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EfficiencySMART Industrial Retro-Commissioning


Optimize Your Facility with Industrial Retro-Commissioning through EnerNOC’s EfficiencySMART Commissioning

Most industrial facilities strive for maximum efficiency, but facility and plant managers face many challenges: aging equipment, reduced capital budgets, disparate or legacy systems that refuse to integrate, a chronic shortage of trained personnel, and a team that is often fighting fires instead of proactively managing energy.

To overcome these challenges, EnerNOC’s EfficiencySMART suite includes a range of industrial energy efficiency solutions to help your facility meet its efficiency goals and gain a competitive advantage. For many industrial facilities, retro-commissioning (RCx) is an excellent place to start.

What Is Industrial Retro-Commissioning?

Just as a car needs periodic tune-ups, so too do energy-consuming systems and equipment. Retro-commissioning ensures that systems are optimized and that machinery is running efficiently. EnerNOC’s energy engineers conduct thorough site reviews, identify major sources of energy consumption, and deliver detailed analysis of systems and equipment performance.

Unlike more generalized energy assessments, RCx requires data gathering and specific system testing. While RCx might require higher up-front costs than an energy assessment, the payback period is fast because the EnerNOC team focuses in particular on identifying low-cost and no-cost energy savings opportunities impact to your bottom line.

These proposed improvements will help your facility run more efficiently and can give your business a competitive edge. With data-backed initiatives, you will avoid “flying blind” when it comes to energy.

Where Do We Start?

With multiple independently controlled systems, industrial facilities are complex. EnerNOC focuses on the largest energy consuming systems within a facility. This approach helps to maximize energy savings and ROI. Among other areas, our analysis includes:

  • Compressed Air Systems
  • Pump and Fan Systems
  • Refrigeration and Chilled Water Systems
  • Process Heat Systems
  • Boilers and Steam Systems

How Can I Ensure That These Savings Continue?

Identifying savings measures is an important first step. As your team implements those measures, EnerNOC is busy helping you secure applicable utility incentives to make the savings even more compelling. Throughout the process, EnerNOC’s energy professionals leverage their deep understanding of measurement and verification (M&V) protocols and processes to ensure that the actions you have taken deliver the expected impact.

Retro-commissioning can have an immediate and powerful impact on your bottom line, but because building efficiency erodes over time, you may want to lock in these savings for the long term. EnerNOC’s EfficiencySMART suite also includes EfficiencySMART Insight, which provides you with the right data, clear baselines, diagnostic tools, and ongoing recommendations to make sure your measures continue to deliver savings.

Retro-Commissioning In Action

EnerNOC was brought in for an RCx study at a Madera, California facility that produces 50 million gallons of wine and juice concentrate annually on a site covering approximately one million square feet. EnerNOC’s recommendations led to combined energy savings of 2.7 million kWh/year, 300 peak kW, and 241,000 therms/ year. These measures covered a broad range of systems and equipment, including:

  • Compressed Air: Careful measurement established that the compressed air leak rate was at least 25%. Repairs bring down the leak rate to less than 10%.
  • Boilers: The facility has three natural gas-fired water-tube steam boilers. Low-cost changes included the automation of the large steam header vent control and boiler blowdown control, as well as repairs of the large steam header vent isolation valve, steam traps, and high-pressure steam line insulation.
  • Refrigeration: EnerNOC specified the use of floating head pressure controls for the refrigeration systems.
  • Nitrogen Generators: The facility operates two leased nitrogen generators, each drawing about 250 kW from a 300 HP centrifugal air compressor and a small cooling tower fan. The facility sees significant savings from adjusting nitrogen use to accept a reduced supply pressure, thus allowing for a smaller air compressor unit in the generators. These changes enable the generator skid to automatically turn down to 60% capacity.
  • Lighting: Lighting fixtures were all on manual control. The installation of occupancy sensors in specified areas reduces the hours of operation by 30% to 90% depending on the area.

Experience Matters

Our experience covers industries as diverse as chemicals production to food processing to metal fabrication. Our team of over 50 energy professionals successfully delivers a wide range of services from simple project support to complex facility assessments. The team consists of electrical, mechanical, chemical, civil, industrial, and environmental engineers as well as economists, business planners, project managers, market researchers, load research professionals, and statisticians.

We have delivered over 500,000,000 kWh in annual savings.

Call upon our expertise in:

  • Energy efficient motors and variable frequency drives
  • Steam systems
  • Compressed air systems
  • Refrigeration systems
  • Heat recovery
  • Industrial process improvements
  • Lighting retrofits and controls
  • Central plant optimization (chilled water, heating, pumping and distribution systems)

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EnerNOC unlocks the full value of energy management for our C&I and utility and grid operator customers, delivering comprehensive demand response, or demand-side management, (including capacity markets, price-response markets, and ancillary services), data-driven energy efficiency (including metering, fault detection, energy data analytics, monitoring-based commissioning/persistent commissioning, commissioning, audits, assessments, and energy services), energy price and risk management (including procurement services and utility bill management), and enterprise carbon management (including GHG reporting). Our world-class energy management applications are continuously supported by our Network Operations Center (NOC) at thousands of sites throughout the world, providing cost-effective alternatives to investments in traditional power generation, power transmission and distribution.