The Innovation Center for U.S. Dairy and The USDA Natural Resources Conservation Service (NRCS)

Transcription

1 Technical Service Provider TSP-B Submits this Sample Agricultural Energy Management Plan Large Florida Dairy 500 Acres Wednesday, November 13, 2013 Funded by: The Innovation Center for U.S. Dairy and The USDA Natural Resources Conservation Service (NRCS)

2 Wednesday, November 13, 2013 Richard Burnstein Burnstein Family Dairy, LLC 467 North County Drive Middleton, FL Dear Mr. Burnstein: As promised, enclosed is your completed Agricultural Energy Management Plan (AgEMP - Headquarters) in which I have identified several opportunities for you to reduce your energy bills by installing energy-efficient equipment and making other operational changes. This plan has been developed in accordance with NRCS Conservation Activity Plan Code 122. Our Lead Energy Engineer, Gary Gawor, has reviewed and signed off on the Energy Plan. Energy savings estimates are based upon information gathered during the site visit and therefore are as accurate as possible. However, changes in equipment operation, such as an increase in operating hours, may affect actual savings. Before moving forward with any of the recommendations in your plan, we encourage you to contact your local USDA NRCS and Rural Development offices to determine if any funding is available through the NRCS Environmental Quality Incentives Program (EQIP) or the USDA Rural Energy for America Program (REAP). Your local USDA NRCS representatives and Rural Development representatives can assist you with the application process for both programs. In the Resources section of your plan, we ve also included some helpful information and websites that can lead you to local utility and state programs where additional funding might also be available. On behalf of all of us at EnSave, Inc. we want to thank you for the opportunity to help you evaluate your farm s energy consumption and energy saving opportunities. This Energy Management Plan will help you determine the best way for you to increase your farm s energy efficiency and profitability. Even if you are not able to implement all of the recommendations immediately, this report will serve as a useful guide for future decisions and improvements. I will be calling you in a few weeks to discuss the Energy Plan with you, but in the meantime, please feel free to contact us if you have any questions. Sincerely, Kyle Booth, EIT, CEM, Energy Engineer Gary Gawor, PE, CEM, Lead Energy Engineer EnSave, Inc. EnSave, Inc. Direct (802) Direct (802) kyleb@ensave.com - garyg@ensave.com 65 Millet Street, Suite 105 Richmond, Vermont Phone Fax om Reviewed by: (Producer name / date) NRCS Acceptance: (NRCS representative name / date)

3 TABLE OF CONTENTS SUMMARY... 1 Overview... 1 Total Project Economics... 1 Farmer Preferences... 1 Conservation Activity Plan... 1 Significant Findings... 1 ENERGY EFFICIENT EQUIPMENT EVALUATION... 2 Summary of Recommendations... 2 Low Cost Energy Saving Tips... 3 Current vs. Projected Electricity Use... 4 Current vs. Projected Propane Use... 7 On-Site Energy Generation... 9 Milk Harvest... 9 Refrigeration: Milk Cooling Lighting Ventilation Water Heating Stock Watering Air Heating and Building Environment Controllers Air Cooling Other Motors and Pumps Waste Handling Material Handling Crop and Feed Storage Water Management Additional Equipment Miscellaneous Electrical Use ENVIRONMENTAL ASPECTS ENERGY PYRAMID RESOURCES INTERNET RESOURCES LIST OF TABLES Table S.1. Summary of Estimated Annual Efficiency Improvements... 2 Table S.2. Energy Savings of Recommendations... 3 Table EGEN.1. Current Generator Inventory... 9 Table MH.1. Vacuum Pump Inventory Table MH.2. Milk Transfer Pump Inventory Table MH.4. Milk Harvest: Recommended Energy Saving Equipment Table MH.5. Milk Harvest: Evaluated Equipment Not Recommended Table MC.1. Gycol Chiller Compressor Inventory Table MC.2. Bulk Tank Compressor Inventory Table MC.3. Plate Cooler Inventory Table MC.5. Refrigeration: Milk Cooling: Recommended Energy Saving Equipment Table MC.6. Refrigeration: Milk Cooling: Evaluated Equipment Not Recommended EnSave, Inc. i

4 Table L.1. Current Lighting Inventory Table L.2. Current Linear Fluorescent Inventory Table L.4. General Lighting: Recommended Energy Saving Equipment Table L.5. General Lighting: Evaluated Equipment Not Recommended Table V.1. Current LVHS Exhaust Inventory Table V.2. Current LVHS Circulation Inventory Table V.3. Current HVLS Ventilation Inventory Table V.5. General Ventilation: Recommended Energy Saving Equipment Table V.6. General Ventilation: Evaluated Equipment Not Recommended Table V.7. General Ventilation: Evaluated Equipment Not Recommended (Cont.) Table WH.1. Water Heater Inventory Table WH.2. Wash Sink Inventory Table WH.4. Hot Water: Recommended Energy Saving Equipment Table SH.1. Current Heater Inventory Table M.1. Current Motor Inventory Table M.3. Other Motors and Pumps: Recommended Energy Saving Equipment Table M.4. Other Motors and Pumps: Evaluated Equipment Not Recommended Table M.5. Other Motors and Pumps: Evaluated Equipment Not Recommended (Cont.) Table AE.1. Additional Equipment Inventory LIST OF FIGURES Figure EU.1. Twelve Month Electricity Use... 4 Figure EU.2. Electricity Use Breakdown... 5 Figure EU.3. Comparison of Current and Proposed Electricity Use... 6 Figure PU.1. Twelve Month Propane Deliveries... 7 Figure PU.2. Propane Use Breakdown... 8 Figure PU.3. Comparison of Current and Proposed Propane Use... 8 Figure MH.3. Milk Harvest: Comparison of Electricity Use Figure MC.4. Refrigeration: Milk Cooling: Comparison of Electricity Use Figure L.3. General Lighting: Comparison of Electricity Use Figure V.4. General Ventilation: Comparison of Electricity Use Figure WH.3. Hot Water: Comparison of Propane Use Figure M.2. Other Motors and Pumps: Comparison of Electricity Use Figure EP.1. Energy Pyramid Note: EnSave s goal is to help our clients save energy and conserve natural resources on America s farms and in food processing facilities. EnSave does not represent any equipment manufacturer or dealer. Any quotes or literature included in this report from a manufacturer are intended as illustrations only. Energy savings presented in this document are estimates and are based upon information gathered during the process of conducting this energy audit. Actual savings may vary from estimated savings due to a variety of factors including changes in energy usage and energy costs. Equipment costs presented in this report are estimates and are based upon available pricing information. Actual costs may vary from estimated costs due to variables such as product availability and geographic location. Numbers presented in this document may not add up precisely due to rounding. Mention of trade and company names used in this report do not imply endorsement nor does omission of names imply criticism. EnSave, Inc. ii

5 SUMMARY Overview EnSave, Inc. conducted an agricultural energy use site assessment at Burnstein Family Dairy, LLC on Tuesday, October 29, This report has been developed with the use of FEAT TM, a product of EnSave, Inc, and provides a plan to increase the facility s energy efficiency. The express written permission of EnSave, Inc. is required prior to reproducing information in this report in whole or in part. This Headquarters Agricultural Energy Management Plan (AgEMP) covers the primary energy uses identified by EnSave, Inc. for this location. These include stationary equipment and processes. Non-stationary energy uses such as motor vehicles, tractors, trucks, and skid steers are outside the scope of a Headquarters AgEMP. An average electricity cost of $0.10 per kwh and an average cost of $1.56 per gallon of propane were used in this report; however, if Burnstein Family Dairy, LLC actual costs are different from these documented values, the energy cost savings in this report would vary accordingly. The electricity and propane usage does not include the residences on site or the irrigation throughout the property. Total Project Economics Installation of the recommended energy efficient equipment identified within this report will result in annual energy cost savings. The recommended equipment may be eligible for federal assistance such as through the USDA NRCS Environmental Quality Incentives Program (EQIP), grants and/or loans through the USDA Rural Energy for America Program (REAP) Section 9007 of the Farm Bill, and utility company incentives. Your first step after deciding to move forward with some or all of these recommendations should be to explore these funding opportunities. Helpful links to these resources are provided at the end of this report to get you started. Farmer Preferences The farmer expressed an interest in energy efficient lighting. This measure was addressed, and the full lighting evaluation can be seen in the Lighting section of the report. Conservation Activity Plan The recommended energy efficiency improvements could possibly be implemented through the use of NRCS Code 374, Farmstead Energy Improvement. Check with your NRCS representative for the most current listing of eligible measures that are applicable to this plan and to determine if any funding assistance is available. Significant Findings The dairy facility at Burnstein Family Dairy, LLC is approximately 31 years old and is equipped wih several energy efficient technologies. Existing energy efficient equipment on the farm includes: vacuum pump and milk transfer pump variable speed drives (VSD), well water plate coolers, and compressor heat recovery (CHR) units. This report focuses on the remaining opportunities at Burnstein Family Dairy, LLC for the installation of energy efficient equipment. EnSave, Inc. 1

6 By taking action on the energy efficiency recommendations detailed in this report, you can save approximately $3,286 per year in propane costs (2,104 gallons) and about $50,699 per year in electricity costs (494,628 kwh). With propane and electric combined, EnSave estimates that your net energy cost savings will amount to $53,985 per year. This represents about 7.6% of the baseline energy costs of $715,182. Bottom Line: Installation of all the recommended energy efficient equipment identified within this report will result in annual energy cost savings of approximately $53,985. ENERGY EFFICIENT EQUIPMENT EVALUATION Summary of Recommendations Burnstein Family Dairy, LLC operates a 4,000 cow dairy farm that produces approximately 111,384,000 pounds (lbs.) of milk per year. This report presents cost effective recommendations for Burnstein Family Dairy, LLC to upgrade to more efficient milk harvest, milk cooling, water heating, lighting, motors, and ventilation. Tables S.1 and S.2 summarize the benefits for all measures recommended by EnSave. These tables are presented as required by NRCS Conservation Activity Plan Code 122. Energy saving equipment lowers usage costs by performing the same or greater work with lower energy inputs. More detailed explanations of energy efficiency equipment are provided later in this report. Measure Table S.1. Summary of Estimated Annual Efficiency Improvements Estimated Reduction in Energy Use Annual Electricity Savings (kwh) Annual Propane Savings (gal) Energy Savings (MMBtu) Estimated Costs, Savings, Payback, and Prioritization for Implementation Installed Cost [a] Energy Cost Savings [b] Payback in Years [a]/[b] Environmental Benefits 1 Greenhouse Gas (Estimated Values) CO 2 (lbs) N 2O (lbs) CH 4 (lbs) Air Pollutant Co- Benefits (Estimated Values) Milk Harvest 37, $6,800 $3, , General Lighting 146, $40,065 $15, , Hot Water 0 2, $10,500 $3, , Refrigeration: Milk Cooling 174, $67,280 $17, , Other Motors and 5, $2,400 $ , Pumps General Ventilation 130, $121,450 $13, , Totals 494,628 2,104 1,882 $248,495 $53, , , ,066.6 Notes: 1. Environmental Benefits are reduction estimates, values are as per 2. A portion of the benefits for some of the improvements offset the benefits of others; for example, insulating side walls will actually seal up some of the air leaks and reduce heat load in the winter. SO 2 (lbs) NO x (lbs) EnSave, Inc. 2

7 Table S.2. Energy Savings of Recommendations Fuel Type Current Use Current Use (MMBtu) Savings Savings (MMBtu) Savings (%) Purchased Electricity (kwh) 6,753,327 23, ,627 1,688 7 % Propane (gal) 14,607 1,344 2, % Totals N/A 24,393 N/A 1,882 8 % The measures recommended in this report are based on energy savings analysis, related energy cost savings, and estimated cost to implement. The simple payback periods (in years) are shown in the respective measure tables. When the payback period is less than or equal to the expected useful life of the measure (in years), the measure is recommended. Estimated cost to implement an energy saving measure is based on EnSave research. Actual costs to your site may vary. The Simple Payback Period can be re-calculated as needed based on site-specific quoted costs. Simple Payback Period is equal to the estimated cost to implement ($) divided by the estimated annual cost of energy saved ($/year) and is expressed as number of years. This method does not account for more complex financial considerations such as loan interest and fees, tax rates, depreciation or any other potential cost impacts. As with any business expenditure proper consideration should be given to all aspects of spending decisions. There may be other factors to consider when making decisions to implement measures recommended and/or considered in this report. These may include aspects such as operational performance, through-put, operation and maintenance costs, labor costs, livestock productivity considerations, integrator contractual requirements, etc. These considerations are beyond the scope of this energy audit. Any new equipment should be properly reviewed for site-specific needs, concerns and applicability. Information on operational schedules and run times is based on input from the producer. Low Cost Energy Saving Tips Some energy savings potential involves primarily management and requires either no or minimal investment other than minor planning or labor. Examples include combining trips and eliminating unnecessary energy expenditures by turning off lights and shutting down engines during periods of inactivity. Another example of a low cost energy saving measure is periodic cleaning of fan blades in dusty environments (e.g., every 3 to 4 weeks) and maintaining belt tension on belt driven fans. This may increase existing fan efficiency by 10% or more without replacement. These actions can increase the useful life of fans. EnSave, Inc. 3

8 Current vs. Projected Electricity Use Figures EU.1 and EU.2 reflect on-site electricity use from October 2012 through September During the twelve month period evaluated, Burnstein Family Dairy, LLC used approximately 6,753,327 kilowatt-hours (kwh) of electricity. The total cost of electricity was $692,371. The peak months typically coincide with hot weather and are the result of increased milk cooling and ventilation loads. The actual monthly electricity use is depicted in Figure EU.1. Figure EU.1. Twelve Month Electricity Use EnSave, Inc. 4

9 Figure EU.2 illustrates the end uses of the electricity used on the farm. Motor usage does not include the milk transfer pump and vacuum pump motors, as they are included in the milk harvest section. Miscellaneous uses include small electrical end uses such as repair shop tools, alley scrapers, and milk agitators. Average dairy farm miscellaneous electricity usage is approximately 5%, and the higher than average miscellaneous electricity usage may be due to increased shop tool usage and variations in stated run hours. The electricity use breakdown by measure is depicted in Figure EU.2. Figure EU.2. Electricity Use Breakdown EnSave, Inc. 5

10 In Figure EU.3, calculated current electricity use is compared to projected use after the installation of all recommended electric energy efficiency equipment. Figure EU.3. Comparison of Current and Proposed Electricity Use EnSave, Inc. 6

11 Current vs. Projected Propane Use Figures PU.1 and PU.2 reflect on-site propane use from October 2012 through September During the twelve month period evaluated, Burnstein Family Dairy, LLC used approximately 14,607 gallons (gal) of propane. The total cost of propane was $22,812. The twelve-month history of propane deliveries are depicted in Figure PU.1. Due to irregular deliveries, the chart does not show actual propane use at the facility. Figure PU.1. Twelve Month Propane Deliveries EnSave, Inc. 7

12 The propane use breakdown by measure is depicted in Figure PU.2. Figure PU.2. Propane Use Breakdown In Figure PU.3, calculated current propane use is compared to projected use after the installation of all energy efficient equipment. Figure PU.3. Comparison of Current and Proposed Propane Use EnSave, Inc. 8

13 On-Site Energy Generation The farm currently operates two diesel generators for testing, upkeep, and maintenance purposes. The generators serve as emergency power supplies and were not in operation for significant time during the twelve month period assessed for the farm. The generators were not evaluated for energy saving opportunities due to low run hours. Table EGEN.1 contains the existing generator details. Table EGEN.1. Current Generator Inventory Equipment Description Manufacturer / Model # Generators Fuel Type Output (kw) Main Farm Generator N/A 1 Diesel (gal) 700 Parlor Buildings Generator N/A 1 Diesel (gal) 250 Milk Harvest Burnstein Family Dairy, LLC currently operates two parlors. The main parlor has (2) 25 hp rotary lobe vacuum pumps that alternate operation so that only one pump is operating at a time. The main parlor vacuum pumps operate for approximately 21 hours per day during milking and an additional 1.5 hours per day for the wash cycles. The main parlor has (3) 3 hp milk transfer pumps that operate about a quarter of the milking time. The main parlor has a total of 80 milking units. The main parlor vacuum pumps are currently equipped with an energy efficient variable speed drive (VSD). This equipment gauges the amount of vacuum suction needed in the parlor and adjusts the speed of the pump motor to deliver no more than is actually needed. The energy savings is from the reduced demand of the vacuum pump. The hospital parlor has (2) 15 hp rotary lobe vacuum pumps that alternate operation so that only one pump is operating at a time. The hospital parlor vacuum pumps operate for approximately 16.5 hours per day during milking and an additional 1.5 hours per day for the wash cycles. The hospital parlor has a 2 hp milk transfer pump that operates about a quarter of the milking time. The hospital parlor has a total of 24 milking units. Burnstein Family Dairy, LLC has an opportunity to improve the energy efficiency of its milk vacuum pump system in the hospital parlor. The installation of a vacuum pump variable speed drive (VSD) for the hospital parlor vacuum pumps is recommended. This equipment gauges the amount of vacuum suction needed in the parlor and adjusts the speed of the pump motor to deliver no more than is actually needed. The energy savings is from the reduced demand of the vacuum pump. To ensure that the variable speed drive (VSD) does not create harmonic distortion with your electricity provider, make sure the installer checks for harmonic distortion and installs any required harmonic distortion mitigation equipment necessary such as harmonic filters. The Institution of Electrical and Electronics Engineers (IEEE) Standard 519 provides guidelines for designing electrical systems with linear and non-linear loads. Also, check with a licensed electrician to determine if the farm's wiring will accommodate a VSD. We do not recommend replacing any of the milk harvest motors. Most of the motors are already NEMA Premium Efficiency motors, and there are no recommendations to replace these motors. EnSave, Inc. 9

14 The other motors are not cost effective to replace due to long payback period. The motor replacement evaluation can be seen in Table MH.5. Tables MH.1 and MH.2 contain the current milk harvest equipment. Equipment Description Main Parlor Vacuum Pump Main Parlor Vacuum Pump Hospital Parlor Vacuum Pump Hospital Parlor Vacuum Pump Run Frequency Alternating Alternating Alternating Alternating Vacuum Pump Type Rotary Lobe Rotary Lobe Rotary Lobe Rotary Lobe Table MH.1. Vacuum Pump Inventory # Milking Units Motor Manufacturer / Model # Motor Motors HP 80 Century Marathon FVN284TTFN48833AAL Emerson AF Westinghouse 1 15 RPM Casing Rating Type Annual VSD? Run Hours Use (kwh) TEFC Yes 4,095 57,554 TEFC Yes 4,095 56,386 TEFC No 3,276 33,709 TEFC No 3,276 33,709 Equipment Description Main Parlor Milk Transfer Pumps Hospital Parlor Transfer Pump Common Receiver Tank? Table MH.2. Milk Transfer Pump Inventory Motor Manufacturer / Model # Motors Motor HP RPM Rating Casing Code VSD? Annual Run Hours Use (kwh) Yes Baldor CWDM361OT TEFC Yes 2,048 13,050 Yes Leeson TEFC No 1,638 2,472 EnSave, Inc. 10

15 Figure MH.3 shows the current milk harvest energy use and the projected milk harvest energy use with the recommended equipment installed. Table MH.4 provides economic details for the recommendation. Table MH.5 lists evaluated equipment options that were not recommended. Figure MH.3. Milk Harvest: Comparison of Electricity Use Equipment Description Hospital Parlor Table MH.4. Milk Harvest: Recommended Energy Saving Equipment Current Equipment 2 vacuum pumps not using a VSD. Recommended Equipment 1 VSD capable of supporting a 15 HP vacuum pump. # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) 1 37,080 $3,801 $6, EnSave, Inc. 11

16 Equipment Description Main Parlor Vacuum Pump Motor Hospital Parlor Transfer Pump Motor Hospital Parlor Vacuum Pump Motors Main Parlor Milk Transfer Pump Motors Main Parlor Vacuum Pump Motor Table MH.5. Milk Harvest: Evaluated Equipment Not Recommended Current Equipment 25 HP, TEFC, RPM, 91.70% Efficiency 2 HP, TEFC, RPM, 84.00% Efficiency 15 HP, TEFC, RPM, 92.40% Efficiency 3 HP, TEFC, RPM, 89.50% Efficiency 25 HP, TEFC, RPM, 93.60% Efficiency Considered Equipment 25 HP, TEFC, RPM, NEMA Premium, 93.6% minimum nominal efficiency 2 HP, TEFC, RPM, NEMA Premium, 85.5% minimum nominal efficiency # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) 1 1,168 $120 $2, $4 $ No Recommendation 2 0 $0 $0 N/A No Recommendation 3 0 $0 $0 N/A No Recommendation 1 0 $0 $0 N/A Note: The motors with no recommendations are NEMA Premium Efficiency motors. Refrigeration: Milk Cooling Burnstein Family Dairy, LLC cools around 306,000 lbs of milk per day from approximately 98 Fahrenheit (F) to about 37 F. The main parlor uses a well water plate cooler as well as a glycol chiller to cool the milk. The main parlor s central milk transfer pump is equipped with a VSD. The hospital parlor uses a well water plate cooler, a glycol chiller, and additional cooling that takes place in the bulk tanks. We recommend installing a milk pump variable speed drive (VSD) on the hospital parlor s milk transfer pump. This equipment can improve the cooling capacity of the plate cooler by regulating the milk flow over the plates, ideally at the slowest and most constant rate possible, thereby allowing time for maximum cooling to take place. We also recommend working with your dairy equipment service provider to install, if necessary, a large enough receiver tank, so that the increase in milk volume in the receiver will allow for a more constant flow of milk through the plate cooler. It would also be sensible that if there were a need to replace the pump motor to consider installing a motor that meets the NEMA Premium standard for an increase in overall efficiency. We also recommend upgrading the main parlor chiller compressors to more energy efficient discus compressors. We recommend replacing the scroll compressors on the main parlor chiller. The existing discus compressors on the main parlor chiller are energy efficient, and there are no recommendations to replace these compressors. Discuss compressors can often be more efficient than scroll compressors for capacities of 10 hp and above, and digitally controlled models with capacity modulation are also available for discus compressors. Work with your refrigeration technician to choose the most efficient compressor available that best meets the needs of the farm. We do not recommend replacing the hospital parlor chiller or bulk tank compressors due to long payback periods. When these compressors require replacement, we recommend replacing them with either high efficiency discus or scroll compressors. EnSave, Inc. 12

17 A supply water temperature of 72 F was used to calculate milk cooling usage and savings figures. Tables MC.1, MC.2, and MC.3 contain the current milk cooling equipment. Energy Efficiency Ratio (EER) is a measure of cooling output per energy input (BTUs / Watt-hour) at a specific operating condition. When installing cooling compressors, be sure to select ones with the highest EER for your application. A larger EER value reflects increased energy savings. Equipment Description Main Parlor Chiller Compressors Main Parlor Chiller Compressors Hospital Parlor Chiller Compressors Hospital Parlor Chiller Compressors Main Parlor Chiller Compressors Table MC.1. Gycol Chiller Compressor Inventory Manufacturer / Model # Copeland ZB75KCE- TWC-551 Copeland 3DB3R12MO TFD 100 Carlyle 06DA5372BA1250 Copeland CRN TF5-970 Copeland ZB75KC- TWD-5 Refrigerant # Compressors Compressor Type Compressor HP EER R-22 4 Scroll R-22 4 Discus R-22 2 Reciprocating R-22 3 Reciprocating R-22 5 Scroll Equipment Description Hospital Bulk Tank Compressor Hospital Bulk Tank Compressor Table MC.2. Bulk Tank Compressor Inventory Manufacturer / Model Refrigerant # Compressors Compressor Type Compressor HP Copeland CRN TF5 R-22 1 Reciprocating Copeland ZB38KC-TF5-250 R-22 1 Scroll EER Table MC.3. Plate Cooler Inventory Equipment Description Manufacturer / Model Type Main Parlor Plate Cooler N/A WW & Glycol Hospital Parlor Plate Cooler N/A WW & Glycol EnSave, Inc. 13

18 Figure MC.4 shows the current milk cooling energy use and the projected milk cooling energy use with recommended equipment installed. Table MC.5 provides economic details the recommendation. Table MC.6 lists equipment that was evaluated but not recommended. Figure MC.4. Refrigeration: Milk Cooling: Comparison of Electricity Use Table MC.5. Refrigeration: Milk Cooling: Recommended Energy Saving Equipment Equipment Description Current Equipment Recommended Equipment # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) Hospital 1 milk transfer pump VSD for Milk Transfer 1 13,743 $1,409 $4, Parlor without VSDs. System 9 compressors with 9 compressor retrofit Main Parlor 9 160,357 $16,437 $63, inefficient compression. kits. Totals 174,100 $17,845 $67, Notes: Energy savings for each recommended piece of equipment assume that all other recommended equipment has been installed. Condensing units and fans must be properly maintained and in good operating condition to insure uniform airflow through the condenser to maximize the energy efficiency ratio. We also recommend making sure the refrigerant lines are properly insulated and the condensing units are cleaned periodically following the manufacturers specifications. EnSave, Inc. 14

19 Table MC.6. Refrigeration: Milk Cooling: Evaluated Equipment Not Recommended Equipment Description Current Equipment Considered Equipment # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) Hospital 6 compressors with inefficient 6 compressor 6 19,267 $1,975 $42, Parlor compression. retrofit kits. 4 Compressors with Efficient No Main Parlor 4 0 $0 $0 N/A Compression Recommendation Hospital 1 Compressors with Efficient No 1 0 $0 $0 N/A Parlor Compression Recommendation Note: The compressors with no recommendations are considered to be energy efficient. Lighting Burnstein Family Dairy, LLC has an opportunity to improve the energy efficiency of its lighting system. We recommend replacing the 400 Watt Metal Halide fixtures with 6-bulb, 4-foot, High Performance T8 (HPT8) fixtures. HPT8 fixtures, specifically designed for demanding agricultural applications, are readily available on the market. Desirable features include a gasketed enclosure to keep out moisture, dust and insects and to facilitate hosedown, premium efficiency ballasts and optically efficient reflectors. The higher efficiency and longer service life will lead to energy savings. HPT8 bulbs maintain around 95% of their initial light output over their lifetime, whereas metal halides lose up to 50% as they age. EnSave, Inc. recommends installing HPT8 lamps with a high correlated color temperature (CCT), greater than 4,000 Kelvin (K) if possible, and a high color rendering index (CRI), greater than 82% if possible. These attributes will result in a higher quality of light and increased apparent brightness. We also recommend the installation of occupancy and daylight harvesting sensors where appropriate in the facility, which will further reduce electrical usage in those areas by reducing the runtimes of the lighting fixtures. For more information on metal halide vs. fluorescent lighting applications, see We recommend replacing the farm s probe start metal halide fixtures in the calf barn, the acid trial barn, and the exterior pole lights with energy efficient pulse start metal halide fixtures. Pulse start fixtures provide more lumens per watt than traditional probe start fixtures and maintain more lumens over the life of the lamp. This means a 400 watt probe start fixture can be replaced with a 320 watt pulse start fixture, still have greater light output and reduce electrical costs by 20%. Pulse start fixtures also warm up faster, have less color variation, and can last up to 50% longer than traditional probe start fixtures. For more information on probe start vs. pulse start metal halide fixtures, see pulse.pdf. We also recommend replacing the farm s T12 lighting fixtures with either High Performance (HP) T8 or T5 High-Output (HO) fluorescent fixtures. HPT8 and T5HO fixtures, specifically designed for demanding agricultural applications, are readily available on the market. Desirable features include a gasketed enclosure to keep out moisture, dust, and insects and to facilitate hosedown, premium efficiency ballasts, and optically efficient reflectors. The higher efficiency and longer service life will lead to energy savings. EnSave, Inc. recommends installing HPT8 and T5HO lamps with a high correlated color temperature (CCT), greater than 4,000 Kelvin (K) if possible, and a high color rendering index (CRI), greater than 82% if possible. These EnSave, Inc. 15

20 attributes will result in a higher quality of light and increased apparent brightness. Please work with your electrician to decide whether the HPT8 or T5HO fluorescent fixtures are more appropriate for your specific operation and geographical location. As an alternative, we recommend that you also look into the option of upgrading the existing eight-foot T12 lamps and magnetic ballasts to eight-foot HPT8 lamps and electronic ballasts using retrofit kits where applicable. This can save on time and material costs by reusing the existing fixture body. For information on high-performance fluorescent lamps and ballasts, see the Resources section of this report, including: T-8 and T-5 Efficient Fluorescent Lighting, published by EnSave; and High-Performance 4' T8 Lamp and Ballast Qualifying List, published by CEE (internet resource). We generally recommend installing vapor-proof fixtures, where appropriate, to keep strip fluorescent fixtures clean, dry, and protected. We also recommend installing vapor-proof lamp guards that can be used on standard incandescent bulb sockets when replacing them with compact fluorescent lamps to also keep them clean, dry, and protected, where appropriate. For safety reasons, it is advised to never fully enclose compact fluorescent lamps greater than 23- Watts in order to prevent heat from building up inside the fixture, which can lead to a potential fire hazard. We also recommend the installation of photocell, occupancy and daylight harvesting sensors where appropriate in the facility, which will further reduce electrical usage in those areas by reducing the runtimes of the lighting fixtures. An example would be to install occupancy sensors in bathrooms and hallways where there is infrequent use. We do not recommend replacing the metal halide light in Lot 4-39 due to long payback period. The T8 linear fluorescent lights are considered energy efficient, and there are no recommendations to replace these lights. Tables L.1 and L.2 contain the current lighting inventory. Table L.1. Current Lighting Inventory Location / Area # Annual Run Total Fixture Fixture Type Bulb Wattage Description Fixtures Hours Wattage Use (kwh) Lot Standard Metal Halide 400 4, ,943 Lot Standard Metal Halide 400 4, ,623 Lot Standard Metal Halide 400 4, ,943 Lot Standard Metal Halide 400 4, ,967 Lot Standard Metal Halide 400 4, ,861 Hospital Barn 4 Standard Metal Halide 400 4, ,967 Feed Barn 6 Standard Metal Halide 400 4, ,951 Shop 4 Standard Metal Halide 400 4, ,967 Exterior Lights 2 Standard Metal Halide 1,000 4,368 1,077 9,409 Acid Trial Barn 1 Standard Metal Halide 175 8, ,826 Calf Barn 8 Standard Metal Halide 175 4, ,303 Lot Standard Metal Halide 250 4, ,271 Main Parlor 4 Standard Metal Halide 400 8, ,934 EnSave, Inc. 16

21 Location / Area Description Table L.2. Current Linear Fluorescent Inventory # Fixtures Fixture Type # Bulbs / Fixture Length of Bulbs (ft) Bulb Wattage Annual Run Hours Total Fixture Wattage Annual Use (kwh) Main Parlor 11 T , ,411 Main Parlor Holding Area 27 T , ,823 Break Room 2 T , ,167 Main Parlor Milk Room 5 T , ,416 Main Parlor Equipment Room 4 T , ,333 Main Parlor Breezeway 3 T , ,250 Main Parlor Health Station Area 3 T , ,717 Hospital Parlor Milk Room 2 T , ,625 Hospital Parlor 7 T , ,146 Hospital Parlor Equipment Room 2 T , ,625 Hospital Parlor Holding Pen 4 T , ,141 Hospital Parlor Health Station 16 T , ,870 Ron's Office 4 T , ,355 Parlor Office 6 T , ,774 Conference Room 12 T , ,548 Embryo Transfer Lab 3 T Dry Cow Patient Area 3 T , ,250 Foot Trimming Area 2 T , ,083 Lot T , ,668 Hospital Barn 4 T , ,167 Maternity Barn 2 T , ,167 Maternity Barn Office 3 T , ,756 Shop 3 T , ,625 Shop 4 T , ,145 Main Office 20 T , ,853 Heifer Building 8 T , ,201 Special Bull Barn 8 T , ,521 Calf Barns 40 T , ,899 Calf Barns 16 T , ,612 Lot T , ,559 Acidic Trial Barn 2 T , ,145 Acidic Trial Barn 1 T , Shop 2 T , Fuel Island 2 T , ,145 Maternity Barn 2 T , ,171 EnSave, Inc. 17

22 Figure L.3 shows a comparison of the estimated current and projected lighting electricity use. Table L.4 provides economic details for each lighting upgrade recommendation. Table L.5 lists equipment options that were evaluated but not recommended. Figure L.3. General Lighting: Comparison of Electricity Use EnSave, Inc. 18

23 Equipment Description Main Parlor Lot 7-8 Lot 1-5 Lot 4-39 Lot 2-6 Feed Barn Hospital Barn Lot Shop Exterior Lights Main Parlor Health Station Area Table L.4. General Lighting: Recommended Energy Saving Equipment Current Equipment 400W Standard Metal Halide (456 Total Input Watts) 400W Standard Metal Halide (456 Total Input Watts) 400W Standard Metal Halide (456 Total Input Watts) 400W Standard Metal Halide (456 Total Input Watts) 400W Standard Metal Halide (456 Total Input Watts) 400W Standard Metal Halide (456 Total Input Watts) 400W Standard Metal Halide (456 Total Input Watts) 400W Standard Metal Halide (456 Total Input Watts) 400W Standard Metal Halide (456 Total Input Watts) 1000W Standard Metal Halide (1077 Total Input Watts) 2-Lamp, 8ft. 75W T12 (180 Total Input Watts) Recommended Equipment 6-Lamp, 4ft. T8 (32W Bulbs, 202 Total Input Watts) 6-Lamp, 4ft. T8 (32W Bulbs, 202 Total Input Watts) 6-Lamp, 4ft. T8 (32W Bulbs, 202 Total Input Watts) 6-Lamp, 4ft. T8 (32W Bulbs, 202 Total Input Watts) 6-Lamp, 4ft. T8 (32W Bulbs, 202 Total Input Watts) 6-Lamp, 4ft. T8 (32W Bulbs, 202 Total Input Watts) 6-Lamp, 4ft. T8 (32W Bulbs, 202 Total Input Watts) 6-Lamp, 4ft. T8 (32W Bulbs, 202 Total Input Watts) 6-Lamp, 4ft. T8 (32W Bulbs, 202 Total Input Watts) 750W Pulse-Start Metal Halide (795 Total Input Watts) Appropriate T8 or T5 Linear Fluorescent Fixture (135 Total Input Watts)¹ # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) 4 8,876 $910 $ ,766 $796 $1, ,036 $5,231 $11, ,766 $796 $1, ,438 $455 $ ,657 $682 $1, ,438 $455 $ ,861 $1,933 $4, ,438 $455 $ ,464 $253 $ ,179 $121 $ Fuel Island 2-Lamp, 8ft. 75W T12 (180 Appropriate T8 or T5 Linear Fluorescent Total Input Watts) Fixture (135 Total Input Watts)¹ $81 $ Calf Barns 2-Lamp, 8ft. 75W T12 (180 Appropriate T8 or T5 Linear Fluorescent Total Input Watts) Fixture (135 Total Input Watts)¹ 40 15,725 $1,612 $6, Acidic Trial 2-Lamp, 4ft. 40W T12 (96 Total Appropriate T8 or T5 Linear Fluorescent Barn Input Watts) Fixture (72 Total Input Watts)¹ $21 $ Acidic Trial 2-Lamp, 8ft. 75W T12 (180 Appropriate T8 or T5 Linear Fluorescent Barn Total Input Watts) Fixture (135 Total Input Watts)¹ $81 $ Acid Trial Barn 175W Standard Metal Halide 150W Pulse-Start Metal Halide (163 (209 Total Input Watts) Total Input Watts) $41 $ Hospital Parlor 2-Lamp, 8ft. 75W T12 (180 Appropriate T8 or T5 Linear Fluorescent Health Station Total Input Watts) Fixture (135 Total Input Watts)¹ 16 4,717 $484 $2, Parlor Office 2-Lamp, 4ft. 40W T12 (96 Total Appropriate T8 or T5 Linear Fluorescent Input Watts) Fixture (72 Total Input Watts)¹ $97 $ Conference 2-Lamp, 4ft. 40W T12 (96 Total Appropriate T8 or T5 Linear Fluorescent Room Input Watts) Fixture (72 Total Input Watts)¹ 12 1,887 $193 $1, Shop 2-Lamp, 8ft. 75W T12 (180 Appropriate T8 or T5 Linear Fluorescent Total Input Watts) Fixture (135 Total Input Watts)¹ $81 $ Ron's Office 4-Lamp, 4ft. 40W T12 (192 Appropriate T8 or T5 Linear Fluorescent Total Input Watts) Fixture (144 Total Input Watts)¹ $86 $ W Standard Metal Halide 150W Pulse-Start Metal Halide (163 Calf Barn 8 1,607 $165 $1, (209 Total Input Watts) Total Input Watts) Totals 146,608 $15,027 $40, Notes: Energy savings for T12 fixtures assume a 25% reduction in wattage. Savings on actual fixtures ranges from 25-35% based on individual fixture, ballast, lamp, etc. EnSave, Inc. uses the lower end of the range to provide a conservative energy savings estimate. Work with your electrician to determine whether the T5HO, HPT8, T5, and T8 fixture is optimal for your specific operation. Considerations when choosing between the different types of fixtures include, cost, availability from suppliers, geographic location of your farm, and operating conditions. It is also important to consider the EnSave, Inc. 19

24 temperature range that the ballast will be performing in as some ballasts are optimum for cold starting but may be too warm for enclosed or vapor-sealed fixtures, a High Output ballast may not be recommended if the ambient temperature will not go below 50 degrees Fahrenheit. Equipment Description Lot 4-39 Table L.5. General Lighting: Evaluated Equipment Not Recommended Current Equipment 250W Standard Metal Halide (291 Total Input Watts) Considered Equipment 250W Pulse-Start Metal Halide (267 Total Input Watts) # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) $11 $ Ventilation Burnstein Family Dairy, LLC has an opportunity to improve the energy efficiency of its ventilation system by installing high efficiency fans. The fans recommended for replacement can be seen in Table V.5. Some of the fans are not recommended for replacement due to long payback periods. These fans can be seen in Table V.6 and Table V.7. The fans we generally recommend represent the midpoint between the minimum efficiency threshold and the highest efficiency fan as grouped and tested by Bioenvironmental and Structural Systems (BESS) Laboratory. Circulation fans are typically rated based on the pounds of force per kw of power rating (lbf/kw) at 0.00 water gauge static pressure; the higher the (lbf/kw) the higher the efficiency. Exhaust fans are typically rated based on the cubic feet of air moved per minute per Watt of power rating (cfm/watt) and airflow ratio, which gives an indication of a fan s ability to push air when there is contrary pressure acting against the fan from either wind or higher static pressure inside a building. Exhaust fans are commonly rated at a static exhaust pressure of 0.10 water gauge. We also recommend that any fans being installed be models previously tested by BESS Lab or the Air Movement and Control Association (AMCA) For more specific information on circulation fan selection and maintenance please refer to the Resources section of this report. EnSave, Inc. 20

25 Tables V.1, V.2, and V.3 provide a list of the fans analyzed in this report. Table V.1. Current LVHS Exhaust Inventory Manufacturer / Location / Area Description Model # Fans Diameter Motor HP Run Hours Model Use (kwh) Main Parlor Acme N/A in. 1 7,056 14,572 Main Parlor Acme N/A in ,056 3,822 Hospital Parlor Acme N/A in ,056 3,822 Lot 3-9 Acme N/A in , ,113 Lot 7-8 Acme N/A in. 1 7, ,409 Lot 1-5 Acme N/A in. 1 7, ,441 Lot 4-39 Acme N/A in. 1 7, ,294 Lot 2-6 Acme N/A in. 1 7, ,400 Special Bull Barn Acme N/A in. 1 7,056 31,253 Special Bull Barn Acme N/A 5 36in ,056 19,063 Special Bull Barn Acme N/A in. 1 8,736 29,021 Shop Acme N/A in. 1 3,528 7,286 Hospital Living Quarters N/A N/A 35 36in , ,048 Hospital Milk House N/A N/A in ,056 1,819 Table V.2. Current LVHS Circulation Inventory Location / Area Description Manufacturer # Fans Fan Style Diameter Run Hours Use (kwh) Main Parlor Pit N/A 5 Basket 36in. 7,056 20,110 Main Parlor Holding Area N/A 5 Panel 50-53in. 7,056 36,480 Main Parlor Holding Area N/A 10 Panel 36in. 7,056 40,078 Wash Pen N/A 25 Panel 36in. 7, ,195 Lot N/A 44 Panel 50-53in. 7, ,236 Maternity Barn N/A 2 Panel 36in. 7,728 8,779 Hospital Barn N/A 30 Panel 36in. 7, ,685 Maternity Barn N/A 4 Panel 50-53in. 7,896 32,658 Hospital Parlor Holding Pen N/A 10 Panel 36in. 7,056 40,078 Hospital Parlor Pit N/A 2 Basket 36in. 3,528 4,022 Hospital Working Station N/A 6 Panel 36in. 3,528 12,023 Foot Trimming Area N/A 2 Panel 36in. 3,528 4,008 Cow Patient Area N/A 3 Basket 36in. 7,056 12,066 Calf Barns N/A 53 Basket 36in. 7, ,162 Shop N/A 3 Panel 36in. 3,528 6,012 Acid Milk Trial Barn N/A 2 Basket 36in. 7,056 8,044 Calf Barns N/A 13 Panel 36in. 7,056 52,102 Acid Milk Trial Barn N/A 1 Box 48-49in. 7,056 8,030 Lot 3-9 N/A 5 Panel 54-60in. 7,728 35,703 Pen N/A 18 Panel 36in. 7,728 79,011 Table V.3. Current HVLS Ventilation Inventory Location / Area Manufacturer Model # Fans Diameter Motor HP Run Hours Use (kwh) Description Heifer Station N/A N/A 2 16ft ,376 12,031 EnSave, Inc. 21

26 Figure V.4 shows a comparison of the estimated current and projected ventilation electricity use. Table V.5 provides economic details for the recommendation. Table V.6 and Table V.7 list equipment options that were evaluated but not recommended. Figure V.4. General Ventilation: Comparison of Electricity Use EnSave, Inc. 22

27 Equipment Description Hospital Parlor Main Parlor Hospital Living Quarters Calf Barns Acid Milk Trial Barn Maternity Barn Lot Table V.5. General Ventilation: Recommended Energy Saving Equipment Current Equipment 24-26in. Exhaust Fan (6,500 cfm, 12.0 cfm / Watt), running 7,056 Hours / Year 24-26in. Exhaust Fan (6,500 cfm, 12.0 cfm / Watt), running 7,056 Hours / Year 36in. Exhaust Fan (10,610 cfm, 15.5 cfm / Watt), running 7,056 Hours / Year 36in. Basket Circulation Fan (10.10 lbf, 0.57 kw, lbf/kw), Running 7,056 Hours / Year 36in. Basket Circulation Fan (10.10 lbf, 0.57 kw, lbf/kw), Running 7,056 Hours / Year 50-53in. Panel Circulation Fan (23.40 lbf, 1.03 kw, lbf/kw), Running 7,896 Hours / Year 50-53in. Panel Circulation Fan (23.40 lbf, 1.03 kw, lbf/kw), Running 7,896 Hours / Year Recommended Equipment 24-26in. Exhaust Fan (6,980 cfm, 17.1 cfm / Watt) 24-26in. Exhaust Fan (6,980 cfm, 17.1 cfm / Watt) 36in. Exhaust Fan (10,650 cfm, 20.0 cfm / Watt) 36in. Basket Circulation Fan (10.10 lbf, 0.47 kw, lbf/kw) 36in. Basket Circulation Fan (10.10 lbf, 0.47 kw, lbf/kw) 50-53in. Panel Circulation Fan (23.80 lbf, 0.90 kw, lbf/kw) 50-53in. Panel Circulation Fan (23.80 lbf, 0.90 kw, lbf/kw) # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) $97 $ $97 $ ,542 $3,848 $31, ,145 $3,910 $34, ,439 $148 $1, ,327 $444 $4, ,597 $4,879 $48, Totals 130,934 $13,421 $121, EnSave, Inc. 23

28 Equipment Description Main Parlor Holding Area Lot 2-6 Main Parlor Pen Maternity Barn Hospital Barn Special Bull Barn Hospital Parlor Holding Pen Main Parlor Holding Area Wash Pen Calf Barns Lot 3-9 Lot 7-8 Lot 4-39 Lot 1-5 Special Bull Barn Shop Table V.6. General Ventilation: Evaluated Equipment Not Recommended Current Equipment 50-53in. Panel Circulation Fan (23.40 lbf, 1.03 kw, lbf/kw), Running 7,056 Hours / Year 48-49in. Exhaust Fan (19,000 cfm, 18.4 cfm / Watt), running 7,728 Hours / Year 48-49in. Exhaust Fan (19,000 cfm, 18.4 cfm / Watt), running 7,056 Hours / Year 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 7,728 Hours / Year 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 7,728 Hours / Year 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 7,728 Hours / Year 50-53in. Exhaust Fan (22,700 cfm, 20.5 cfm / Watt), running 8,736 Hours / Year 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 7,056 Hours / Year 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 7,056 Hours / Year 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 7,056 Hours / Year 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 7,056 Hours / Year 50-53in. Exhaust Fan (22,700 cfm, 20.5 cfm / Watt), running 7,728 Hours / Year 50-53in. Exhaust Fan (22,700 cfm, 20.5 cfm / Watt), running 7,728 Hours / Year 50-53in. Exhaust Fan (22,700 cfm, 20.5 cfm / Watt), running 7,728 Hours / Year 50-53in. Exhaust Fan (22,700 cfm, 20.5 cfm / Watt), running 7,728 Hours / Year 50-53in. Exhaust Fan (22,700 cfm, 20.5 cfm / Watt), running 7,056 Hours / Year 48-49in. Exhaust Fan (19,000 cfm, 18.4 cfm / Watt), running 3,528 Hours / Year Considered Equipment 50-53in. Panel Circulation Fan (23.80 lbf, 0.90 kw, lbf/kw) 48-49in. Exhaust Fan (19,700 cfm, 21.6 cfm / Watt) 48-49in. Exhaust Fan (19,700 cfm, 21.6 cfm / Watt) 36in. Panel Circulation Fan (10.80 lbf, 0.52 kw, lbf/kw) 36in. Panel Circulation Fan (10.80 lbf, 0.52 kw, lbf/kw) 36in. Panel Circulation Fan (10.80 lbf, 0.52 kw, lbf/kw) 50-53in. Exhaust Fan (23,200 cfm, 23.0 cfm / Watt) 36in. Panel Circulation Fan (10.80 lbf, 0.52 kw, lbf/kw) 36in. Panel Circulation Fan (10.80 lbf, 0.52 kw, lbf/kw) 36in. Panel Circulation Fan (10.80 lbf, 0.52 kw, lbf/kw) 36in. Panel Circulation Fan (10.80 lbf, 0.52 kw, lbf/kw) 50-53in. Exhaust Fan (23,200 cfm, 23.0 cfm / Watt) 50-53in. Exhaust Fan (23,200 cfm, 23.0 cfm / Watt) 50-53in. Exhaust Fan (23,200 cfm, 23.0 cfm / Watt) 50-53in. Exhaust Fan (23,200 cfm, 23.0 cfm / Watt) 50-53in. Exhaust Fan (23,200 cfm, 23.0 cfm / Watt) 48-49in. Exhaust Fan (19,700 cfm, 21.6 cfm / Watt) # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) 5 4,833 $495 $5, ,953 $2,865 $33, ,702 $174 $2, ,233 $741 $11, $82 $1, ,056 $1,236 $19, ,585 $265 $4, ,669 $376 $6, ,669 $376 $6, ,173 $940 $16, ,770 $489 $8, ,015 $4,922 $94, ,010 $3,281 $63, ,486 $3,125 $60, ,729 $4,687 $90, ,783 $285 $6, $87 $2, EnSave, Inc. 24

29 Equipment Description Hospital Working Station Foot Trimming Area Hospital Milk House Special Bull Barn Main Parlor Pit Cow Patient Area Hospital Parlor Pit Shop Acid Milk Trial Barn Heifer Station Table V.7. General Ventilation: Evaluated Equipment Not Recommended (Cont.) Current Equipment 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 3,528 Hours / Year 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 3,528 Hours / Year 16-19in. Exhaust Fan (2,810 cfm, 10.9 cfm / Watt), running 7,056 Hours / Year 36in. Exhaust Fan (9,780 cfm, 18.1 cfm / Watt), running 7,056 Hours / Year 36in. Basket Circulation Fan (10.10 lbf, 0.57 kw, lbf/kw), Running 7,056 Hours / Year 36in. Basket Circulation Fan (10.10 lbf, 0.57 kw, lbf/kw), Running 7,056 Hours / Year 36in. Basket Circulation Fan (10.10 lbf, 0.57 kw, lbf/kw), Running 3,528 Hours / Year 36in. Panel Circulation Fan (10.40 lbf, 0.57 kw, lbf/kw), Running 3,528 Hours / Year 48-49in. Box Circulation Fan (21.70 lbf, 1.14 kw, lbf/kw), Running 7,056 Hours / Year 16ft Exhaust Fan (147,569 cfm, cfm / Watt), running 5,376 Hours / Year Considered Equipment 36in. Panel Circulation Fan (10.80 lbf, 0.52 kw, lbf/kw) 36in. Panel Circulation Fan (10.80 lbf, 0.52 kw, lbf/kw) 16-19in. Exhaust Fan (3,000 cfm, 12.5 cfm / Watt) 36in. Exhaust Fan (9,840 cfm, 18.6 cfm / Watt) 36in. Basket Circulation Fan (10.90 lbf, 0.57 kw, lbf/kw) 36in. Basket Circulation Fan (10.90 lbf, 0.57 kw, lbf/kw) 36in. Basket Circulation Fan (10.90 lbf, 0.57 kw, lbf/kw) # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) 6 1,101 $113 $3, $38 $1, $13 $ $41 $4, $14 $3, $9 $1, $3 $1, No Recommendation 3 0 $0 $0 N/A No Recommendation 1 0 $0 $0 N/A No Recommendation 2 0 $0 $0 N/A Lot in. Panel Circulation Fan (21.20 lbf, 0.92 kw, lbf/kw), Running 7,728 Hours / Year No Recommendation 5 0 $0 $0 N/A Notes: Fans recommended represent the midpoint between the minimum efficiency threshold and the highest efficiency fan as grouped and tested by Bioenvironmental and Structural Systems (BESS) Laboratory. To be eligible for incentives, fans must be tested by BESS Lab or the Air Movement and Control Association (AMCA) EnSave, Inc. 25

30 Water Heating Burnstein Family Dairy, LLC heats approximately 3,428 gallons of water a day from 72 Fahrenheit (F) to 180 F. The main parlor heats approximately 2,086 gallons of water per day using a propane-fired water heater as well as energy efficient compressor heat recovery (CHR) units. These devices are insulated storage tanks with heat exchangers that use the heat extracted from the milk through the hot gas refrigerant line from the refrigeration system s compressors, to pre-heat the water to approximately 110 F before it enters the conventional water heaters. The energy savings comes from the reduced heating required in the actual water heater. The hospital parlor heats approximately 1,342 gallons of water a day using (2) propane-fired water heaters. We recommend the installation of compressor heat recovery units (CHR) in your hospital parlor refrigeration system. The actual number of heat recovery units and their location will depend on the operating hours of the compressor and the configuration of the existing system. Please contact your EPA certified refrigeration technician to determine the preferred and practical number of CHR units that will operate most efficiently with your system. Tables WH.1 and WH.2 contain information on the hot water and wash basin equipment. Equipment Description Main Parlor Water Heater Hospital Parlor Water Heater #1 Hospital Parlor Water Heater #2 Manufacturer / Model Table WH.1. Water Heater Inventory Capacity (gal) Hot Water Temp. ( F) Gallons Used Daily CHR? Fuel Type Energy Use Lochinvar ,086.4 Yes Propane (gal) 6,011 Rheem G75-75N No Propane (gal) 2,990 Rheem G No Propane (gal) 2,990 Table WH.2. Wash Sink Inventory Length / Avg. Fill Depth # Hot # Warm Misc. Gallons Type Width (in) Diameter (in) (in) Washes / Rinses Washes / Rinses Heated / Day Round Bottom Receiver Vat 36 N/A EnSave, Inc. 26

31 Figure WH.3 shows a comparison of the estimated current and projected energy use. Table WH.4 provides economic details for the recommendation. Figure WH.3. Hot Water: Comparison of Propane Use Equipment Description Hospital Parlor Water Heater #1 Hospital Parlor Water Heater #2 Table WH.4. Hot Water: Recommended Energy Saving Equipment Current Equipment Hot Water Heater Hot Water Heater Recommended Equipment Compressor Heat Recovery System Compressor Heat Recovery System # to Install Propane Savings (gal) Cost Savings ($) Installed Cost ($) Payback (Years) 1 1,052 $1,643 $4, ,052 $1,643 $6, Totals 2,104 $3,286 $10, Stock Watering There are no activities or equipment at this site that are applicable to this section. Air Heating and Building Environment It is quite costly to heat the air using a forced hot air furnace. Rather than heating the air, radiant heaters use radiant energy to efficiently heat the objects in a room. Like sitting in a room with a wood stove, greater comfort can be achieved at lower air temperatures and lower energy EnSave, Inc. 27

32 costs. The forced hot air furnace transfers 40% of their energy as radiant heat to the floor and 60% to the air as convection heat. Because of their design, radiant heaters are able to transfer 90% of their heat to the floor. As a result radiant heaters consume 15-30% less fuel than the forced hot air heaters. Burnstein Family Dairy, LLC is currently using the most energy efficient form of heating in the use of the radiant heaters in the milking parlors. At this time there are no recommendations to improve the space heating on the farm. Table SH.1 provides a list of the heaters evaluated on the farm. Location / Area Description Manufacturer / Model Table SH.1. Current Heater Inventory Total # Heaters Heater Type Ignition Type Main Parlor N/A 4 Radiant Electronic Hospital Parlor N/A 2 Radiant Electronic Fuel Type Propane (gal) Propane (gal) Output Rating (Btu/Hour) Run Hours Input Rating (Btu/Hour) Annual Use 40, ,105 1,744 40, , Controllers The farm has the opportunity to install milking vacuum pump and transfer pump variable speed drives (VSD) on the hospital parlor milking equipment. More information on these recommendations can be seen in the Milk Harvest and Milk Cooling sections of the report. Air Cooling The farm has several air conditioning units for the offices. These units were evaluated in the Additional Equipment section of the report. Other Motors and Pumps Burnstein Family Dairy, LLC has an opportunity to improve the energy efficiency of the chiller circulation pump systems by upgrading to motors that meet the NEMA Premium standards. For information on NEMA Premium, see: Improving the efficiency of a pump motor will likely increase the life of the pump and reduce operating costs significantly. Proper maintenance and monitoring techniques will help to detect problems early on and determine solutions for creating a more efficient system. If it was not possible to read motor nameplate information, a Totally Enclosed Fan Cooled (TEFC) motor type and/or 1,800 revolutions per minute (RPM) were assumed. When actual motor efficiencies were not available, the estimated energy and related cost savings assume a baseline using the Energy Policy Act of 1992 minimum requirements, which all motors manufactured after 1997 meet. Due to low operating hours, some motors are not recommended for upgrades, as it would not be cost effective. To consistently have the lowest possible energy consumption from motors, when a EnSave, Inc. 28

33 three phase motor 1 hp or greater burns out, always install the most energy efficient motor available. We recommend replacing motors with units that meet the NEMA Premium standard. Although we are not recommending the replacement of the air compressor motor at this time, proper maintenance and monitoring techniques will help to detect problems early on and determine solutions for creating a more efficient system. Compressed air systems can be very costly to operate and effective maintenance and repair are key elements to controlling these costs. Prompt identification and repair of leaks is extremely cost effective as they create additional and unnecessary loads on the system. Proper air pressure is also important as each 2 psig (pound-force per square inch gauge) can equate to approximately 1% energy savings. Thus it is important to match the supply pressure with the requirements of the tools or end uses. Distribution pressure drop should not be greater than about 10%, for example 90 psig at the tank should be sufficient to provide 80 psig at the tool. Table M.1 provides a list of the motors analyzed in this report. Equipment Description Table M.1. Current Motor Inventory Manufacturer / Model # Motor Motors HP RPM Rating Casing Type VSD? Annual Run Hours Motor Estimated Annual Electricity Use 1-29 Well Pump Motor N/A 1 60 N/A N/A Yes 8, ,796 Bull Lot Well Pump Motor N/A 1 50 N/A N/A Yes 8, ,119 North Pivot Well Pump Motor N/A 1 75 N/A N/A No 1,344 67,898 Main Parlor Well Pump Motor N/A 1 50 N/A N/A Yes 8, ,119 Lot 51 Well Pump Motor N/A 1 75 N/A N/A No 3, ,889 Shop Well Pump Motor N/A 1 75 N/A N/A No 2, ,333 Calf Yard Well Pump Motor N/A 1 20 N/A N/A No 2,912 40,566 Main Chiller Circulation Pump Motors Baldor JMM3711T TEFC No 7, ,336 Hospital Chiller Circulation Pump Motors N/A TEFC No 6,006 26,715 Hospital Truck Loading Pump Motor Baldor CM3615T TEFC No ,404 Hospital Parlor Air Compressor Motor 1 Westinghouse TEFC No 1,456 10,231 Hospital Parlor Air Compressor Motor 2 Baldor M3313T TEFC No 1,456 10,311 Pit Floor Wash Motors WEG 00736ES3E213JM TEFC No 2,184 24,006 Free Stall Mister Pump Motors WEG 00718E213TC-W TEFC No ,095 Free Stall Mister Pump Motor N/A TEFC No 896 6,346 Main Parlor Truck Loading Pump Motor Baldor M3313T TEFC No 1,092 7,734 Hospital Barn Well Pump Motor N/A 1 5 N/A N/A No 1,456 5,274 Main Parlor Cow Wash Pump Motor US Electric 1 25 N/A N/A No ,485 Pen Float Pump Motor N/A 1 20 N/A TEFC No ,142 Drip Irrigation Pivot Well Pump Motor N/A 1 50 N/A N/A No 1,344 45,800 Emerson T55MWCET- Molasses Pump Motor TEFC No 1,092 1, Lat and Whey Pump Motor Dayton A TEFC No 1,092 4,120 Main Parlor Air Compressor Motor Ingersoll Rand 1 25 N/A N/A Yes 4,368 44,064 EnSave, Inc. 29

34 To consistently have the lowest possible energy consumption from motors, when a motor greater than 1 horsepower (HP) burns out, always replace them with the most energy efficient motor available. EnSave, Inc. recommends replacing motors with units that meet the National Electrical Manufacturers Association (NEMA) Premium standard. For more information on NEMA Premium, see Motors.aspx. Figure M.2 shows a comparison of the estimated current and projected motor electricity use. Table M.3 provides economic details for each motor upgrade recommendation. Table M.4 and Table M.5 list equipment options that were evaluated, but not recommended. Figure M.2. Other Motors and Pumps: Comparison of Electricity Use Equipment Description Main Chiller Circulation Pump Motors Table M.3. Other Motors and Pumps: Recommended Energy Saving Equipment Current Equipment 10 HP, TEFC, RPM, 85.50% Efficiency Recommended Equipment 10 HP, TEFC, RPM, NEMA Premium, 90.2% minimum nominal efficiency # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) 2 5,906 $605 $2, EnSave, Inc. 30

35 Equipment Description Bull Lot Well Pump Motor Main Parlor Well Pump Motor 1-29 Well Pump Motor Calf Yard Well Pump Motor Pit Floor Wash Motors Lot 51 Well Pump Motor Lat and Whey Pump Motor Hospital Chiller Circulation Pump Motors Main Parlor Air Compressor Motor Hospital Parlor Air Compressor Motor 2 Shop Well Pump Motor Hospital Barn Well Pump Motor Main Parlor Truck Loading Pump Motor Drip Irrigation Pivot Well Pump Motor Hospital Parlor Air Compressor Motor 1 North Pivot Well Pump Motor Pen Float Pump Motor Table M.4. Other Motors and Pumps: Evaluated Equipment Not Recommended Current Equipment 50 HP, TEFC, RPM, 93.00% Efficiency 50 HP, TEFC, RPM, 93.00% Efficiency 60 HP, TEFC, RPM, 93.60% Efficiency 20 HP, TEFC, RPM, 91.00% Efficiency 7.5 HP, TEFC, RPM, 86.50% Efficiency 75 HP, TEFC, RPM, 94.10% Efficiency 5 HP, TEFC, RPM, 84.00% Efficiency 3 HP, TEFC, RPM, 85.50% Efficiency 25 HP, TEFC, RPM, 92.40% Efficiency 10 HP, TEFC, RPM, 89.50% Efficiency 75 HP, TEFC, RPM, 94.10% Efficiency 5 HP, TEFC, RPM, 87.50% Efficiency 10 HP, TEFC, RPM, 89.50% Efficiency 50 HP, TEFC, RPM, 93.00% Efficiency 10 HP, TEFC, RPM, 90.20% Efficiency 75 HP, TEFC, RPM, 94.10% Efficiency 20 HP, TEFC, RPM, 91.00% Efficiency Considered Equipment 50 HP, TEFC, RPM, NEMA Premium, 94.5% minimum nominal efficiency 50 HP, TEFC, RPM, NEMA Premium, 94.5% minimum nominal efficiency 60 HP, TEFC, RPM, NEMA Premium, 95% minimum nominal efficiency 20 HP, TEFC, RPM, NEMA Premium, 93% minimum nominal efficiency 7.5 HP, TEFC, RPM, NEMA Premium, 89.5% minimum nominal efficiency 75 HP, TEFC, RPM, NEMA Premium, 95.4% minimum nominal efficiency 5 HP, TEFC, RPM, NEMA Premium, 88.5% minimum nominal efficiency 3 HP, TEFC, RPM, NEMA Premium, 86.5% minimum nominal efficiency 25 HP, TEFC, RPM, NEMA Premium, 93.6% minimum nominal efficiency 10 HP, TEFC, RPM, NEMA Premium, 91.7% minimum nominal efficiency 75 HP, TEFC, RPM, NEMA Premium, 95.4% minimum nominal efficiency 5 HP, TEFC, RPM, NEMA Premium, 89.5% minimum nominal efficiency 10 HP, TEFC, RPM, NEMA Premium, 91.7% minimum nominal efficiency 50 HP, TEFC, RPM, NEMA Premium, 94.5% minimum nominal efficiency 10 HP, TEFC, RPM, NEMA Premium, 91.7% minimum nominal efficiency 75 HP, TEFC, RPM, NEMA Premium, 95.4% minimum nominal efficiency 20 HP, TEFC, RPM, NEMA Premium, 93% minimum nominal efficiency # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) 1 2,780 $285 $4, ,780 $285 $4, ,077 $315 $6, $89 $2, $82 $2, ,506 $257 $8, $21 $ $32 $1, $58 $2, $25 $1, ,503 $154 $8, $12 $ $19 $1, $75 $4, $17 $1, $95 $8, $22 $2, EnSave, Inc. 31

36 Table M.5. Other Motors and Pumps: Evaluated Equipment Not Recommended (Cont.) Equipment Description Main Parlor Cow Wash Pump Motor Molasses Pump Motor Hospital Truck Loading Pump Motor Free Stall Mister Pump Motor Free Stall Mister Pump Motors Current Equipment 25 HP, TEFC, RPM, 92.40% Efficiency 1.5 HP, TEFC, RPM, 82.50% Efficiency 50 HP, TEFC, RPM, 93.00% Efficiency 10 HP, TEFC, RPM, 89.50% Efficiency 7.5 HP, TEFC, RPM, 91.70% Efficiency Considered Equipment 25 HP, TEFC, RPM, NEMA Premium, 93.6% minimum nominal efficiency 1.5 HP, TEFC, RPM, NEMA Premium, 84% minimum nominal efficiency 50 HP, TEFC, RPM, NEMA Premium, 94.5% minimum nominal efficiency 10 HP, TEFC, RPM, NEMA Premium, 90.2% minimum nominal efficiency # to Install Electricity Savings (kwh) Cost Savings ($) Installed Cost ($) Payback (Years) $16 $2, $2 $ $20 $4, $5 $1, No Recommendation 11 0 $0 $0 N/A Waste Handling Manure is scraped from the barns with tractors to a manure pit and then removed from the pit with trucks. This equipment is beyond the scope of the AgEMP. Material Handling The farm uses non-stationary equipment for material handling. This equipment is beyond the scope of the AgEMP. There is also a whey pump and a molasses pump motor for mixing with the feed. These motors were evaluated in the Other Motors and Pump section of the report. Crop and Feed Storage There is no stationary equipment associated with crop and feed storage on site. Water Management The water sources used for agricultural purposes on this farm are wells. Non-submersible electric motors used for water management are listed in the Other Motors and Pumps section of this report. Additional Equipment Burnstein Family Dairy, LLC also uses equipment that cannot be easily categorized in the previous measures. Table AE.1 provides an inventory of additional equipment. The electricity usage associated with this equipment is accounted for in the miscellaneous electrical usage. Table AE.1. Additional Equipment Inventory Item Description Manufacturer / Model Quantity Primary Fuel Type Refrigerators N/A 3 Electricity (kwh) AC Units N/A 3 Electricity (kwh) EnSave, Inc. 32

37 Miscellaneous Electrical Use On the dairy there are minor electrical uses that are not accounted for in the previous sections. These uses include grain auger motors, shop tools, alley scrapers, and milk agitators. These motors may operate every day, yet there are three reasons why it is not justifiable to replace these motors based on energy savings: First, they do not operate for a sufficient number of hours, annually, to justify replacement. Typically, to justify replacing a motor, based upon energy savings alone, it needs to run a minimum of 2,000 hours annually. A motor would have to run about five hours a day to justify replacement. Second, most of these motors are small, 3/4 hp or 1 hp, and motors of that size do not consume enough energy to justify replacing them. Third, motors such as ally scrapers and milk agitators run at very low speeds. A slower moving motor uses less electricity than a higher speed motor. These motors do not consume enough energy to justify replacement. ENVIRONMENTAL ASPECTS Measure Soil Water Animal* Plant Air Milk Harvest N/A N/A N/A N/A Milk Cooling N/A N/A N/A N/A Hot Water N/A N/A N/A N/A Lighting See Note 1 See Note 1 N/A N/A Motors N/A N/A N/A N/A Ventilation N/A N/A N/A N/A *This resource refers to endangered species. See Table S.1 and Note 2. Note 1: The farm is currently using compact fluorescent lights. Fluorescent lights are regulated under the Resource Conservation and Recovery Act. These lights cannot be disposed with trash, it is against the law. Please contact your local waste district for information on how to properly dispose of fluorescent lamps. Additional information is provided in the resource section of this report. Note 2: This report recommends replacing an old refrigeration system. Refrigerant is regulated by the EPA under section 608 of the Clean Air Act and cannot be released to the atmosphere, it is against the law. Please make sure that the contractor that is replacing the refrigeration system is aware of this and other applicable regulations, as well as how to properly dispose of the refrigerant. Section 608 can be found by following this link: EnSave, Inc. 33

38 ENERGY PYRAMID EnSave uses an energy pyramid as a model to outline the steps necessary for reducing energy usage. Figure EP.1 shows the energy pyramid. Figure EP.1. Energy Pyramid The energy pyramid is a concept used to help guide farmers toward energy independence. The energy pyramid has been proven to be very effective, and it serves as a road map to show where a farm is on their way to energy independence. Burnstein Family Dairy, LLC has done a great job with energy analysis and conservation. The next step for the farm would be to implement the energy efficiency measures recommended in this report. EnSave, Inc. 34