable head pressure control / condenser fan speed control • Head pressure setpoint depending on load and
ambient conditions • Significant savings at: • Cool Ambient Conditions • Part Load
VSDs on condensers Temperature/Humidity sensor Wednesday, 26 September 12
Compressor speed and staging control
Wednesday, 26 September 12
Compressor speed and staging control • Unloading via Speed Control rather than Slide
Valve
Wednesday, 26 September 12
Compressor speed and staging control • Unloading via Speed Control rather than Slide
Valve • VSD’s on Compressors
Wednesday, 26 September 12
Compressor speed and staging control • Unloading via Speed Control rather than Slide
Valve • VSD’s on Compressors • Appropriate Control Logic
Wednesday, 26 September 12
Economisers on Screw compressors
Wednesday, 26 September 12
Economisers on Screw compressors • Sub-‐cooling receiver liquid
Economiser vessel Eco port connection Wednesday, 26 September 12
Economisers on Screw compressors • Sub-‐cooling receiver liquid • Improved efficiency (5-‐10%)
Economiser vessel Eco port connection Wednesday, 26 September 12
Economisers on Screw compressors • Sub-‐cooling receiver liquid • Improved efficiency (5-‐10%) • Increase in compressor capacity (3-‐8%)
Economiser vessel Eco port connection Wednesday, 26 September 12
Economisers on Screw compressors • Sub-‐cooling receiver liquid • Improved efficiency (5-‐10%) • Increase in compressor capacity (3-‐8%) • Needs VSD on compressor
Economiser vessel Eco port connection Wednesday, 26 September 12
High efficiency motors
Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
OLD Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
• Modern motors >95% efficient
NEW
OLD Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
• Modern motors >95% efficient • Savings up to 10% possible
NEW
OLD Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
• Modern motors >95% efficient • Savings up to 10% possible • 2-‐3% loss with every re-‐wind!!
NEW
OLD Wednesday, 26 September 12
High efficiency motors • Older motors (pre 1990) generally low efficiency
• Modern motors >95% efficient • Savings up to 10% possible • 2-‐3% loss with every re-‐wind!! • Match with VSD NEW
OLD Wednesday, 26 September 12
Review of Mixing Arrangement • VSD’s on both primary and secondary brine pumps • Review of tank / brine circuits / control logic
Serves a double purpose:
Reduce pump motor power consumption Increase of compressor suction temperature
Wednesday, 26 September 12
Review of Mixing Arrangement • VSD’s on both primary and secondary brine pumps • Review of tank / brine circuits / control logic
Serves a double purpose:
Reduce pump motor power consumption Increase of compressor suction temperature
Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis • Conclusions
Wednesday, 26 September 12
Load Profile of Food Manufacturer
Wednesday, 26 September 12
Load Profile of Food Manufacturer
Wednesday, 26 September 12
Load Profile of Food Manufacturer • Represents monitored
hourly load profile for 1 week
Wednesday, 26 September 12
Load Profile of Food Manufacturer • Represents monitored
hourly load profile for 1 week • Refrigeration Plant load is dominated by production variations
Wednesday, 26 September 12
Load Profile of Food Manufacturer • Represents monitored
hourly load profile for 1 week • Refrigeration Plant load is dominated by production variations • Weekend operation clearly distinctive from weekdays
Wednesday, 26 September 12
Load Profile of Food Manufacturer • Represents monitored
hourly load profile for 1 week • Refrigeration Plant load is dominated by production variations • Weekend operation clearly distinctive from weekdays As far as production stays constant throughout year, load profile will not vary much throughout the year. (Will be slightly elevated during summer.)
Wednesday, 26 September 12
Load Profile of Dairy
Wednesday, 26 September 12
Load Profile of Dairy 2 Weeks profile shows no distinct weekday/weekend operation
Wednesday, 26 September 12
Load Profile of Dairy 2 Weeks profile shows no distinct weekday/weekend operation
Wednesday, 26 September 12
Load Profile of Dairy 2 Weeks profile shows no distinct weekday/weekend operation Annual load profile influenced by varying production and heat infiltration
Wednesday, 26 September 12
Load Profile of Winery
Wednesday, 26 September 12
Load Profile of Winery • Distinctive peak
coinciding with vintage period and summer conditions
Wednesday, 26 September 12
Load Profile of Winery • Distinctive peak
coinciding with vintage period and summer conditions • Refrigeration plant at significant part load for long periods of the year
Wednesday, 26 September 12
Load Profile of Winery • Distinctive peak
coinciding with vintage period and summer conditions • Refrigeration plant at significant part load for long periods of the year • Profile dependent on vintage period, fermenting, cold stabilisation, weather conditions …
Wednesday, 26 September 12
Load Profile of Winery • Distinctive peak
coinciding with vintage period and summer conditions • Refrigeration plant at significant part load for long periods of the year • Profile dependent on vintage period, fermenting, cold stabilisation, weather conditions … • Possibility of having base load and peak load refrigeration plants
Wednesday, 26 September 12
Load Profile Comparison
Wednesday, 26 September 12
Load Profile Comparison
• Significant difference in load profile throughout the year, which heavily influences
viability of energy savings projects.
Wednesday, 26 September 12
Load Profile Comparison
• Significant difference in load profile throughout the year, which heavily influences
viability of energy savings projects. • The same investment in an abattoir/dairy/… might not result in the same returns for a winery.
Wednesday, 26 September 12
Load Profile Comparison
• Significant difference in load profile throughout the year, which heavily influences
viability of energy savings projects. • The same investment in an abattoir/dairy/… might not result in the same returns for a winery. • Different opportunities need to be carefully assessed when planning investments in refrigeration plant(s).
Wednesday, 26 September 12
Load Profile Comparison
• Significant difference in load profile throughout the year, which heavily influences
viability of energy savings projects. • The same investment in an abattoir/dairy/… might not result in the same returns for a winery. • Different opportunities need to be carefully assessed when planning investments in refrigeration plant(s). • If site has base and peak load refrigeration plant, special consideration must be given as to how plants are operated throughout the year and where capital is spent Wednesday, 26 September 12
Content • Typical Refrigeration Energy Savings
Opportunities • Why are wineries different? • Business Case Analysis • Conclusions
Wednesday, 26 September 12
The modelling approach
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Step 2: Develop a site-‐specific load profile
Will depend on production
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Step 2: Develop a site-‐specific load profile
Will depend on production
Step 3: Prepare a computer model of existing and upgraded plants
Calculates the annual power consumption
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Step 2: Develop a site-‐specific load profile
Will depend on production
Step 3: Prepare a computer model of existing and upgraded plants
Calculates the annual power consumption
Step 4: Run the model with current load profile and current ambient
Difference between existing and upgraded plants = savings Compare results to current site power use = baseline
Wednesday, 26 September 12
The modelling approach Step 1: Understand the current plant operation
Monitor plant operation Understand daily/weekly/annual site processes Understand plant control logic
Step 2: Develop a site-‐specific load profile
Will depend on production
Step 3: Prepare a computer model of existing and upgraded plants
Calculates the annual power consumption
Step 4: Run the model with current load profile and current ambient
Difference between existing and upgraded plants = savings Compare results to current site power use = baseline
Step 5: In future, run same models with new load profile and ambient
Difference between existing and upgraded plants = savings Compare results to future power use
Wednesday, 26 September 12
Modeling to find savings
Wednesday, 26 September 12
Modeling to find savings System Load Profile Ambient Conditions
•
Wednesday, 26 September 12
System Model • • • •
Plant control logic Equipment etails Needs to cdonsider: Temperature levels Upgrade concepts
Establish Annual Energy Consumption
• Existing plant – Energy usage
Modeling to find savings System Load Profile Ambient Conditions
•
System Model • • • •
Plant control logic Equipment etails Needs to cdonsider: Temperature levels Upgrade concepts
Establish Annual Energy Consumption
• Existing plant – Energy usage
Compare Predicted Savings after Implementation with Project Cost
Wednesday, 26 September 12
Modeling to find savings System Load Profile Ambient Conditions
•
System Model • • • •
Plant control logic Equipment etails Needs to cdonsider: Temperature levels Upgrade concepts
Establish Annual Energy Consumption
• Existing plant – Energy usage
Compare Predicted Savings after Implementation with Project Cost Payback / Internal Rate of Return Wednesday, 26 September 12
Examples – Project Savings Project
Compressor VSD’s and Optimised Compressor Staging
Condenser Fan VSD’s and Variable Head Pressure Control
Brine Pump VSD’s and Mixing Avoidance
Wednesday, 26 September 12
Abattoir
Energy Savings [% of refrigeration plant] 8.08
Dairy
11.07
Winery A
1
Winery B
2.74
Abattoir
5.92
Dairy
8.89
Winery A
8.15
Winery B
4.98
Winery A
6.18
Winery B
4.45
Site
Establishing Plant Load Profile
Wednesday, 26 September 12
Establishing Plant Load Profile Problems:
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of:
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant • Site and plant power meter data
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant • Site and plant power meter data • Wine production data (crush data, vintage periods …)
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant • Site and plant power meter data • Wine production data (crush data, vintage periods …) • Interviewing site personnel
Wednesday, 26 September 12
Establishing Plant Load Profile Problems: • Plant operational data usually only available for a limited time period • Although required to understand plant performance / equipment condition / control logic / …
Does not provide information on load conditions throughout the rest of the year!
Specific to each winery, load profile can be established through a combination of: • Obtaining operational data of refrigeration plant • Site and plant power meter data • Wine production data (crush data, vintage periods …) • Interviewing site personnel
Wednesday, 26 September 12
Average Refrigeration Plant Load Profile
Establishing Plant Load Profile Year 1
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to: Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables Disease
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables Disease other…
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables Disease other…
Year 2
Year 3
Wednesday, 26 September 12
Establishing Plant Load Profile Getting profile exactly right is very hard, but also not essential.
Year 1
Profile varies from year to year anyway, due to:
Varying climatic variables Disease other…
Need to acknowledge that Energy/Cost Savings will vary from year to year.
Wednesday, 26 September 12
Year 2
Year 3
Content • Typical Refrigeration Energy Savings
Opportunities • Business Case Analysis • Why are wineries different? • Conclusions
Wednesday, 26 September 12
Conclusions
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not Analysis difficult for wineries due to unique load profile
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not Analysis difficult for wineries due to unique load profile Transfer of recommendations valid for other industries (dairy,
meat, cold storage) to wineries is not recommended
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not Analysis difficult for wineries due to unique load profile Transfer of recommendations valid for other industries (dairy,
meat, cold storage) to wineries is not recommended Achieved energy savings will inevitably vary from year to year
Wednesday, 26 September 12
Conclusions Many different energy savings opportunities available Some are viable for wineries, some are not Analysis difficult for wineries due to unique load profile Transfer of recommendations valid for other industries (dairy,
meat, cold storage) to wineries is not recommended Achieved energy savings will inevitably vary from year to year Modeling yields best results, but not always those that you
would like to see.
Wednesday, 26 September 12
Ques%ons?
Wednesday, 26 September 12
