Press Release: November 2004
User Selects Contractor On Quality of Site Review
Food Co. Moves Plant, Gets Improved Version of Old EMS

 Press Release: November 2004

Energy Consulting Services and 1st Rochdale Cooperative Group Inc.
Installation of an Energy Management Strategy at Dairyland, U.S.A.
Hunts Point, Bronx, NY

1st Rochdale Cooperative Group created Direct Connection I, to provide consumers with the energy management and information systems that allow them to manage their electrical consumption based on real time and day-ahead market prices. The Energy Management program of 1st Rochdale Cooperative Group Inc. used new ‘energy smart’ technology to help its customer, Dairyland, USA, reduce its energy costs while improving the quality of its operations. Dairyland, USA is a wholesale food distributor based in the Hunts Point district of the Bronx. Dairyland teamed up with 1st Rochdale to install an Energy Management System (EMS) to control energy usage while improving the quality of Dairyland’s product – food. The EMS paid for itself in just over 1 year while saving Dairyland, USA more than $1,000,000 over 10 years

Facility Description
Dairyland, USA is a wholesale fine food warehouse and distribution facility located in the Bronx, New York. Totaling 100,000 square feet and growing, this facility has 22,000 square feet of refrigeration/freezer storage space.

Electricity Profile
At the time this project began, Dairyland, USA had a peak load of approximately 500 kW and annual consumption of 2.5 million kWh. Freezers and refrigeration consume the bulk of the electricity at Dairyland, USA, although the electricity needed to recharge batteries in the electric forklifts is significant as well. Business growth has resulted in the need for additional cooling, battery charging and lighting capacity. As a result, the facility load is now in excess of 600 kW.

Energy Retrofit: Energy Management System
1st Rochdale and its partners, the New York State Energy Research and Development Authority (NYSERDA) and Energy Consulting Services, installed a Danfoss electronic refrigeration control system at Dairyland, USA. The control system now more efficiently monitors the temperature as well as the operation of the compressors in the chilled spaces. Energy Consulting Services also upgraded lighting systems and implemented a new management strategy for recharging electric fork lift batteries during off peak periods. The system cost of $165,000 will be recouped in less than 2 years, which is an impressive return on investment in the food industry. Over 10 years, the system will save Dairyland, USA over $1,000,000 while improving grid reliability and reducing emissions from their operations. The system also provides Dairyland, USA management with the ability to monitor and control their refrigeration systems from remote locations and receive a security call if temperatures in the space are outside normal operating ranges. This reduces the likelihood of food spoilage and increases the value of inventory while improving Dairyland, USA’s bottom line.

Dairyland, USA: Where the Savings Come From

Source of Savings Demand Savings kWh Savings Annual $$Value
Refrigeration 200 kW 295,000 kWh/year $81,000
Battery Charging 120 kW N/a $7,000
Lighting 15 kW 50,000 kWh/year $6,000
Tax Benefits N/a N/a $26,000
TOTAL 335 kW 345,000 kWh/yr $120,000

Detailed System Specification and Narrative – Dairyland, USA Inc.

Danfoss Electronic Monitoring & Control EMS Specification Information

This system provides for:
  • Electrical Demand Limiting
  • Refrigerated Space Temperature Control
  • Refrigeration System Defrost Monitoring
  • Refrigeration System Evaporator Control & Monitoring
  • Refrigeration System Compressor Status Monitoring (all compressors)
  • Zoned Demand Limiting (i.e., Office HVAC)
  • Time of Day Control and Battery Charger Demand Limiting
  • Partial Lighting Control
  • Monitoring & Alarming
Itemized System Specification and Narrative – Dairyland, USA Inc.
  1. Limiting the amount of Electricity being used in a 15 minute Electrical Demand Window: The Danfoss system monitors the electrical demand through the primary utility service meter, located at the service entrance to the building. The Danfoss system instantaneously measures the incoming electrical demand and predicts the electrical demand for the sliding 15 minutes period to facilitate a pro-active response to rising electrical demand. This allows the controller to maximize electrical demand savings in real time.
  2. More Accurate Refrigerated Space Temperature Control: The Danfoss electronic space temperature sensors are highly accurate and self-calibrating. The Danfoss electronic temperature control provides a 2-degree, ‘start & stop’ temperature range for refrigeration systems. This eliminates over cooling of the space and increases the refrigeration system efficiency. The existing mechanical refrigeration thermostats typically have a ‘turn on/turn off’ range of up to six degrees Fahrenheit. This wide spread in temperature causes the existing mechanical space thermostats to be set lower than the Danfoss electronic space temperature controller must be set at. This means that more energy is required to maintain the same temperature. This is due to the fact that that the refrigeration system must operate longer than it needs to as compared to the more precise means of establishing and regulating the required temperature that is provided by the Danfoss system. Furthermore, when the refrigeration system over cools a space, it accelerates the transfer of cool air to the outside spaces through the walls and ceiling. Finally, as the refrigerated space temperature decreases, so does the efficiency of the compressor(s), which causes even greater, wasteful energy usage.
  3. Limiting the Evaporator Fan Motor Run Time: The evaporator fan motors consume large amounts of electricity in two ways. When the fans are operating, the motors use electricity to run. They also produce heat that the refrigeration system must ultimately remove. The Danfoss controller program turns the evaporator fans ‘on and off’ with the refrigeration system. A smart electronic ‘off delay’ allows the Danfoss controller to take advantage of all of the refrigerated air within the evaporator before turning off the evaporator. Another smart Danfoss control program prevents stratification of the refrigerated box’s temperature by monitoring the run time of the evaporators and turning on the fan motors to mix the box air every 30 minutes. This happens if the fans did not run in the previous 30 minutes time period.
  4. Monitoring Compressor Status: This allows for the user to see the on/off status of the compressor, compressor short cycle monitoring, compressor off and on cycle timers, compressor total run time and number of current daily run cycles at a central location.
  5. Monitoring Refrigeration Compressor Head Pressure: Higher than normal refrigeration compressor head pressure makes the compressor work harder, causing increased wear and electric energy consumption. The electronic head pressure transducers constantly monitor the refrigeration system head pressure and send an alarm signal when the pressures go out of the normal operating range. This informs the EMS service provider and/or the facility’s management, of a minor refrigeration problem (e.g., condenser fan motor failure, dirty condenser coil) before it causes excessive compressor wear, increased electrical consumption, possible safety limit trips, and/or compressor failure. Any of these events could result in product loss. This would be a major liability for this and most customers and has served as yet another motivating factor for the installation of this system by Dairyland.
  6. HVAC Demand Load Control and Time of Day Savings: The HVAC controls were upgraded to time of day temperature control with demand load control. This reduced energy usage when the offices are not being used and when peak electrical usage periods are detected by the Danfoss system.
  7. Battery Charger Demand and Time of Day Control: This allows the forklift battery chargers to be automatically turned off when peak electrical usage periods are detected by the Danfoss system.
About Energy Consulting Services, Inc.: Energy Consulting Services was formed in 1981 to provide industrial and commercial energy engineering and the sale and service of energy conserving products. Our energy engineering expertise includes the design, fabrication and troubleshooting of mechanical systems, energy usage assessment, energy usage litigation, system cost/benefit analysis, system life cycle costing and construction management.

The President of Energy Consulting Services, Jack Davidoff, has extensive field engineering design and trouble-shooting experience and his company is uniquely qualified to provide a broad spectrum of energy engineering services.

Energy Consulting Services, Inc. is a design and construction engineering company with the in-house staff to complete the job on time. Our extensive client list and letters of recommendation attest to our proficiency.

About 1st Rochdale: 1st Rochdale Cooperative was created in 1997 by a large and long established group of New York City housing cooperatives to protect the interests of residential consumers and to address new consumer needs in light of federal and state mandates to restructure the electric utility industry.

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 Energy User News

Food Co. Moves Plant, Gets Improved Version of Old EMS

Queens, N.Y. – By moving part of its food production Hebrew National Kosher Foods Inc. received a 60 percent discount on its electric demand rate, but left its energy management system behind. The food company then asked the design and install engineering firm that had installed the system – Energy Consulting Services (ECS) Inc. New York City – to duplicate the EMS at the new location and to improve upon it.

The improvement was the addition of an extensive alarm capability that is preventing costly losses in food spoilage at the new production and cold storage facility according to ECS president Jack Davidoff. By hardwiring 16 analog input points to the system, the plant’s freezer and cooler temperatures can be monitored continuously. When the temperature drifts above setpoint limits, the EMS generates an alarm signal and calls assigned phone numbers, Davidoff said.

This has worked so well in the new system that the older system has been upgraded with the alarm function also, noted Hebrew National’s vice president of engineering, James De Prima. The original 54-point system had no alarm capability whatsoever, and the user did not know when cooler or freezer setpoints were exceeded, Davidoff said. When this happened, though, a mechanical override would bypass the EMS, and equipment would run until someone noticed and reactivated the control system, he explained.

Both the original 54-point system and the new 20-point were designed and installed by Energy Consulting Services, its president Mr. Davidoff said.

The older system at the Queens plant used powerline carrier equipment when it was installed, Davidoff said. “The first job we did for Hebrew National, the user wanted us to do inexpensively,” Davidoff explained. He said the size of the facility in Queens – 100,000 square feet – made it much more economical to use PLC than to hardwire the system.

The system was upgraded with an alarm capability, he added. The new 20-point system was hardwired, Davidoff said. It was less expensive to hardwire this system than to use PLC because the building's electrical service is rated at 480 volts, and this would have required coupling the PLC signals around dozens of transformers, he added.

"The second time around, the user trusted us to do the job properly and show him what it could do," he said. Hebrew National's incentive to split its operation and move some of the food production was largely due to a special "area development" electric rate from its utility company, De Prima said.

A utility spokesman said this rate is available to commercial and industrial users who are willing to move into specified depressed areas. For Hebrew National, this meant a 60 percent discount on its electric demand rates for the next five years, after which the rate will be prorated back up to a non-discounted charge, the spokesman said. De Prima estimates monthly fuel and electric bills at the new location will reach $30,000 when the refrigeration systems begin working at full capacity. He said the demand discount will trim about $3,300 from this bill. The EMS control strategies, which schedule about 20 points of coolers, freezers, air conditioners, and pasteurizes used to sterilize kosher pickles, will save an additional $20,000 per year, he added.

The older system at the Queens plant cuts the $1 million annual energy bill by about $40,000, or 4 percent, he said. Greater savings cannot be achieved because the Queens plant runs production lines around the clock in the summer and is open 24 hours a day year around.

These savings "are the best we can do" De Prima said, because neither process nor refrigeration systems can be turned off during most hours. The new system will save slightly more, trimming 6 percent from the annual bill at the new plant because production runs there are shorter - 9 hours a day compared to 18 or 24 - and systems can be scheduled more thoroughly, Davidoff said.

While installing this system, Energy Consulting decided to configure it with 16 analog input points and 13 analog sensors, including an outdoor air sensor. The outdoor air sensor instructs the system to readjust ambient office area setpoints up and down as needed, Davidoff said.

The alarm function is activated by the analog sensors, he added. When a sensor diagnoses that a low or high limit setpoint is exceeded in the cooler, freezer or office to which it is assigned, the corresponding digital output point activates an alarm, which dials out to three locations: the ECS office, an alarm company and De Prima's home.

Schedules can be reprogrammed from any of these locations, Davidoff said. "We've gotten to know the facility and we've spent the time to get know it," he added.

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 Energy User News

User Selects Contractor On Quality of Site Review

Kearny, N.J. - Goody Products, in seeking an energy management system, bypassed the branch offices of major equipment manufacturers and made its decision based on its regard for the efforts of a local contractor. Energy Consulting Services (ECS), New York, offered the lowest bid, but the user said that his decision was influenced even more by the contractor's thoroughness in his assessment of the Goody facility.

According to John Snyder, director of office services for Goody, "Other vendors simply did a walk-through and based their bids on that. Jack Davidoff - the president of ECS - went up to ceiling, crawled around in back, made measurements, and came in at night to see what was happening, and their estimates were based on 'experience' not data.

Goody also based its decision on recommendations from other ECS customers and visits to previous ECS installations to verify energy savings, Snyder said. ECS's system uses a powerline carrier transmitter to control 42 points, he added.

The installation, completed in January, paid for itself in avoided gas and electricity costs in seven months, Snyder said. Honeywell Inc.'s Westfield, N.J., office bid a 23 control point system, according to Snyder. New Jersey Bell Co., now AT&T Information Systems Inc., Morristown, N.J., offered to lease Goody an AT&T system to control 32 points. Timothy McCabe, technical consultant at AT&T Information Systems in Woodbridge, N.J., said that at the time the bid was submitted, AT&T was only offering larger systems on a leased basis, but the company now has smaller systems that would have been more appropriate for the Goody installation. IBM did not submit a formal bid, but proposed a system that could interface with Goody's existing mainframe IBM computer, at an estimated cost of $100,000, Snyder said. "They wanted to give us more or would ever use," he said.

The ECS bid was selected because it was 10 percent less expensive than Honeywell's offering, but had additional features such as more control points, and because ECS submitted a more in-depth proposal for work to be done, Snyder said. "I could offer a better price because I spent more time preparing my bid than they did," explained Davidoff. "I spent enough time to figure out exactly what needed to be done, so I didn't have to include extras in the bid to cover unforeseen circumstances."

Snyder says Goody is "very pleased" with the services provided. "When the system went in, lots of fine-tuning was required. We were never charged extra for all the tinkering that inevitably had to be done," Snyder noted. The EMS is being monitored and fine-tuned remotely via telephone from the ECS offices, he added. After being hired to install the electronic energy management and control system, ECS proposed and installed a flue gas heat exchanger. Although initial estimates indicated a payback in about two years, the system has saved over $36,000 in the first eight months, and is expected to save $60,000 annually, Davidoff noted. The Goody facility consists of 93,000 square feet of warehouse and factory space, and 8,000 square feet of office space. The system controls the facility's HVAC equipment, including fans, heaters, air conditioners and a hydroponic loop for space heating, Davidoff said. The system performs duty cycling based on temperature setpoints, enthalpy control, start/stop optimization based on outside temperature, and demand limiting.

The EMS has reduced kilowatt hour consumption by almost 12 percent and demand charges by almost 9 percent in the eight months since installation, he said. Natural gas consumption has dropped 12 percent, 40 percent of which is due to the heat reclaimer, and 60 percent to the EMS, he noted. The stack economizer is a welded steel heat exchanger installed in the flue stack that reclaims heat from a process steam boiler, Davidoff explained. The exiting flue gas, which is about 430 degrees, is lowered by 100 degrees, and the temperature in the condensate return tank is raised from 120 to 140 degrees. The heat exchanger can preheat 18 gallons of water per minute before the water re-enters the boiler. The boiler operates round the clock, 365 days per year, making an economizer particularly effective, Davidoff explained.

Goody pays its utility, Public Service Gas & Electric Co., Newark, N.J., for its gas and electric, Davidoff said. The initial success of the project has led Goody to hire ECS for energy conservation projects in four other locations, with a total budget of $300,000 to $350,000 for such projects, Snyder said. In addition, the company will ask ECS to evaluate energy consumption patterns before occupying new facilities. "The ECS guidelines [energy consumption projections] could be incorporated into future leasing agreements before we sign," he noted.

ECS will provide recommendations and construction management at new office and warehouse sites in Dallas; Beaumont, Calif.; Columbus, Ohio; and Manchester, Ga., Snyder said. The Dallas conservation program may include installation of either an EMS or an energy time optimizer. Ceiling fans and curtain stripping for shipping dock doors are also being considered. "We're committed to Mr. Davidoff and his company but not any one manufacturer's equipment," Snyder said.

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