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Industrial Newsbriefs

September 2012

Welcome to this edition of Industrial Newsbriefs, produced by the Washington State University Extension Energy Program, and sponsored by the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy (EERE). Please forward this issue to those of your colleagues interested in industrial energy efficiency. View archive 

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Announcements

ASERTTI Fall Meeting: Transformative Innovations in Energy Efficiency and Clean Energy Generation

The fall meeting of ASERTTI, the Association of State Energy Research & Technology Transfer Institutions, will take place in Seattle on October 10-12, 2012. This year’s meeting brings together ASERTTI members, private sector energy technology leaders, national energy research experts, and others to discuss energy innovation, investment, and deployment. State and private research and technology transfer institutions are changing the way we create, deliver, and use energy, and ASERTTI’s Fall Meeting offers a one-of-a-kind venue to access experts in the fields of energy storage, advanced manufacturing, bioenergy, building technology, and combined heat and power. Hosted by the Washington State University Energy Program and the Pacific Northwest National Laboratory, this event includes visits to Microsoft and Boeing, and is open to ASERTII members. If you would like to learn more about becoming an ASERTTI member, please contact Christine Love at 360-956-2172 or lovec@energy.wsu.edu.

Made in Washington Program launched

In August 2012, Impact Washington launched the Made in Washington Program. The program showcases locally made products, and highlights to the public the many contributions of the Washington State manufacturing community. Joining the program is free for manufacturers; benefits include a company directory profile, use of the Made in Washington logo, and an opportunity to become a Featured Manufacturer of the Week on the Impact Washington website and social media sites.

Biofuels/Biomass

Harbor Paper acquires biomass turbines from Grays Harbor PUD

On August 6, 2012, Grays Harbor PUD completed the sale of three biomass turbines and a substation to Harbor Paper LLC. The mill, closed since March 2011, originally leased the equipment from the Grays Harbor PUD after it was acquired as part of a state-assisted local jobs initiative in 2006. The mill will soon reopen under new ownership. For details, see "Grays Harbor PUD Announces Sale of Renewable Generation Assets to Harbor Paper," posted August 6, 2012, at KBKW News.

Compressed Air

Compressed Air Best Practices

The August 2012 edition of Compressed Air Best Practices is now available for download; this issue’s focus is Compressed Air Automation. Article topics include centralized compressor controls, "Value in Valves," and three examples of well-functioning compressed air control systems.

Energy Management

New mill equipment equals big energy savings at NORPAC

NORPAC, a large paper manufacturer in Longview, Washington, recently completed an innovative, state-of-the art energy efficiency upgrade expected to save 100 million KW of energy a year (enough to power 8,000 Northwest homes). The system incorporates two processes: the pretreatment of wood chips with steam and chemicals to make them easier to process into pulp, and the screening out of wood fibers fine enough to bypass the second stage of refining. Along with the enormous energy savings, the mill can now produce a brighter and whiter paper made from less wood chips than a similar grade from their competitors. For more information, see "Going Big: Building the Largest Ever Energy Efficiency Project," published August 30, 2012, on the U.S. Department of Energy website.

HVAC/R (Heating, Ventilation, Air Conditioning, and Refrigeration)

Cost comparison tool for boiler fuels

"New Tool Allows Cost Comparisons of Pellets, Natural Gas and Heating Oil," by Anna Simet, appeared in a July 6, 2012 post on the Biomass Magazine blog. This life-cycle cost analysis dashboard was developed by FutureMetrics Inc. and is free to download.

Motors

A call for better motor efficiency standards

The National Electrical Manufacturers the American (NEMA), in conjunction with the American Council for an Energy-Efficient Economy (ACEEE), Northwest Energy Efficiency Alliance (NEEA), and others, are calling for more robust standards for the energy efficiency of pumps, conveyors, fans, and other motors used in industrial and commercial applications. The new standards would increase the efficiency level of currently covered motors, and would also incorporate more motors into the standards system, thus greatly reducing exemptions. If enacted and enforced, the new standards could save 4.4 quadrillion Btus of energy by 2044. For information, see the August 15, 2012, press release.

Policy and Legislation

Public-private partnership for manufacturing innovation

On August 16, 2012, the Obama administration announced funding for a pilot institute of the National Network of Manufacturing Innovation. The institute will provide infrastructure, support, education, and tools for the development and adoption of additive manufacturing, also known as 3D printing. Sponsors of the program include the U.S. Department of Energy, Department of Defense, Department of Commerce, the National Science Foundation, and NASA. For information, see the EERE News press release, or read about additive manufacturing on Energy.gov.

Washington State Green Chemistry Roadmap

A collaborative report by the Washington State Department of Ecology and the Washington State Department of Commerce, A Roadmap for Advancing Green Chemistry in Washington State, was released in draft form in August 2012. The document recommends actions Washington State should undertake over the next five years to advance and sustain green chemistry in Washington. Green chemistry is the design of chemical products and processes that reduce or eliminate the use and generation of hazardous substances. Comments will be accepted until September 30, 2012.

Boiler MACT rule and energy efficiency

"Output Based Standards and Conservation Credits can Help Manufacturers Comply with Boiler MACT," published August 29, 2012 on the Alliance to Save Energy website, explains how energy efficiency measures can be utilized to attain compliance with the EPA Boiler MACT rule. Along with specific provisions such as boiler tune-ups, the rule allows for the use of Output-Based Standards (OBS), an option which rewards efficiency approaches such as CHP and waste heat recovery.

Executive order on industrial energy efficiency

On August 30, 2012, president Obama signed an executive order to accelerate investments in industrial energy efficiency. The order comprises a goal of 40 GW of new CHP installations over the next 10 years; the organization of regional workshops to encourage policies and investment models that promote industrial energy efficiency by increasing investment potential; and a multi-agency coordination to provide policy and technical assistance to states. To learn more, read the DOE press release.

Pumps

Pumping system analysis pays off

"Unlock Opportunities to Improve Oversized Pump Efficiency," by Tony Simon, Washington State University Energy Program, illustrates first-hand the importance of careful examination, analysis, and measurement when identifying energy efficiency opportunities in pumping systems. Simon walks the reader through pumping system assessments at two pulp and paper mills, both of which had oversized pumps. A careful analysis of each system revealed different but equally effective opportunities for efficiency improvements. This article was published in the August 2012 issue of Pumps & Systems.

Vintage pump upgrade

"Upgrades Maximize Efficiency of 82-Year-Old Refinery Pump," published in the August 2012 issue of Pumps & Systems, explains the steps taken to upgrade an Indiana BP refinery pump built in 1928. A redesign and modifications to the shaft, bearings, and other components improved performance to the point where one pump’s increased efficiency could eliminate the need for three unmodified pumps.

A primer on pumps for the wine industry

A primer on the types of pumps used in the wine industry appeared in the July 2012 issue of Pumps & Systems. "Wine Industry Pumps," written by Keith Evans of Xylem, Inc., describes the advantages and disadvantages of four pump types, and advises the wine maker to choose a pump with the greatest versatility for a given application.

Resources

Industrial Efficiency Technology Database

A new database of industrial energy efficiency technologies, the Industrial Efficiency Technology Database (IETD), was released by the Institute for Industrial Productivity (IIP) on July 30, 2012. This interactive database includes information on technologies and resources, benchmarks, key data, organizations and programs, and energy management systems for the cement, iron and steel, and electric motor-driven systems markets.

Thermal Technologies

The following five articles appeared in the July 2012 issue of Industrial Heating:

"Energy vs. Safety – Trade-offs and Risks" was written by Richard J. Martin. The complexity of industrial processes requires special caution when adding energy efficiencies into the mix. The author shows how, in five instances, introducing energy efficiency and maintaining safety can be a challenge.

"Heating," by Daniel H. Herring, President of the Herring Group Inc., explains what is involved with heating in the context of industrial processing. He focuses on loading parts into the furnace and on critical temperatures for heating or cooling them. He includes a short section on some of the effects of alloying elements on steel during heat treatment.

"How to Reduce Energy Requirements for Efficient Vacuum-Furnace Operation" was co-authored by Nicholas R. Cordisco and Reàl J. Fradette, both of Solar Manufacturing. The author suggests ways to increase energy efficiencies in vacuum furnace hot-zones, variable-frequency drives, and more.

"Revolutionary Backup for Molten-Metal Processes" was jointly written by Brian Bradley, Unifrax I, LLC; Niagara Falls, N.Y., and by Luiz Carlos Simao, Unifrax Brazil, Sao Paulo. The backup lining in a steel transfer-ladle refractory is a Unifrax product, an insulating board that lines the safety lining which, in turn, lines the working lining. The system is thought to enable high temperatures with reduced thermal losses from conduction.

"Standard Temperature and Pressure," by Art Morris, Thermart Software, tackles the problem of figuring out the STP (standard temperature and pressure) for a gas to be combusted in situations where calculations for heating values must be made.

UPCOMING EVENTS AND TRAININGS

Note: Trainings and webinars from the NEEA calendar now link to the main NEEA calendar page. To see full description and register, search for the title and/or navigate to the appropriate date.

Pacific Northwest

Fan Systems Assessment Tool (FSAT)
September 20, 2012
Developed to highlight the benefits of fan system optimization, this training discusses performance and practical issues, as well as introduces the Fan System Assessment Tool (FSAT). You will learn how the software functions, what data is required, what to do when measured data is not available, and how to interpret the assessment results. After completing this course, you will understand how to use FSAT to actively determine the best configuration for your fan system in order to achieve optimal energy and cost savings. This course is coordinated by the NEEA Industrial Training project and is sponsored by Avista, Inland Power and Light, Bonneville Power Administration, Washington State University Energy Program, and Northwest Food Processors Association.

PGE Series: Motors and Motor Controls
September 19 – November 7, 2012, Wednesdays, 6:00-9:00 PM, Tualatin, Oregon
In this in-depth course, you’ll learn about motor fundamentals, electrical codes, starting, braking, speed control, variable frequency drives, over current protection, overload protection, motor controls and drive system efficiency. Attendees may be eligible to earn up to 21 Continuing Education Units (CEUs) for their Oregon or Washington electrical license, professional development credit hours, and will receive a certificate of completion.

PGE Series: Power Quality 1-Day Course
September 28, 2012
This one-day Power Quality (PQ) course provides practical information that you can apply to prevent and solve power quality and reliability problems. With over 20 years of experience, the instructor will help you; learn how to eliminate costly downtime due to power quality and grounding issues, and avoid problems through proper specification and purchase of equipment. The information provided will help you avoid equipment damage and improve productivity. Attendees are eligible to earn 8 hours of Continuing Education Units (CEUs) for their Oregon or Washington electrical license renewal. Also qualifies for State of Washington Basic Classroom Credits for Trainees. PGE Special Sponsored Rate: $250 per person, valued at $399.

Adjustable Speed Drive Applications and Energy Efficiency
October 4: Roseburg, OR
November 15: Yakima, WA
This course addresses the choices available and relevant issues regarding the use of adjustable speed drives (ASD) with electric motors, and demonstrates the energy cost savings and other benefits made possible by this technology. In this course we explore how adjustable speed drives work and ways to assess the savings. Variable frequency drives (VFD) are the most common speed control method and is the major focus of the course content which will cover the benefits of pulse width modulation technology and well as discovering and mitigating harmful electromagnetic interference that can cause motor failure. This course is coordinated by the NEEA Industrial Training project.

ASERTTI Fall Meeting: Transformative Innovations in Energy Efficiency and Clean Energy Generation
October 10-12, Seattle, Washington
This year’s Fall Meeting brings together ASERTTI (Association of State Energy Research & Technology Transfer Institutions) members, private sector energy technology leaders, national energy research experts, and others to discuss energy innovation, investment, and deployment. State and private research and technology transfer institutions are changing the way we create, deliver, and use energy, and ASERTTI’s Fall meeting offers a one-of-a-kind venue to access experts in the fields of energy storage, advanced manufacturing, bioenergy, building technology, and combined heat and power. This event is sponsored by the Washington State University Energy Program.

Innovation Engineering Leadership Institute
October 15-17, 2012, Blaine, Washington
This 2 ½ day training, hosted by Impact Washington, is an excellent opportunity for you to learn various innovation tools that will help your organization create, communicate and commercialize new ideas. NIST MEP is focused on increasing manufacturers’ capacity for innovation and ultimately helping them achieve more profitable sales growth.

Industrial Refrigeration Systems Energy Management
October 23: Hermiston, OR
October 24, 2012, Caldwell, Idaho
With a focus on industrial refrigeration systems that use ammonia as the refrigerant, this training will equip attendees with the knowledge and tools to reduce energy usage and operating costs, and improve the reliability of refrigeration systems. With the knowledge and tools gained, past attendees and their customers have implemented low/no cost strategies resulting in annual energy savings greater than $50,000.

PGE Series: Compressed Air Systems
November 11, 2012, Wilsonville, Oregon
This free half-day seminar provides an overview of how compressed air systems work and practical advice about making the most of your compressed air system investment. Compressed air systems can be one of the largest energy consumers in your facility. Learn how to start saving energy and money today.

Webinars and Online Courses

Webinar: Variable Speed Drives Make "Cents"
September 11, 2012, 10:00 AM – 10:30 AM PST
The free webinar by Pump Systems Matter is an introduction to Variable Speed Drives covering common applications and when not to use a Variable Speed Drive.

PGE WEBINAR: What is Power Quality and Why it’s Important
September 12, 2012, 8:00 AM-9:00 AM
This 1.5 hour webinar will introduce you to some of the basic fundamentals of Power Quality, and the steps your organization can take to avoid and/or correct Power Quality Issues. The presenter, Gary P. Larkins with Advanced Power Solutions, has over 20 year of experience in power quality consulting, failure analysis and commissioning.

Variable Speed Drives 4-Part Webinar Series Package
September 20, September 27, October 11, and October 18
10:00 AM - 11:00 AM PST
This 4-part series from Pump Systems Matter will cover Variable Speed Drives in pump systems and how they can generate large benefits to the user in cost savings and reliability improvements. The series will also cover how VSDs can be used to accommodate varying operating conditions, reduce and/or optimize system components, reach optimal energy savings and life cycle cost reduction, convert single-phase power to three-phase power, and reduce inrush current at start up. Register by September 7, 2012 and receive a promo code with your registration email for $5.00 off the webinar companion Variable Speed Pumping Guidebook.

Energy Management Opportunities for Industrial Customers
September 25, 8:00-9:00 AM PST
This webinar on industrial energy efficiency will cover the basics, including kW versus kWh, power factor, and more. We will also discuss end-use technologies such as motors, boiler or furnace heating systems, compressed air, industrial heat pumps, induction heating, and HVAC. You will learn to identify top energy-efficiency opportunities and potential savings for each; valuable information that will help you stay within your energy budget.

Webinar: Adjustable Speed Drives
October 4, 2012, 10:00-11:00 AM PST
In the right applications, adjustable speed drives (ASDs) offer great energy-saving potential from high power factor to improved speed control, soft-start capabilities, and more. This webinar will discuss how they work, the savings potential, best applications, sizing, and how to solve variable frequency drive (VFD) power-quality issues.

Webinar: Introduction to Compressed Air Systems
October 24, 2012: 8:00-9:00 AM PST and 12:00-1:00 PM PST
 At this introduction webinar you will learn highlights from our four-hour seminar of how compressed air systems work and practical advice about making the most of your compressed air system investment. The four-hour seminar on this subject is scheduled November 11 in Wilsonville.

Webinar: Energy Auditing and Troubleshooting
November 6, 2012, 1:00-2:00 PM
This webinar will show you how to estimate energy consumption by end use without the need for submetering. We will focus on refrigeration, compressed air end uses, HVAC, lighting, and office equipment. In addition, you will receive audit checklists for energy conservation. Several third-party auditing tools will also be reviewed.

MORE TRAININGS IN INDUSTRIAL ENERGY EFFICIENCY

For a listing of other upcoming industrial energy efficiency trainings, visit the following websites:

Energy Events Calendar

Northwest Regional Training Calendar

U.S. Department of Energy Industrial Best Practices Training Calendar

Input Requested: Is there something else you would like to see in Industrial Newsbriefs?

If you have thoughts or ideas for what you would like to see in this publication, please email suggestions to Talia Mathews at MathewsT@energy.wsu.edu . We strive to keep this publication as useful and relevant as possible to you, our readers.


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