Holston Army Ammunition Plant Moving Beyond Static Energy Audits

Holston Army Ammunition Plant
Moving Beyond Static Energy Audits
E.O. Compliance in Energy Management
Mr. Thomas (Ben) Rogers
Energy Management Engineer
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Agenda
• Introduction
• Legislation and Regulations
– Energy Management Requirements
– Program Structure
– Program Key Aspects
• Holston Army Ammunition Plant
– Who, What, and Where
– HSAAP Energy Management Program
– Example Project
• Fully Burdened Cost of Energy Analysis
• Project Results and Recommendations
– Lessons Learned
• Questions
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Energy Legislation and Regulations
• Several important sources for requirements
– Most are complimentary or supplementary
• Energy Policy Act of 2005
– Enacted Aug. 2005
• Executive Order 13423
– Signed Jan. 2007 by President Bush
• Energy Independence and Security Act of 2007
– Enacted Dec. 2007
• Executive Order 13514
– Signed Oct. 2009 by President Obama
Details can be found at DoE’s FEMP website www.eere.energy.gov/femp
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Executive Orders for Energy Managers
• E.O. 13423 requires
– Environmental
Mangagement System
• E.O. 13514 expands
requirements for
– Sustainable building design
– Improved Metering
– Fleet management
– Energy Auditing
– Petroleum use reduction
– Life-cycle Cost Analysis
– Green procurement
– Green procurement
– Overall energy reduction
– Fleet management
– Overall energy reductions
– …and more
• And introduces
– GHG emissions tracking
and reporting
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Program Structure
• Executive Orders are a great outline for an energy
management program
– Baseline your facility (energy audits, GHG emissions)
– Identify metering needs (improved metering)
– Prioritize users by size and category
– Evaluate projects (life-cycle costs, etc.)
– Implement best candidates (reductions in use, independence, security, etc)
– Document improvements (EMS, reporting)
– Repeat
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Program Key Aspects
• Management commitment
– EM’s #1 duty is to win support
for the program
• Environmental team
engaged
– Almost every EM project has
environmental impact
• Data, Data, Data
– Accurate projections and
follow-up verification will make
or break your program
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BAE Systems, Inc. locations
Land & Armaments and Electronics, Intelligence and Support Operating Groups
Kingsport, TN
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Ordnance Systems – Holston Army Ammunition Plant
OSI Safety, Environmental &
Quality Registrations
Safety – OSHAS 18001
Environmental – ISO 14001
Quality – ISO 9001
st
1 GOCO to Receive All 3
Explosives Production
Holston Army Ammunition Plant - Operating Contractor
25 year Facility Use Contract commencing in 1998
Modernization
R&D
Premier JM&L LCMC GOCO Facility
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Current Manufacturing Mix
• CXM-7 – JDAAM Bomb
• Comp C-4 – M112, MICLIC
• HMX 80S – Trident
• PAX-21 – 60mm Mortar
• PBXN-9 & CXM-7 – Hellfire
• Comp B / B-4 – APKWS
• PBXN-10 – APOBS, Mongoose
• Comp A-3 – SMAW, 40mm
• LX-14 - Javelin
• CXM-3 – Cruise Missile
• CXM-9 – SLAM-ER
• IMX-101 (OSX CAN)* – 155mm Artillery
• IMX-104 – Multiple applications
• PAX-28 – Precision Guided Mortar Munition
• PAX-34 – Egyptian 120mm Mortar (ARDEC FMS)
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HSAAP Energy Management Program
•
•
•
•
High level energy survey
Integration with EMS
Prioritization of facilities
Baseline audits
– Try to follow 80/20 rule
– Collect data in a central
system
• Identification of
opportunities
• Project evaluation
• HSAAP examples
– 3rd party energy audit
– Developed audit list of ~20
facilities from over 200
candidates
– Integrating existing and
planned meters with central
database and monitoring
program
– Evaluated life cycle costs
of proposed projects with
FBCE analysis
– FBCE type analysis
• Project implementation
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Manufacturing Overview
Raw Materials
Nitration Facility
Effluent
Treatment
Recrystallization
and Purification
Computer
Control
Waste Water
Treatment
Facility
Acid Recovery
and
Concentration
Product
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Major Energy Sources
• Coal for steam production
is our largest energy
source
• Purchased steam,
electricity, and natural
gas are also significant
• Vehicle fuels and nonprocess electricity are
small parts of our energy
mix
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Fully Burdened Cost of Energy Analysis
• Develop Baseline
• Validate Model
• Iterate Options
• Analyze Results
– Sanity Check
– Sensitivity Analysis
– Carbon Footprint
Baseline Model Diagram
• Recommendations
Analysis Results
16.0
Option 4
($ million)
15.5
Option 3
Option 3+5
i
15.0
• FBCE analysis projected
savings for various
projects
Option 5
14.5
Option 6
Baseline
14.0
2012
2017
2022
• Estimated impact on
GHG production
600
CO2 (million lbs)
500
400
Biomass
300
Electricity
• Supplied common base
for project comparison
and prioritization
200
Other
Energy
100
50
0
Central Coal
Boiler
Central
Biomass
Boiler
3 Distributed
Boilers
• Recommended
cogeneration project
1 Distributed
Boiler,
1 Central Coal
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Lessons Learned
• Times change – don’t be afraid to revisit previously
rejected ideas
– Cogeneration had been evaluated multiple times but never
implemented
• Take advantage of existing structures
– Initial audits took advantage of prior work by 3rd parties and
environmental audits
• Partner with your environmental team
– Don’t overlook complimentary benefits or regulatory hurdles
• You can’t talk too much about energy but you can talk
too distantly; saving starts with the individual
– Find ways to localize and personalize your program
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Keep It Local
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Resources
• Websites
– FEMP website - www.eere.energy.gov/femp
• Industry Best Practices - http://www1.eere.energy.gov/industry/bestpractices/index.html
• Fleet Management –http://www1.eere.energy.gov/femp/program/fedfleet_management.html
– Energy Star
• www.energystar.gov
– Energy Efficiency and Renewable Energy
• www.eere.energy.gov
• Books
– Guide to Energy Management by B. Capehart, W. Turner, and W. Kennedy
– Energy Management Handbook by W. Turner and S. Doty
– Handbook of Energy Audits by A. Thumann and W. Younger
• Training
– Association of Energy Engineers – www.aeecenter.org
– EMC Engineers – www.emcengineers.com
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Acknowledgements
• BAE Systems Inc.
–
–
–
–
–
–
• Holston Army Ammunition Plant
– Mike Vestal
– Paul Hively
– Scott Shelton
Bob Winstead
Paul Gebhardt
Butch Jones
Barb Smart
Nigel House
Jerry Hammonds
• FEMP / EMC Engineers
– Celeste Cizik
– Matt Dubrovich
• BAE Systems plc.
–
–
–
–
Victoria Hinchcliffe
Emily Leeper
Robert Hyde
Chris Courtaux
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Questions?
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