6/17/2015

1

Innovation in Customized Energy

Programs for Business

John R. Buckley, Plant Engineer

The Siemon Company – Watertown, CT

Facilities Background

Company Location Position Experience

(Years)

Ensign-Bickford Simsbury Plant Engineer 8

OFS Specialty Fiber

Optics

Avon Facilities

Manager

8

Holy Family Monastery

& Retreat Center

West

Hartford

Director of

Physical Plant

5

The Siemon Company Watertown Plant Engineer 3+

6/17/2015

2

Perspective on CT Energy Programs

• The Eversource Account Executives have been outstanding

• Eversource’s annual large customer meetings have always

been well done

• Qualified vendors and suppliers access to program funding is

straight forward

• Help is always available

• Keeping it real makes it happen easier - relationships

• I have been fortunate to work for places who are onboard with

reducing energy & costs

Lessons Learned

• Energy Measurement & Monitoring

• Management of Change # 1

– Talking to the stakeholders

– Establishing a sense of urgency

– Everyone on the team

• Detailed Planning

• Contact Eversource – Account Exec

• Engage qualified vendors

• Manage the project

• Close out with Eversource

• Monitor performance

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Project List Summary

• Lighting

– 150 Watt “Jelly Jars” to 30 Watt HPS

– Fluorescent – T12 to T8

– Lighting – Compact Fluorescent Ceiling “Cans”

– Lighting Control – Occupancy Sensors

• Variable Frequency Drives (VFD)

– Air Compressors

– Pumps

Project List Summary

• Compressed Air

– Higher Efficiency Air Compressors

– Compressor Consolidation

– Compressed Air Monitoring

– Compressed Air Control Valves

• Building Automation System (BAS)

• Old Fashioned Checklists to turn off energy wasters

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4

BUILDING AUTOMATION SYSTEM

(BAS)

Depot

Mall Dynamic Manufacturing

The Siemon Companies – Campus

Watertown, CT

Assembly

Manufacturing

& Offices

Princeton

Building -

West

Princeton

Building -

East

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5

Assembly Building Floor Plan

FIRST

FLOOR

RTU 01

RTU 04

RTU 07

RTU 08

RTU 09

CU 11

SECOND

FLOOR

RTU 02

RTU 03

RTU 05

RTU 06

RTU 10

CU 12

CU 14

Typical Roof Top Unit (RTU)

RA = Return Air

(from space) SA = Supply Air

(to space)

OA = Outside

Air

Heating Unit

Cooling Coil

Supply

Air Fan

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6

Dynamic Building – Process Cooling and

EDM Chilled Water System

Main Thrust (March 2014)

• NO COST – LOW COST Tactical Actions – NOW!

• If we turn off unnecessary systems and equipment, we don’t

have to pay for the energy they use

• But . . . Things are left on which equals a base load that we

want to reduce or eliminate

• We want to “zero base” the base load

– What is on?

– Why is it on?

– Can it be turned off without harming the process?

• Requires communication and cooperation

6/17/2015

7

WEEKEND – March 2014

• Turn off more items during the weekends

– Manually

– Automatically

• Install Building Automation System (BAS)

• Wring out waste with BAS – ASAP

A weekend is 29% of a week – how many things

can we shut off during the weekend?

The BAS Made Me Do It

• Once BAS on line – looked at HVAC & Pump Status

• Asked self why things were on or off & when

• Established trends – Asked why again

• Weekend Shut Down – GO! Manual

– Dynamic Molding - 3rd Shift – Saturday Shutdown

– Dynamic EDM – 4 Machines, 2 Chillers and Process

Cooling System

– Assembly – 2nd shift – Friday Night Shutdown

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The BAS Made Me Do It

• Weekend Shut Down – Automatic

– Dynamic Molding – Wittmann Dyer – Ben M – Timer Enabled

– Dynamic New Air Compressors and Controls – November

2014

• Nights and Holidays

– Vigilance – any opportunity – snow, light work – 01/02/2015

– Turn stuff off or set up (summer) & setback (winter)

– Creates a “Sixth Sense” of how the plant operates

• LESS LOAD = MORE SOLAR CREDITS directly off invoice

3,756,240

3,451,704

2,778,735

3,109,566

2,974,681 2,892,611

2,748,001

2,346,445

2,200,000

2,400,000

2,600,000

2,800,000

3,000,000

3,200,000

3,400,000

3,600,000

3,800,000

4,000,000

2007 2008 2009 2010 2011 2012 2013 2014

KW

H

The Siemon Company - Dynamic Building - PAST 7 YEARS Annual

-41% vs 2007 (Before Solar PV)

-16%

vs

2013

6/17/2015

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SIMPLE CHECKLIST TO TURN

ENERGY USERS OFF

6/17/2015

10

WEEKEND SHUTDOWN CHECKLIST as of 05/24/2014

A. PROCESS COOLING LOOP

1. Unplug solenoid valve from hanging outlet (right side of skid around back)

2. Observe water treatment system flow meters go to zero

3. Variable Frequency Drive (VFD) - Process Cooling Pump - Press the "OFF" button

4. Observe VFD speed % drop to 0.00% (this ensures that the pump is not dead headed)

5. Close Heat Exchanger Process Discharge Valve

6. Verify that the process tank does not continue to fill up

B. TOWER LOOP

1. Variable Frequency Drive (VFD) - Process Cooling Pump - Press the "OFF" button

2. Observe VFD speed % drop to 0.00%

C. PROCESS COOLING

MAIN WATER SHUTOFF

Close the MAIN water supply to ALL equipment

In the back corner to the right side

D. SHUT OFF BOTH AIR COMPRESSORS

E. TURN OFF THE WITTMANN DRYER

E. TURN OFF THE NUCONN VACUUM BLOWERS

These are under Mezzanine towards the

Wittmann Dryer

PLEASE SEE REVERSE SIDE FOR MORE - THANK YOU

F. TURN OFF THE MOTON VACUUM BLOWERS

These are on top of the Mezzanine

at the north end by main door

IF IN DOUBT DO NOT HESITATE TO CALL

HAVE A GREAT MEMORIAL DAY!

THANK YOU!!

John Buckley = 860-944-3060 - CELL

DYNAMIC

BUILDING

WEEKEND

SHUTDOWN

CHECKLIST –

“You Can Do It

Award” for Tim

Farland’s exceptional

attention to detail

and consistency ASSEMBLY

BUILDING

WEEKEND

SHUTDOWN

OWN LIST

“You Can Do It

Award” for Geoff

Platt and David

Leary’s exceptional

attention to detail

and consistency

REFLECTIVE WHITE ROOF

SARNAFIL BRAND

THERMOPLASTIC

6/17/2015

11

Before & After

PROCESS HEATING FOR

INJECTION MOLDING

6/17/2015

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6/17/2015

13

NEW – “HIGH TECH” AIR

COMPRESSORS

Dynamic Air Compressors - Too much

inefficiency to bear – NOT ANY MORE! We wake up our big, 200 HP

Compressor to do a little work

What we need – smaller, right

sized, nimble, flexible

6/17/2015

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250

260

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340

350

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Dynamic Building - 200 HP vs. Nirvana Night Test

2/6/2015 Nirvana Average Linear (2/6/2015) Linear (Nirvana Average)

9.4% Less

184,614

167,371 150,000

200,000

250,000

300,000

350,000

400,000

Usa

ge

The Siemon Company - Dynamic Building kWh Usage - Month to Month

2007 2008 2009 2010 2011 2012 2013 2014 2015

6/17/2015

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COMPRESSOR AIR SYSTEM

MONITOR

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Siemon Company - Compressed Air

Case Study – J Buckley

50 HP on at

night now!

USED TO

BE THE 75

HP

50 HP

takes a nap

in the

evening

Closing Off the South End – Easter Weekend

• No 2nd Shift Metal Stamping

or Sheet Metal

• Climbed up in the attic

• Shut off valves to south end

• Easter Monday –

compressors come on for

Motan @ 12:30 AM

• Normally the 50 & the 75

pump up the system and the

75 shuts off

• Then due to no leaks . . .

At times they both were off!

Cool!

Siemon Company - Compressed Air

Case Study – J Buckley

6/17/2015

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COMPRESSED AIR SYSTEM

CONTROLS

The Siemon Company - Dynamic Building - SIMPLIFIED Compressed Air Functional Flow Diagram - FUTURE

CFM 75 HP 50 HP

Control Load UnLoad Control Load UnLoad

1st Shift 485 Lead 109 114 Trim 105 114

2nd Shift 337 Lead 109 114 Trim 105 114

3rd Shift 237 Back Up 105 114 Lead 109 114

8

MoldingPress

Tower

4

MoldingPress

Tower

200

HPAir

75 HP

Air Comp

Compressed

Air Dryer

METAL STAMPING,

SECONDARY & CLIP ROOM

MOLDING North 3"

Copper Loop

MOLDING Plastic

Material Drying

EDM

2 x 2

2 HP Compressor

CompressedAir Dryer

CompressedAir Hose

Sheet Metal

Loop

50 HP

Air Comp

Expand Air

Control Valve

6/17/2015

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The Siemon Company - Dynamic Building - 2014 Compressor Upgrade Project

Compressor Control Squence of Operation COMPRESSORS *

Control

Configuration Time Production Need Description 75 HP 50 HPMotan

Dryers Molding

Metal

Stamping

Sheet

Metal

Monday AM

Start Up

0200-0600 Motan and Wittmann raw

material drying system

turns on

1. Timer turns on 50 HP with

pressure setpoints as lead

Lag Lead Open Closed Closed Closed2. Timer turns on 75 HP with

pressure setpoints as lag (back

up for 50 HP)

1st Shift 0600-1500 Molding & Metal

Stamping starts up

1. Control switches 75 HP to

lead machineLead Trim Open Open Open Closed

(Mon-Fri) 2. Control switches 50 HP to lag

/ trim machine

0700 -

1530

Sheet Metal Starts Up Same configuration as 0600

Lead Trim Open Open Open Open

2nd Shift

(Mon-Fri)

1500-2330 Molding & Sheet Metal

only

Anticipate 75 HP holding its

own with Metal Stamping goneLead Lag Open Open Closed Open

3rd Shift

(Tue-Sat)

2330-0700 Sheet Metal leaves -

Molding Dept Only

1. Timer turns on 50 HP with

pressure setpoints as leadTrim Lead Open Open Closed Closed

2. Timer turns on 75 HP with

pressure setpoints as lag

Weekend

(Sat-Mon AM)

0700 Sat -

0200 Mon

No compressed air

required

Timer turns off both 50 and 75

Off Off Closed Closed Closed Closed

"Lag"

"Lead"

"Trim" The compressor is most likely operating below full load but could be at full load if needed

"Off" The compressor is off on a hard timer function and/or an "UnOccupied" command from BAS

"Open" The control valve for that particular loop is in the closed position

"Closed" The control valve for that particular loop is in the opend position

LOOP CONTROL VALVES - CONTROLLED By

HONEYWELL - Building Automation System

(BAS)

The compressor is in auto re-start but most likely not operating

The compressor is in lead role - running the current plant configuration

NOTES AND DEFINITIONS - * in all configurations, the existing IR - SSR - 200 HorsePower compressor is the back up

Compressed Air Rated - High Quality

Control Valves

120 Volt Actuator Motor Stainless Steel Body

Pro Press joints

6/17/2015

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BUILDING AUTOMATION SYSTEM

(BAS) EXPANSION

The Siemon Company - Watertown, CT

Honeywell EBI Building Automation System (BAS) - Phase 2 Blue color are left overs from original project

Honeywell

PRIORITY System

Project ID

Number Components Quantity Remarks

Chiller Chiller 2015-04 Small Chiller - Start Stop 2 Have 2 pair going to these now monitoring Return Water Temp and

On/Off Status. Phase 1 did have other point but they were for a larger

chiller so we re-invested in some other points.

Control Control 2013-81 Assembly Building RTU 02 - Static Pressure,

etc programming

1 New development due to new VFD and information from Carrier tech.

Carrier CCN being replaced by Honeywell. Quality Mech (Scott) and Hon

(Vinny) felt it could be done. In the past it was not determined to be the

safest way (Hon-Matt).

Control Control 2015-05 Dynamic RTU 03 - Temperature Averaging 1 Add a sensor in the Maintenance shop to average with the temperature in

the tool room for Metal Stamping. Average them to try and get more

cooling in to the Maint Shop

Control Control 2015-09 Showroom Control - Control that room? ConvergeIT - Possibly add a controller to control the VAV boxes, lighting,

CDU and chiller remotely as a demo for customer demonstrations.

Control Control 2015-10 Heated side walk - North & South 2 Would like to remote read whatever the controller can give us. Would

like to remotely start / stop this equipment

Control Control 2015-11 Tie in to new air compressor control

package

1 Most likely will a robust system from Ingersoll-Rand called X8I - "system

Modbus Gateway"

Control Control 2015-12 Compressed Air Pressure Loop Control

Valves

3 + TBD Simply install control signal to open and close a motorized valve for

various compressed air loops

Control Control 2015-14 EDM Waste Heat Removal 1 Turn on an attic fan(?) to take heat from plant in colder weather to cool

EDM rather than run RTU 07. EDM seems to heat up the internal office

space like a wood stove.

Control Control 2015-15 Motan Drying Waste Heat Removal 1 It is warm / hot in the Motan drying area. It may be feasible for this heat

to be sent towards the north loading dock door in the winter. Could

consider the use of a vent sock.

Control Control 2015-16 Air compressor waste heat 1 New equipment being installed

Control Control 2015-17 Process cooling remote control 2 Process cooling system - pumps on and off remotely

Lighting Lighting 2015-08 Lighting - All Over RIBs?? Wiring

Meter Meter 2013-80 Assembly Building Meter working 1

Meters Meters 2015-01 Water Meters 5 Need BAS capable water meters - tie back to software in EBI

Meters Meters 2015-02 Natural Gas Meters - Honeywell Brand 2 Would like to remote read these / capture information

Monitor Monitor 2015-03 Compressed Air Pressure Transducer 2 Simple?

Monitor Monitor 2015-06 Assembly - Clean Room Temperature 1 Monitor

Monitor Monitor 2015-07 Assembly - Clean Room Dew Point 1 Monitor

Program Program 2013-90 Smart Phone - Mobile App ON 1 Left over item - need licensing cost

Program Program 2015-13 Demand Limiting - Programming 2 Both Assembly & Dynamic determine what is required to

Program Program 2015-18 Process cooling remote control 1 Process cooling system - tie in to Red Lion "brain"?

Schedule Schedule 2013-00 Global Scheduling working 100% 1 Carl G from NJ has a plan to re-beam up the global sked. Either Vinny or

he needs to get this done (or someone else)

Training Training 2013-91 EBI - 5 Day Training 1 Winter travel not desired - not clear what course I need

6/17/2015

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Thank you

John R. Buckley, Plant Engineer

The Siemon Company – Watertown, CT