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FACILITIES / PAINT 7TH
TERM IMPROVEMENT
PLAN
Natural Gas Consumption
Natural Gas Consumption Analysis
Actual Billing ( including Taxes and Surcharges from Provider)
Period CCF'sBTU Factor Therms Nymex Adder $ / Therm Gas Cost Plus Service
April '02 13,052 1.013 13,222 $0.3472 $0.180 $0.527 $6,970 $8,713
May '02 10,198 1.008 10,280 $0.3319 $0.180 $0.512 $5,262 $6,578
June '02 10,862 1.007 10,938 $0.3420 $0.180 $0.522 $5,710 $7,137
July '02 12,703 1.005 12,767 $0.3278 $0.180 $0.508 $6,483 $8,104
Aug '02 12,723 1.005 12,787 $0.2976 $0.155 $0.453 $5,787 $7,234
Sept '02 16,209 1.006 16,306 $0.3278 $0.155 $0.483 $7,873 $9,841
Oct '02 16,043 1.005 16,123 $0.3686 $0.155 $0.524 $8,442 $10,553
Nov '02 22,742 1.007 22,901 $0.4126 $0.155 $0.568 $12,999 $16,248
Dec '02 20,194 1.011 20,416 $0.4140 $0.155 $0.569 $11,617 $14,521
Jan 03 26,718 1.016 27,145 $0.4998 $0.155 $0.655 $17,775 $22,219
Feb 03 24,686 1.019 25,155 $0.5660 $0.155 $0.721 $18,137 $22,671
Mar 03 16,936 1.018 17,241 $0.9113 $0.155 $1.066 $18,384 $22,980
April 03 17,044 1.018 17,351 $0.5146 $0.155 $0.670 $11,618 $14,523
May 03 13,303 1.008 13,409 $0.5123 $0.155 $0.667 $8,948 $11,185
June 03 10,560 1.006 10,623 $0.5945 $0.155 $0.750 $7,962 $9,953
July 03 12,516 1.001 12,529 $0.5291 $0.155 $0.684 $8,571 $10,713
Aug 03 13,703 1.003 13,744 $0.4693 $0.120 $0.589 $8,099 $10,124
Sept 03 16,228 1.006 16,325 $0.4927 $0.120 $0.613 $10,003 $12,503
Oct'03 16,306 1.005 16,388 $0.4430 $0.120 $0.563 $9,226 $11,533
Nov '03 17,653 1.008 17,794 $0.4459 $0.120 $0.566 $10,070 $12,587
Dec'03 19,202 1.009 19,375 $0.4860 $0.120 $0.606 $11,741 $14,676
Jan '04 19,329 1.018 19,677 $0.6150 $0.120 $0.735 $14,463 $18,078
Feb '04 17,963 1.018 18,286 $0.5775 $0.120 $0.698 $12,755 $15,943
Mar '04 15,821 1.019 16,122 $0.5150 $0.120 $0.635 $10,237 $12,899
Apr 04 14,827 1.011 14,990 $0.5365 $0.120 $0.657 $9,841 $12,400
May 04 13,373 1.009 13,493 $0.5935 $0.120 $0.714 $9,627 $12,130
June 04 11,450 1.007 11,530 $0.6680 $0.120 $0.788 $9,086 $11,448
July 04 11,370 1.007 11,450 $0.6680 $0.120 $0.788 $9,022 $11,639
Aug 04 14,646 1.005 14,719 $0.6140 $0.120 $0.734 $10,804 $13,613
Sept 04 14,700 1.005 14,774 $0.5082 $0.145 $0.653 $9,650 $11,580
Oct 04 16,968 1.009 17,121 $0.5723 $0.145 $0.717 $12,281 $14,184
Nov 04 18,182 1.008 18,327 $0.7626 $0.145 $0.908 $16,634 $18,830
Dec 04 18,805 1.01 18,993 $0.7976 $0.145 $0.943 $17,903 $20,266
Jan 05 20,779 1.018 21,153 $0.6123 $0.145 $0.757 $16,019 $18,502
Feb 05 19,158 1.018 19,503 $0.6840 $0.145 $0.829 $16,168 $18,351
Mar 05 18,845 1.016 19,147 $0.6840 $0.145 $0.829 $15,872 $18,015
Apr 05 15,334 1.016 15,579 $0.7323 $0.145 $0.877 $13,668 $15,650
May 05 16,524 1.013 16,739 $0.6748 $0.145 $0.820 $13,723 $15,713
June 05 16,367 1.008 16,498 $0.6123 $0.145 $0.757 $12,494 $14,407
July 05 15,261 1.007 15,368 $0.6976 $0.145 $0.843 $12,949 $14,889
Aug 05 16,193 1.007 16,306 $0.7647 $0.145 $0.910 $14,834 $16,862
Sept 05 16,628 1.008 16,761 $1.0847 $0.124 $1.209 $20,259 $22,465
Oct 05 20,134 1.008 20,295 $1.3900 $0.124 $1.514 $30,741 $33,576
Nov 05 22,060 1.007 22,214 $1.3800 $0.124 $1.504 $33,481 $36,479
Dec 05 20,271 1.016 20,595 $1.1180 $0.124 $1.242 $25,579 $28,103
Jan 06 20,774 1.025 21,293 $1.1430 $0.124 $1.267 $26,980 $29,588
Feb 06 20,413 1.019 20,801 $0.8400 $0.124 $0.964 $20,052 $22,244
Mar 06
To Date Average 17657 0.802$ 13,929$ 16,499$
5th Term Average 16267 0.776$ 12,742$ 15,080$
6th Term to date Average 18405 1.082$ 20,433$ 22,725$
Historical Consumption
0
5,000
10,000
15,000
20,000
25,000
30,000
April '0
2
May '02
June '02
July
'02
Aug '02
Sept
'02
Oct
'02
Nov '02
Dec '02
Jan 0
3
Feb 0
3
Mar
03
April 03
May 0
3
June 0
3
July
03
Aug 0
3
Sept
03
Oct'03
Nov '03
Dec'0
3
Jan '04
Feb '04
Mar
'04
Apr
04
May 0
4
June 0
4
July
04
Aug 0
4
Sept
04
Oct
04
Nov 0
4
Dec 0
4
Jan 0
5
Feb 0
5
Mar
05
Apr
05
May 0
5
June 0
5
July
05
Aug 0
5
Sept
05
Oct
05
Nov 0
5
Dec 0
5
Jan 0
6
Feb 0
6
Month
Th
erm
( 1
000 B
TU
)
$0.000
$0.200
$0.400
$0.600
$0.800
$1.000
$1.200
$1.400
$1.600
$ / T
herm
Usage$ / ThermLinear ($ / Therm)Linear (Usage)
5th Term Consumption
0
5,000
10,000
15,000
20,000
25,000
Apr
04
May 0
4
June 0
4
July
04
Aug 0
4
Sept
04
Oct
04
Nov 0
4
Dec 0
4
Jan 0
5
Feb 0
5
Mar
05
Month
Th
erm
( 1
000 B
TU
)$0.000
$0.100
$0.200
$0.300
$0.400
$0.500
$0.600
$0.700
$0.800
$0.900
$1.000
$ / T
herm
Usage$ / ThermLinear ($ / Therm)Linear (Usage)
6th Term Consumption
0
5,000
10,000
15,000
20,000
25,000
Apr
05
May 0
5
June 0
5
July
05
Aug 0
5
Sept
05
Oct
05
Nov 0
5
Dec 0
5
Jan 0
6
Feb 0
6
Month
Th
erm
( 1
000 B
TU
)
$0.000
$0.200
$0.400
$0.600
$0.800
$1.000
$1.200
$1.400
$1.600
$ / T
herm
Usage$ / ThermLinear ($ / Therm)Linear (Usage)
Calculations of Natural Gas Consumption by Component
Incinerator on line with Current Paint Schedule
Component Max Avg. Hrs Therms Daily $/Therm $ / Day $ / Year
Demand Therm/HrDaily per Day Therm
Oven Full (100%) 25 3 75 186.25 0.77$ 143.41$ 34,419.00$
Maintain(25%) 17 106.25
Low Fire(10%) 2 5
Incinerator Full (100%) 35 3 105 588 0.77$ 452.76$ 108,662.40$
Maintain(80%) 17 476
Low Fire(10%) 2 7
Boiler Full (100%) 40 4 160 330 0.77$ 254.10$ 60,984.00$
Maintain(25%) 15 150
Low Fire(10%) 5 20
Total 1104.3 850.27$ 204,065.40$
Trial
•Run the oven without the oxidizer while using the
blower to expel the smoke out the stack
•Record the Natural Gas consumption and
compare to average daily consumption
•Note any changes in operation
Trial Results
• The oxidizer was turned off for three days
• During that time , our Natural Gas consumption dropped
from 70,000 cu. ft / day to 40,000 cu. ft which equals 47%
which is about $8000 / month
Oxygen Meter Test
On August 23 at 10:30 am, the "sniffer " or multi gas monitor was used to check for abnormalities
at the oven stack on the roof. The oxidizer was by passed at the time of this test.
Four sets of readings were taken for a period of 5 minutes at each location.
Results were as follows
Location CO H2S O2 LEL
Carbon Hydrogen Oxygen Combustible
Monoxide Sulfide Gases
Measurement PPM PPM % %
Limits 35 - 70 10 - 20 19.5 - 23.5% 10%-20%
Base of Stack
with monitor directly in smoke 4-6 0 20.8 0
10' from stack
with monitor directly in smoke 1 0 20.9 0
30' from stack
with monitor directly in smoke 0 0 20.9 0
70' from stack ( edge of roof )
0 0 21 0
Concept Now After Judgement
Investigate an air scrubber
to remove / control the smoke Might be effective
and possibly the smell for Bluish smoke
but would not
provide air
velocity
The most
effective method
of smoke and odor
control
More expensive
Investigate the concept of injection
of clean air into the smoke stack
at a 3~5 to 1 ratio and push it up into More commonly
the air to dissipate the visual concern used in industry
Will mix fresh air
and smoke at a
predetermined ratio
and drive it up into
the air
Will reduce smell
Oven
Air Scrubber and
fan
Roof mounted Fan
Manually Controlled
Dampers (2)
Manually Controlled
Dampers (2)
Oven
Oven
Oven
Concept Options
Incinerator off line with Current Paint Schedule
Component Max Avg. Hrs Therms Daily $/Therm $ / Day $ / Year
Demand Therm/Hr Daily per Day Therm
Oven Full (100%) 25 3 75 186.25 0.77$ 143.41$ 34,419.00$
Maintain(25%) 17 106.25
Low Fire(10%) 2 5
Incinerator Full (100%) 35 0 0 0 0.77$ -$ -$
Maintain(80%) 0 0
Low Fire(10%) 0 0
Boiler Full (100%) 40 6 240 456 0.77$ 351.12$ 84,268.80$
Maintain(40%) 12 192
Low Fire(10%) 6 24
Total 642.25 494.53$ 118,687.80$
YEARLY SAVINGS OF
$80/000
F&P Georgia Improvement Plan Made
Glen Tuplin
Purpose Investment and Payback Equipment
To reduce the Natural Gas utility expense Blower $12,500 Based on Natural gas prices and Trial results ,
Ductwork, Dampers and Insulation $5,000 Payback would be less than 4 Months
Electrical $1,000 Investment
Installation $6,000 Savings / 12
$24,500
Consulting Fees An air scrubber would add $40,000 to the investment which
Baseline of Emissions $3,500 would extend the payback schedule to 11 months
$28,000
Current Situation ScheduleEvents
Our biggest consumers of Natural Gas are in the Paint system. The oven, the oxidizer, and April May
the hot water boiler. Equipment Evaluation
With our new generation paint from PPG, it has been determined that the oxidizer is not necessary Plan Approval
in our case to super heat the solvents and fumes from the paint oven.
Order Equipment
The oxidizer also heats up a hot water generator which we use for paint system tank heating .
Install Ductwork and Dampers
Install Equipment and Auto Control Programming
Trial and Monitor Results
Report
Improvement / Countermeasure Merit
By-pass the oxidizer exhaust piping with duct work and controls as per concept #2 shown in Reduce Natural Gas monthly Bill by up to 47% or $8000 / month
attachment.The oven exhaust would go directly outside with the assistance of a roof mounted blower.
This blower would also introduce outside air at a 3 : 1 ratio and accelerate it into the air to remove the bluish
color and the undesirable appearance seen during a previous trial.
By accelerating it up into the air, the odor noticed during the last trial would also be dissipated.
Installing an Air Scrubber would eliminate the exhaust particulate and the odors but an investigation
would be needed to ensure expectations are met without compromise
The by-pass would still allow oxidizer operation should the EPA restrictions become Demerittighter in the Rome area.
Hot Water boiler will have increased load, need to ensure PMs are adequate and back up plan is available
Increase emissions into environment (Blower Option only)although below allowable limits of permit
Must purge the oxidizer periodically to ensure no build up of fumes getting past the dampers
Monday morning paint system start up might need to be modified to allow the boiler to do the extra heating necessary in
cold weather months
An air scrubber would add to water consumption, and waste discharge
Comments: Evaluation / Further InstructionOur air permit is based on the calculated emissions given the paint VOC data. Our
permit was based on no credit for oxidizer benefit which means we would be still within our permitted
restrictions but a baseline or scientific test could be performed to ensure compliance
With recent price increases on Natural Gas, a recalculation based on an average cost / therm, our payback would be:
Incinerator on line with Current Paint Schedule Incinerator off line with Current Paint Schedule
Component Max Avg. Hrs Therms Daily $/Therm $ / Day $ / Year Component Max Avg. Hrs Therms Daily $/Therm $ / Day $ / Year
Demand Therm/HrDaily per Day Therm Demand Therm/Hr Daily per Day Therm
Oven Full (100%) 25 3 75 186.25 1.15$ 214.19$ 51,405.00$ Oven Full (100%) 25 3 75 186.25 1.15$ 214.19$ 51,405.00$
Maintain(25%) 17 106.25 Maintain(25%) 17 106.25
Low Fire(10%) 2 5 Low Fire(10%) 2 5
Incinerator Full (100%) 35 3 105 588 1.15$ 676.20$ 162,288.00$ Incinerator Full (100%) 35 0 0 0 1.15$ -$ -$
Maintain(80%) 17 476 Maintain(80%) 0 0
Low Fire(10%) 2 7 Low Fire(10%) 0 0
Boiler Full (100%) 40 4 160 330 1.15$ 379.50$ 91,080.00$ Boiler Full (100%) 40 6 240 456 1.15$ 524.40$ 125,856.00$
Maintain(25%) 15 150 Maintain(40%) 12 192
Low Fire(10%) 5 20 Low Fire(10%) 6 24
Total 1104.3 1,269.89$ 304,773.00$ Total 642.25 738.59$ 177,261.00$
Estimation: Based on removing the oxidizer from the operation, and running a two shift schedule, saving of $125,000 / year would be realized.
Project Status
• Matching equipment to requirement
• Ensure expectation / result is achieved
• Investigating Vertical Scrubber application
• Capital cost
• Expense to operate – added water cost
• Procurement and Installation information
