This impact evaluation of a refrigeration control system (RCS) recently installed at Vitamilk Dairy, Inc. (Vitamilk) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy $avings Plan (E$P) Program. The RCS installation at Vitamilk uses microcomputer- based controls to automate refrigeration equipment previously controlled manually. This impact evaluation assessed how much electricity is being saved at Vitamilk as a result of the E$P and to determine how much the savings cost Bonneville and the region. On a unit savings basis, this project will save 9.7 kWh/tonne (8-8 kWh/ton) of milk and ice cream produced, based on the product mix for June 1992 through May 1993, representing a 28% reduction in energy consumption. The project was installed in 1992 for a total cost of $129,330, and Vitamilk received payment of $62,974 from Bonneville in 1993 for the acquisition of energy savings. The real levelized cost of these energy savings to Bonneville is 8.5 mills/kWh (in 1993 dollars) over the project`s assumed 15-year life, and the real levelized cost to the region is 17.9 mills/kWh (in 1993 dollars), not including transmission and distribution effects. Based on the expected project installation costs and energy savings benefits, the RCS would not have been implemented by Vitamilk without the E$P acquisition payment. The expected acquisition payment reduced the estimated payback period from 7.0 to 2.8 years. Although Vitamilk would generally require an energy conservation project to have a payback period of two years or less, the slightly longer payback period was accepted in this case.

This report describes Pacific Northwest Laboratory`s (PNL`s) evaluation of the impact of an energy conservation project completed in the fall of 1992. The project (a mill tailings thickener) was installed at J.R. Simplot Company`s (Simplot`s) Smoky Canyon Mine in Caribou County, Idaho near Afton, Wyoming. The project at Simplot is one in a continuing series of industrial energy conservation projects to have its impact evaluated by PNL. All of the projects have received or will receive acquisition payments from the Bonneville Power Administration (Bonneville) under the Energy $avings Plan (E$P) Program. The E$P is being offered to reduce electricity consumption in the industrial sector of Bonneville`s service territory. For the Simplot project, the acquisition payment offered under the program was equal to the lesser of 10{cents}/kilowatt-hour (kWh) saved in the first year or 80% of eligible project costs, up to a limit of $250,000. The general objective of the impact evaluation was to determine how much electricity is saved by the project and at what cost to Bonneville and to the region.

This impact evaluation of adjustable speed drives (ASDs), programmble logic controllers (PLCs), and high efficiency motors (HEMs) that were recently installed at Mayr Brothers Logging Co., Inc. (Mayr Bros.) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy $avings Plan (E$P) Program. The project consists of ASDs, PLCs, and HEMs that were installed at the Mayr Bros. new small log nill at their facility in Hoquiam, Washington. Energy savings directly accrue through improved motor efficiency and indirectly accrue via an increase in production rate. This latter effect reduces energy consumption per unit of production by spreading fixed energy requirements over a greater number of units. The objective of this impact evaluation was to assess how much electricity is being saved at Mayr Bros. as a result of the E$P and to determine how much the savings cost Bonneville and the region. The impact of the project was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (Mayr Bros. proposal and completion report). The energy conservation measures were incorporated into the small log mill while the mill was constructed in 1992 and 1993. Financing the new mill had stretched Mayr Bros. cash and credit resources to the limit. Without the acquisition payment, Mayr Bros. would not have been able to afford the additional investment in the energy conservation measures. Therefore, all of the project`s impact can be attributed to the E$P. The key recommendation resulting from this impact evaluation is to avoid the direct comparison of energy consumption estimates derived via engineering calculations and metering. If ``before and after`` metering is not possible, engineering calculations should be calibrated against metered data to enhance comparability.

This impact evaluation of the bypass of a slush stock chest that was recently installed at Scott Paper Company (Scott Paper) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy $avings Plan (E$P) Program. The project consists of installing an adjustable speed drive, a 74.6 kW (100 hp) pump, a re-sized impeller, and piping modifications to bypass the slush stock chest and related equipment. The objective of this impact evaluation was to assess how much electrical energy is being saved at Scott Paper as a result of the E$P and to determine how much the savings cost Bonneville and the region. The impact of the project was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (Scott Paper`s proposal and completion report). Based on this impact evaluation, energy savings from this project are expected to be 763,600 kilowatt-hours/year (kWh/yr) or 0.087 average megawatts (aMW). On a per-ton basis, this project will save 4.64 kWh/ton or 39.2%. The project cost $120,098 to install, and Scott Paper received payment of $82,232 (in 1993 dollars) from Bonneville for the acquisition of energy savings. Pacific Northwest Laboratory calculated the real levelized cost of the energy savings to Bonneville as 14.2 mills/kWh (in 1993 dollars) over the project`s assumed 15-year life, and the real levelized cost to the region as 21.9 mills/kWh, not including transmission and distribution effects. The project would not have been implemented without the acquisition payment from Bonneville and therefore is not a free rider.

This paper presents the pros and cons of several energy, savings estimating methods considered as part of a recent impact evaluation of energy conservation measures installed at a lumber mill in the Pacific Northwest. The energy conservation measures (adjustable speed drives, programmable logic controllers, and high efficiency motors) were installed when the mill was initially constructed rather than being installed as a retrofit. Therefore, direct measurement of baseline energy consumption was impossible. As described in this paper, several reasonable methods can be formulated for estimating the energy savings when a physical baseline does not exist. The alternative methods will often result in radically different energy savings estimates, which may translate into significantly different conclusions regarding the efficacy of the energy conservation measures and/or the energy conservation program being evaluated. Therefore, it is critical to understand and carefully consider the options for estimating energy savings when a physical baseline does not exist.

This impact evaluation of two lighting retrofit projects that were recently installed at Boeing Commercial Airplane Group (Boeing) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy $avings Plan (E$P) Program. The first project was a light-fixture and lighting control retrofit, consisting of five individual measures installed in Building 40-05. The second project was a retrofit of all parking lot lighting on the site. The objective of this impact evaluation was to assess how much electrical energy is being saved at Boeing as a result of the E$P projects and to determine how much the savings cost Bonneville and the region. The impact of the project was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (Boeing`s proposals and completion reports).

This impact evaluation of an induction furnace replacement that was recently installed at Mackenzie Specialty Castings, Incorporated (Mackenzie Castings) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy Savings Plan (ESP) Program. The project consists of replacing old power supplies and induction furnace with new, more efficient supplies and equipment. The objective of this impact evaluation was to assess how much electrical energy is being saved at Mackenzie Castings as a result of the ESP and to determine how much the savings cost Bonneville and the region. The impact of the project was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (Mackenzie Castings`s proposal and completion report). Based on this impact evaluation, energy savings from this project are expected to be 425,257 kWh/yr at minimum annual production, 647,037 kWh/yr at typical annual production, and 1,294,074 kWh/yr at maximum annual production, or 0.05, 0.07, and 0.15 average megawatts, respectively. On a per-ton basis, this project will save 608 kWh/ton or 31% at minimum production and 431 kWh/ton or 39% at typical and maximum production. The project cost $277,110 to install, and Mackenzie Castings received payment of $102,551 (in 1993 dollars) from Bonneville for acquisition of the energy savings. The real levelized cost of these energy savings to Bonneville is 22.9 mills/kWh at minimum production, 15.1 mills/kWh typical production, and 7.5 mills/kWh at maximum production (in 1993 dollars) over the project`s assumed 15-year life. The real levelized cost to the region is 59.1 mills/kWh at minimum production, 38.8 mills/kWh at typical production, and 19.4 mills/kWh at maximum production in 1993 dollars, not including transmission and distribution effects.

This impact evaluation of adjustable speed drives (ASDs) that were recently installed at Great Western Malting Company (GWM) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy $avings Plan (E$P) Program. The project consists of four ASDs that are used to control the power to motors driving kiln exhaust fans. The ASDs are being used to control the air flow rate through the compartment house malt drying kilns, which was previously controlled with dampers. The objective of this impact evaluation was to assess how much electrical energy is being saved at GWM as a result of the E$P and to determine how much the savings cost Bonneville and the region. The impact of the project was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (GWM`s proposal and completion report).

This impact evaluation of adjustable speed drives (ASDS) that were recently installed at Hewlett-Packard Company (HP) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy savings Plan (E$P) Program. The Program makes acquisition payments to firms that install energy conservation projects in their industrial processes. The objective of this impact evaluation was to assess how much electrical energy is being saved at HP as a result of the E$P and to determine how much the savings cost Bonneville and the region. The impact of the project was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (HP`s Proposal and Completion Report). The project consisted of installing 24 ASDs on 24 variable air volume system supply- and return-fans at HP`s Vancouver, Washington manufacturing facility. A secondary benefit to adding the ASDs was the ability to program in a night-setback feature. This feature was always present in the existing central computer system but was not used because of the lack of ASDs. Based on this impact evaluation, energy savings from this project are expected to be 2,582,900 kilowatt-hours/year (kWh/yr), or 0.30 average megawatts. The project cost $252,068 to install, and HP received payment of $201,654 (1992 dollars) from Bonneville for the acquisition of energy savings. The real levelized cost of these energy savings to Bonneville is 7.0 mills/kwh (in 1992 dollars) over the project`s assumed 15-year life, and the real levelized cost to the region is 10.8 mills/kwh in 1992 dollars, not including transmission and distribution effects. This project would not have been implemented without the acquisition payment from Bonneville.

Over the past 10 years, the Pacific Northwest has gone from a region with excess electricity generating capacity to one facing dramatic short-ages. Faced with potential deficits, the region's largest power producer, the Bonneville Power Administration (Bonneville), has embarked on an aggressive industrial energy conservation and savings evaluation program. Bonneville's Energy $avings Plan (E$P) Program targets industrial customers by offering acquisition payments for approved industrial energy conservation projects. Since the program's inception in 1987, 52 E$P projects have been completed for a combined annual savings of more than 98 million kilowatt-hours per year, or 11.2 average megawatts. To date, the 52 participants have received acquisition payments totaling $3,441,000 on projects with a total installed cost of $37,495,000.

This impact evaluation of four energy conservation measures (ECMs) that were recently installed at Holnam Incorporated (Holnam) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy $avings Plan (E$P) Program. The Program makes acquisition payments to firms that install energy conservation measures in their industrial processes. The objective of this impact evaluation was to assess how much electrical energy is being saved at Holnam as a result of the E$P and to determine how much the savings cost Bonneville and the region. The impact of the ECMs was evaluated with a combination of engineering analysis, financial analysis, site visit and interview, and review of previous program submittals (Holnam`s Proposals and Completion Reports). The four ECMs were all electronic power control devices that replaced less efficient technologies for controlling power to the kiln drive motors, cooler grate drive motors, cooler fan motors, and kiln stack gas precipitators. Energy savings from this project are expected to be 1,782,000 kWh/yr or 0.20 average megawatts. On a unit production basis, this project will save 3.4 kWh/ton of cement, based on Holnam`s projected average annual future production rate. The four ECMs cost a total of $248,232 to install, and Holnam received payment of $115,615 from Bonneville for the acquisition of energy savings. Program administrative costs incurred by Bonneville, Pacific Northwest Laboratory (PNL), and Seattle City Light (SCL) were estimated to be $29,362. The real levelized cost (1992 $) of these energy savings to Bonneville will be 6.2 mills/kWh over the project`s expected 15-year life, and the real levelized cost (1992 $) to the region will be 14.1 mills/kWh. Based on expected ECM installation costs and energy savings benefits alone, none of the four ECMs would have been implemented by Holnam without the E$P acquisition payment.

This impact evaluation of an adjustable speed drive that was recently installed at Ball-InCon Glass Packaging Corporation (Ball-InCon) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy $avings Plan (E$P) Program. The Program makes acquisition payments to firms that install energy conservation projects in their industrial processes. The objective of this impact evaluation was to assess how much electrical energy is being saved at Ball-InCon as a result of the E$P and to determine how much the savings cost Bonneville and the region. The impact of the project was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (Ball-InCon`s Abstract, Proposal, and Completion Report). The project consists of switching from inlet guide vanes to adjustable frequency drives for 10 motors that provide cooling air to glass container molds. Based on this impact evaluation, energy savings from this project are expected to be 1,711,500 kWh/yr, or about 0.20 average megawatts. On a per-ton basis, this project will save approximately 7.8 kWh/ton of glass produced. The project cost $182,834 to install, and Ball-InCon received payment of $95,581 from Bonneville for the acquisition of energy savings. The real levelized cost of these energy savings to Bonneville is 5.2 mills/kWh over the projects`s assumed 15-year life, and the levelized cost to the region is 10.7 mills/kWh in 1992 dollars, not including transmission and distribution effects. This project would not have been implemented without the acquisition payment from Bonneville, so all of the energy savings can be attributed to the E$P.

To meet the increasing demand for energy at reasonable cost, while minimizing the effects of energy production on the environment, the Pacific Northwest will actively pursue energy conservation as a source of energy. Bonneville Power Administration`s (Bonneville`s) goal is to save 660 average megawatts (aMW) by the year 2000 as its share of the Northwest conservation goal. Bonneville recognizes that a potential source of significant energy conservation is the industrial sector. Accordingly, in 1987, Bonneville began offering the Energy $avings Plan (E$P) Program to obtain electrical energy conservation in this sector. Combined annual savings for ail of the completed projects to date total over 104 million kilowatt-hours (kWh) per year. In terms of capacity, the program is saving about 11.9 aMW thus far. To date, the program has made acquisition payments totalling $3,853,800 to 55 participants. The total installed cost of the projects is $38,178,100. The average project is saving 1,892,300 kWh/yr (1,482,900 kWh/yr excluding the largest project which saves 24,000,000 kWh/yr).

This impact evaluation of an energy conservation measure (ECM) that was recently installed at Elf Atochem North America (Atochem) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy savings Plan (E$P) Program. The Program makes acquisition payments to firms that install energy conservation measures in their industrial processes. The objective of this impact evaluation was to assess how much electrical energy is being saved at Atochem as a result of the E$P and to determine how much the savings cost Bonneville and the region. The impact of the ECM was evaluated with a combination of engineering analysis, financial analysis, site visit and interview, review of previous program submittals and review of process evaluation results from 1989. The ECM itself consists of adding anode area to each of the sodium chlorate (chlorate) cells at Atochem's Tacoma facility. Increasing the anode area reduces the current density, which reduces cell resistance at the same current, thus reducing energy consumption at the same chlorate production rate. Energy savings resulting from this ECM are expected to average about 24,000,000 kWh/yr or about 1000 kWh/ton of chlorate produced. The net cost of the ECM was $1,410,400, and Atochem received a payment of $212,500 from Bonneville for the acquisition of energy savings. The levelized cost of these energy savings to Bonneville will be 0.7 mills/kWh over the ECM's expected 15-year life, and the levelized cost to the region will be 5.7 mills/kWh. Bonneville's offer to pay Atochem $212,500 via the E$P Program was viewed by Atochem management as a big incentive that made a difference.

The Pacific Northwest Laboratory evaluated the potential feasibility of using chemical energy storage at the Solar Electric Generating System (SEGS) power plants developed by Luz International. Like sensible or latent heat energy storage systems, chemical energy storage can be beneficially applied to solar thermal power plants to dampen the impact of cloud transients, extend the daily operating period, and/or allow a higher fraction of power production to occur during high-valued peak demand periods. Higher energy storage densities make chemical energy storage a potentially attractive option. The results of the evaluation indicated that a system based on the reversible reaction, CaO + H2O = Ca(OH)2, could be technically and economically feasible for this application, but many technical and economic issues must be resolved.

This impact evaluation of an energy conservation measure (ECM) that was recently installed at Lenroc Company/Moorman Manufacturing (Lenroc/Moorman) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy Savings Plan (ESP) Program. The Program makes acquisition payments to firms that install energy conservation measures in their industrial processes. The objective of this impact evaluation was to assess how much electrical energy is being saved at Lenroc/Moorman as a result of the ESP and to determine how much the savings cost Bonneville and the region. The impact of the ECM was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (Lenroc/Moorman`s Abstract, Proposal, and Completion Report). The ECM itself consists of installing two heat exchangers to recover waste heat from a process water line to preheat incoming process air. The air and water are used in a proprietary process to produce biuret, a cattle feed supplement derived from urea. Energy savings resulting from this ECM are expected to be 339,400 kWh/yr. On a per ton basis, this ECM will save 56.6 kWh/ton of biuret. The ECM cost $15,754 to install, and Lenroc/Moorman received payments of $9452 from Bonneville and $3933 from Grant County PUD for the acquisition of energy savings for a net cost to Lenroc/Moorman of $2369. Without the acquisition payments from Bonneville and Grant County PUD, this ECM would not have been implemented. The levelized cost of these energy savings to Bonneville will be 2.3 mills/kWh over the ECM`s expected 15-year life, and the levelized cost to the region will be 4.0 mills/kWh.