Best practices in Energy Efficiency

This round recognizes outstanding applications in Energy Efficiency.

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The Plant Services Best Practices Awards recognize management techniques, work processes, and product and service implementations that exemplify the definition of a Best Practice according to the Society of Maintenance and Reliability Professionals (SMRP): “A process, technique or innovative use of resources that has a proven record of success in providing significant improvement in cost, schedule, quality, performance, safety, environment or other measurable factors that impact the health of an organization.”

Plant Services Best Practices Awards

Entries must demonstrate how to implement a best practice, show the potential payoffs in both qualitative and quantitative terms, and provide inspiration for those who must overcome cultural inertia and make effective changes. Entries may be submitted by plant personnel, vendors, engineering firms, consultants or anyone familiar with the application and has permission to make it public knowledge. Our categories also include Equipment, Reliability and Management, but this round’s focus is on Energy Efficiency.

Every contender offered an impressive practice that increases energy efficiency, reduces energy consumption, decreases energy costs or improves energy supply sustainability. Judging criteria included percentage reductions or cost savings, return on investment and broadness of applicability, with recognition given for innovation and creativity.

The winning practice was submitted by Mark Kopera, energy services manager, and Christine Charter, associate, commodity management, at Pratt & Whitney, Middletown, Conn. They will receive $1,500 and a donation of $5,000 will be made to the charity or scholarship fund of their choice, courtesy of Atlas Copco.

“I liked the Pratt & Whitney entry because it tackles both demand efficiency and fuel efficiency, greatly reduces site greenhouse gases, and avoids grid losses,” says Peter Garforth, contributing editor and principal of energy productivity consulting company Garforth International. “The return calculations suggest that management understands the risk-adjusted long-term benefits of investments like these and isn’t just looking for one-year payback windfalls. And it shows a company putting its money where its mouth is by using its own products for its own benefit rather than just trying to get its customers to do it.”

Working together, Carrier and Pratt & Whitney have demonstrated a powerful cogeneration model that benefits the company, the environment and the community at large.

More information about the Plant Services Best Practices Awards can be found at www.PlantServices.com/bestpractices. Along with your entries, we are actively seeking sponsors for other award categories. For more information, contact Editor in Chief Paul Studebaker at pstudebaker@putman.net.

Contenders

Reconfiguration Reduces RTO Consumption
Central Motor Wheel of America reduced the energy consumption of its paint line emission controls by reconfiguring its regenerative thermal oxidizer (RTO) systems to idle the least efficient RTO and more fully load its more efficient RTOs. Natural gas consumption was reduced by 80% (7.25 million Btu/h). Projected annual savings is $427,000. ROI was less than 12 months.
Dürr Systems Inc. (www.durr.com)

Steam Generators Recover Oven Heat
Frito-Lay added roof-mounted heat recovery units to its corn chip toasting ovens, producing steam for process heating. ROI was 18 months.
Clayton Industries (www.claytonindustries.com)

Systemic Analysis Identifies Energy Opportunities
GlaxoSmithKline’s Cidra, Puerto Rico pharmaceutical plant used value stream mapping and interrelationship analysis to identify and prioritize 17 undesirable effects that affect energy consumption. From 2007 to 2008, energy consumption was cut 34% without capital investment, with a further 25% reduction coming for 2009.
GlaxoSmithKline (www.gsk.com)

Controller Cuts Compressor Energy Costs
Lacks Enterprises, an automotive supplier painting facility in Grand Rapids, Mich., performed a compressed air energy audit using a purpose-designed datalogger to evaluate overall efficiency and indicate potential improvements based on CAGI compressor ratings. Based on audit results, Lacks installed a controller that raised efficiency from 25.8 KW/100 CFM to 17.88 KW/100 CFM. Payback was less than 7 months.
Airleader (www.airleader.us)

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