Greening Tinker: OC-ALC striving for more efficient, less wasteful energy solutions

Published March 1, 2013
By Brandice J. O'Brien
Tinker Public Affairs

TINKER AIR FORCE BASE, Okla. -- The Oklahoma City Air Logistics Complex may be the largest energy consumer at Tinker, but personnel aren't discouraged by the statistic. In fact, they are encouraged and inspired to reduce energy usage and save money. The complex has achieved a $1.4 million cost savings in the first quarter of fiscal 2013 compared to the same period in FY2012.

The complex is taking measures to reduce its energy consumption and to change the culture. Right now, complex personnel are working several industrial-process energy projects, and exploring many more. The changes will help the Air Force achieve its energy-reduction goals. To date, the OC-ALC is on track, often exceeding Air Force Sustainment Center goals and Air Force targets.

"The vision of Tinker is to partner with federal and state government, industry and academia in developing Tinker into a model industrial city for energy use and independence," said Joseph Cecrle, OC-ALC Energy Program technical officer. "A key goal is to reduce energy consumption at Tinker beyond federally mandated levels to ensure future viability and to maximize available resources. This must be accomplished without negatively impacting the speed, safety, quality or cost of production."

The Energy Policy Act of 2005, Energy Independence and Security Act of 2007, Executive Orders and Title 10 United States Code are the drivers behind several Air Force goals. Many of the targets include reducing energy intensity, increasing renewable energy use, reducing water use and metering facilities.

"It is reported that we as a country are one of the most energy inefficient in the world. Wasted energy causes increased operating costs for energy production resulting in decreased Department of Defense operating funds, which may affect Operations and Maintenance funds that support civilian salaries," said Michael Kessler, 76th Maintenance Support Group Energy Office program analyst. "Non-renewable resources such as natural gas, coal and crude oil are limited resources and as such should be protected by conservation efforts."

Lt. Gen. Bruce Litchfield, AFSC commander, set a center goal of reducing energy consumption by 5 percent each year. In the first quarter of fiscal 2013, Tinker has already reduced its energy consumption by 14 percent. By the end of fiscal 2013, it is estimated Tinker will show an overall 11 percent savings.

Achieving the goals is not a one-person job. Complex personnel said it takes a team and the right mindset.

"Everyone in the OC-ALC is part of the energy team," said Julie Fowler, 76th Propulsion Maintenance Group Energy manager.

Kathy Guerra, 776th Maintenance Support Squadron Infrastructure Maintenance Flight Logistics Management specialist, agreed.

"Energy conservation plays a role in our budget in our daily process," she said. "As an employee and member of the energy team, we have to find ways to conserve energy and increase awareness for our future."

In addition to changing the mindset, the complex's units are independently seeking processes to improve. One way is by seeing how each organization uses their utilities. Personnel are brainstorming ways to lower energy usage, but still be effective.

Data Collection
There are more than 100 advanced electric, steam and water meters installed throughout OC-ALC facilities. The meters are used to see usage, determine patterns and monitor residual energy even when appliances are turned off, which might be unavoidable.

The meters, in place since 2011, collect data every 15 minutes.

Mr. Cecrle said it's easier to tie consumption to the smaller buildings as it's difficult to pinpoint which occupants are doing which activities in the larger facilities. Despite the task, the former General Motors plant proves to be a success. Although there are frequently new personnel moving in with new workloads, there's a reduction in consumption.

Mr. Cecrle said the data contributes to the reduction by enabling personnel to be more cognizant of energy consumption.

"We can see when we've fired up an oven, when the lights were turned on, and when we're at work or when we're not. We can also see how it varies between day shift, off shift and weekends," Mr. Cecrle said. "A part of our day is spent looking at consumption data from a variety of sources and trying to analyze and understand what's driving the energy consumption."

Mr. Cecrle said it's his hope that one day the meters will deliver information to a single focal point where anyone interested in the energy program on base can find the desired data.

Through this effort, Mrs. Guerra said each of the complex's groups will be assigned individual utility bills, which will spark savings even greater than the $1.4 million seen in the first quarter of fiscal year 2013.

Heat Treat
Within the 76th Propulsion Maintenance Group, personnel have taken measures to reduce the frequency of furnace burnouts, an oven-cleaning procedure.

Mr. Cecrle said the process involves "ramping the oven to a high temperature" to clean the oven. Prior to the initiative, it had been done once a week, but now they do it every other week, which has resulted in a drop in consumption.
Ms. Fowler said the effort has saved 2,087 Mbtu per year.

Lighting
As Tinker strives to become a model industrial city, Mr. Cecrle said some things have to change. Among them is the lighting as not every area is bright enough or uses energy-efficient light bulbs.

Beginning in 2012, 100-watt incandescent light bulbs were be phased out. By 2014, 40-, 60-, 75- and 100-watt bulbs will cease to exist commercially. In their place will be cost and energy-efficient replacements.

Wattage bulbs will be replaced with lumens, another measure of light. For example, a 60-watt bulb is the equivalent of a 1,600-lumen bulb. Plus, consumers will be offered various levels of warmth -- a soft light versus warm light.

New light bulbs will be offered in a variety of styles -- compact fluorescent lumen light bulbs, or CFL, are traditionally pigtailed shaped and light-emitting diodes, LED, bulbs have a bluish hue to them. A halogen bulb, the latest style to hit the market, is commonly referred to as the "designer's choice for lighting" because it doesn't have the pigtail shape, offers a bright, crisp light from the moment its switched on and lasts 50 percent longer than an incandescent light. Additionally, the bulb doesn't fade over its length of its life.

The change in light bulbs is the result of the Energy Independence and Security Act of 2007, which former President George W. Bush signed. The purpose of the act is to steer the U.S. toward energy independence and efficiency. Incandescent light bulbs producing 310 to 2,600 lumens of light will be phased out under this act. Essentially, it means incandescent light bulbs that produce less than 40 watts or more than 150 watts will remain in existence.

Within industry, linear and U-shaped fluorescent T-12 lights will also be phased out for T-8 lamps. Parabolic aluminized reflector, or PAR, lamps will be changed to meet Halogen efficiency levels or phased out entirely.

Compressed Air
For certain industrial activities, compressed air is expensive to produce. Mr. Cecrle said it takes seven units of power to manufacture one equivalent unit of compressed air.
"In other words, it takes seven horsepower of electricity to generate one horsepower of compressed air," he said. "As such it is very expensive to generate but we use it everywhere."

Mr. Cecrle said Tinker is working with state offices and commercial companies to find opportunities to reduce the energy used in compressed air systems.

Corrosion Control Facilities
Mr. Cecrle said corrosion control facilities are also large energy consumers. Some of the systems, in their current design, must run all the time to meet operating, safety and environmental standards and requirements.

Yet, the OC-ALC is researching alternative parts to make the systems more energy friendly. One idea is replacing the traditional electric motor with a variable-frequency drive motor, which adjusts the speed of the fan.

"So, when they're not painting and don't need the full air flow we can turn the system down, which will reduce the amount of energy used," Mr. Cecrle said. "Making changes to the actual motor and modifications to the control system will result in some pretty significant savings."