Retired

1

• Retired
• Engineer
• Technical
• Assistance
• Program
• Richard W. Savage
• Executive Director, RETAF
• March 18, 2009

2
RETAPer Skills

• Energy Management (and energy efficiency
  opportunities)
• Waste Recycling
• Automotive Systems
• Metal cutting, forming, plating
• Plastics (blow molding, injection molding,
  extrusion)
• Tool Die Manufacturing
• Water and Waste Treatment
• Boilers
• Industrial Ventilation
• Agricultural and Food Processes
• Lighting Systems
• HVAC
• Lubricants, Fluids
• Paint Systems
• Organic Inorganic Chemical Manufacturing
• Environmental, Safety Health
• Technical Writing

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Assessment Process

• Assessment Checklist
• Receive/Analyze Utility and Waste Bills
• Research Company and P2 Opportunities (website,
  similar assessments)
• Facility Tour
• Walkthrough with company host or team
• Observe processes, waste streams, practices
• Top to bottom, inside out
• Document observations
• Preliminary set of recommendations at exit
  meeting
• Assessment team consolidates notes into draft
  report
• Editing into Final Report
• Company-specific status and recommendations
• Many relevant resources and attachments
• Follow-up at 8 weeks, 12 months, 24 months
• Follow-up Technical Assistance
• Implementation Status
• Quantification of Results

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Typical Recommendations

• Expand scope of Safety (Hazardous Waste, etc.)
  Committee to include P2
• Educate employees on sources of wastes
• Improve methods to keep recyclables from getting
  into general trash
• Evaluate waste handling procedures
• Develop a Green Purchasing program
• Provide secondary containment for all chemicals,
  flammable and hazardous materials
• Energy-conserving practices for office equipment
• Lighting efficiency improvements

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More Typical Recommendations

• Heating and Cooling Upgrades
• Insulation on water heaters, steam hot water
  piping, valves, fittings
• Hot water temperature setting (lt110 F)
• 7-day programmable thermostats
• Make-up air and exhaust fan controls
• Compressed Air Systems
• Leak detection repair program
• Lowest possible pressure
• Steam traps for condensate purge
• Lower intake air temperature to compressors
• Utilize waste heat from air compressors
• Utilize synthetic lubricants in air compressors
• Water-conserving devices

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Interesting Recommendations

• Evaluate potential markets, such as local
  farmers, who may accept food waste at no cost
• Donate used equipment to World Relief or other
  humanitarian organization
• Periodically review sources for removal of
  chemicals and other wastes to ensure that
  competitive rates are being paid
• Establish partnerships with nearby schools,
  government facilities, and/or businesses to
  combine recycling efforts

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Sample Recommendation

• Found
• Only cardboard recycled, but with no revenue
• Recommend
• Expand recycling to include non-confidential
  office paper, plastic, glass, metal, and foamed
  containers
• Purchase a baler for cardboard
• Potential Result
• 20 of waste stream (280,000 lbs/year) could
  potentially be recycled
• Generate revenue of gt7,000/year from baled
  cardboard

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Sample Recommendation

• Found
• Power factor was high but could be improved
• Demand charges too high

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Sample Recommendation

• Recommend
• Identify meters with low power factor (PF) and
  add capacitors or replace
• Examine power suppliers demand profile chart and
  determine time and cause of high demand.
• Correct by
• Starting motors at staggered intervals or
• Add soft start equipment to machinery
• Potential result
• Reduction in energy costs (PF credit of 16,000)
  and pollution from generating power

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Sample Recommendation

• Found
• Lighting included T12 fluorescent and metal
  halide (MH) fixtures
• High wattage (95 watt) T8 fixtures
• 3- and 4-lamp fixtures (T12 T8)

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Sample Recommendation

• Recommend
• Conduct lighting intensity audit
• Replace T12 with T8 lamps and electronic ballasts
• Reduce number of lamps in fixtures
• Replace MH with T8 fluorescent
• Potential Result
• 350,000 kWh/year reduction
• 32,000/year savings
• Immediate to less than 2 years payback

12
Sample Recommendation

• Found
• No leak detection or repair program for
  compressed air system
• Compressed air system operating pressure much
  higher than needed for pneumatic equipment
• Inside air used as make-up for compressors
• Waste heat from compressors vented outside

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Sample Recommendation

• Recommend
• Institute regular leak detection and repair
  program
• Reduce operating pressure to minimum required
• Lower compressor intake air temperature by
  supplying outside air
• Vent warm exhaust air outside in summer and
  inside during heating season

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Sample Recommendation

• Potential Result
• Reduce leaks by 10
• 72,000 kWh/year reduction
• 6,340/year savings
• Reduce operating pressure by 20 psi
• 72,000 kWh/year reduction
• 6,340/year savings
• 3 efficiency increase
• 29,600 kWh
• 1,900/year savings
• Reduced heating costs
• 5,970 CCF
• 5,200/year savings

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Assessment Distribution