energy management system (enms) expert...

Energy Management System (EnMS) Expert Training

UNIDO International Energy Efficiency and EnMS Expert

Module 2 – Operations – Day 1

Based on the contents of the UNIDO Practical Guide for Implementing and Energy management System

Module 2 – Operations – Day 1Topic Duration

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DAY 1Registration 15 08:30 08:45Welcome and opening remarks 10 08:45 08:55

Review progress on planning 5 90 08:55 10:30Break 15 10:30 10:45Exercise - Force Field Analysis - barriers 5 60 10:45 11:50Review of the EnMS emphasising connections to SEUs 30 11:50 12:20

Lunch 45 12:20 13:05Operational Control 45 45 13:05 14:35Break 15 14:35 14:50Procurement 30 30 14:50 15:50Competency, training & awareness 30 10 15:50 16:30TOTALS 2.58 3.92 1.50

Exercise - Report on progress

What is your target reduction in kWh nextyear for each energy source in yourscope?

How did you decide this target?What are your action plans to achieve this

target? How will your EnPIs show progress

against this target?

See you in 15 minutes!

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Review progress on planning 5 90 08:55 10:30

Break 15 10:30 10:45Exercise - Force Field Analysis - barriers 5 60 10:45 11:50Review of the EnMS emphasising connections to SEUs 30 11:50 12:20

Force Field Analysis

Exercise: Use Force Field Analysis to identify solutions to any problems encountered to date

Force field analysis (Lewin, 1951)

Energy PerformanceOpportunity

(EnMS System)

Significant Improvement potential

Low investment

Good Training

Energy Cost Increase

Knowledge of plant

It is working OK Now

We have no money for Investment

What improvement Potential?CSR

I haven't time for this FAD?

Behaviour change

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Planning & DO How much energy am I using? Where am I using it? What Legal requirements are related to

my energy use? What Other requirements are related to

my energy use? Which are significant users? What is driving it? Who is influencing its use? Do I need to have an energy audit? System Optimization Renewable energy options Are there legal or other requirements? Develop baseline & indicators Set objectives and targets Action Plans

Significant Energy Uses

Electricity GJ Fossil Fuel GJ Total GJ

SEU Sankey Diagram

Connections to Significance

Significant energy uses

Objectives, targets and action plan

Competence, training and awareness

Operational control

Procurement

Monitoring, measurement and analysis

Designation of an energy use as Significant willhave profound effects on the implementationand operation of an Energy ManagementSystem

Connections to significance exist throughout theEnMS and must be addressed. Specificrequirements include operator competence andtraining, procurement, operational controls,monitoring, measuring and analysis and objectives,targets, and action plans.

Significant Energy Uses-ConnectionsWhat does this mean to me?

Recall: Simple Steam System

A profile of losses operating a 500 hp boiler with NG at60% firing rate (annual fuel bill = $800,000)

Boiler Losses Stack Losses 18% $144,000 Blowdown Losses 4% $ 32,000 Surface Losses 3 % $ 24,000 25%

Distribution System Losses Insulation Losses 7% $ 56,000 Steam Leaks 6% $ 48,000 Blowing Traps 5% $ 40,000 Flash Losses 11% $ 88,000 Return Losses 9% $ 72,000 38% $304,000

Combined Losses 63% $504,000 System Efficiency 37% $296,000

Steam System Performance

Operator competence and associated training

Steam System Connections-Example

Competency TrainingGeneral knowledge of boiler operation

Complete 2 day-Boiler Operation, Maintenance & Safety course

Ability to understand and follow startup and shutdown procedures

1 week on-the-job training with experienced boiler operator

Ability to test boiler water and make necessary adjustments

1 day on-site training with water treatment chemical tech rep

Ability to test burner performance, calculate combustion efficiency and adjust combustion controls as needed

Complete 1 day-Combustion Analysis and Fuel Efficiency course and pass HVAC Excellence Combustion Analysis exam

Procurement of services, products and equipmentassociated with steam system - Procedures

Notify potential suppliers of steam system equipment andproducts that evaluation of their offerings are partly dependentupon energy performance (e.g. includes products like watertreatment chemicals or steam traps and equipment likedeaerators, feed pumps or stack economizers).

Assess energy use over lifetime: Inform purchasing that largecapital items (> $20,000) will have a lifecycle cost evaluationprepared that includes at a minimum initial cost, annualmaintenance, energy cost savings and salvage cost based onexpected lifetime.

Steam System Connections-Example Operating control topic Control methodGeneral boiler operation Attend boiler operator training course

Boiler startup/shutdown On-the-job training on how to follow procedures

Emergency conditions Safety covered in operator training course

Maintenance control topic Control methodSteam trap inspection Traps are tested monthly with ultrasonic

meter and losses tracked. Trap replaced or repaired when loss >$2.5K/yr

Boiler tune-up Boiler performance monitored weekly and tune-up is completed when efficiency decreases by 3%

Steam leak inspection/repair Boiler operating procedure requires weekly inspection and write-up of visible leaks by operators that are then assigned to maintenance for repair

Monitoring & measurement practiceMaintenance procedure: monthly test of exhaust stack excess

oxygen and temperature to determine combustion efficiency Record feedwater flow rate from water meter daily Measure feedwater and boiler water solids concentration daily, use

ratio of concentrations to calculate blowdown rate Record natural gas flowrate daily from gas meter Boiler performance determination:

1. Steam production - Subtract blowdown rate from feedwater rate2. Calculate energy in steam – enthalpy difference of steam and

feedwater3. Boiler efficiency - steam energy divided by fuel input4. Compare calculated boiler efficiency with measured combustion

efficiency

Barriers associated with SEUs Incomplete equipment lists and inadequate

consumption data for energy uses

Relying on part of the organization when determining significance criteria

Deciding that everything is significant – instead of keeping it manageable!

Ignoring required connections when developing SEU methodology

Lack of metering to adequately monitor and measure SEU performance

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Implementation & Operation Competence, training and awareness

Documentation

Operational control• Key Area

• Operation and Maintenance

• Service Contractors

• Training

Communication

Design• Energy Efficient Design (EED)

Purchasing energy, services, goods

Action Plan

Operational control

Procurement

Determine and plan operations associated with significant energy uses

Set criteria for operation and maintenance of significant energy uses

Communicate to the appropriate personnel

Operate and maintain according to criteria - handle significant deviations

NOTE: May include energy performance consideration in contingency planning

What is Required by the EnMS?

Operational Control: A critical element of the EnMS for energy savings

Steps in achieving effective operational control: 1. Determine and establish maintenance and operational

criteria2. Communicate operational controls3. Operate according to the criteria

Leads to,

SIGNIFICANT ENERGY SAVINGS & BENEFITSWITHOUT CAPITAL EXPENDITURE!

Sources of Criteria Manufacturer’s recommendations System operational manuals, including automated controls Service personnel suggested operating settings Service personnel suggested maintenance practices Internal expert’s suggestions Guidance from energy system experts Benchmarking performance of similar

equipment Past issues or problems

Developing Criteria

Operating criteria • Temperature• Pressure• Residence time• Humidity• Control schemes• Others

Operational Criteria

Maintenance-Definitions The primary purpose of maintenance has traditionally

been to maintain reliability and availability. If equipment is properly maintained it is more likely to be

energy efficient also. Reactive maintenance will undoubtedly waste energy The cost of the energy will often be more than the cost of

the maintenance (also a different budget!) All significant energy users need to be maintained

correctly Applies equally to external service contracts as internal

maintenance staff

Maintenance options• Preventive maintenance• Predictive maintenance• Reliability centred maintenance (RCM)• Overall equipment effectiveness (OEE)• Total productive maintenance (TPM)

Note: reactive maintenance may be appropriate for items that are relatively unimportant in terms of reliability and energy use

Maintenance criteria• Filters• Lubrication• Tune-ups, adjustments

Maintenance factors• Operating schedules• Inspection methods and

intervals• Start up & shut down

frequency• Severity of service

Maintenance Criteria & Factors

Document Criteria Use the tab in the tools Include operating limits for the criteria where

appropriate

On-the-job training

Work instructions or operating procedures

Classroom training

Posted list of specified settings

Logbooks

Communication of Criteria

Procedures BasedProcedures or work instructionsEquipment logbooksPM Schedule

Technology BasedControl systemsAlarm/alert systemsComputer automated activitiesPreventive maintenance system

Training BasedMaintenance trainingOperations trainingContractor training

May already have many operational controls in place!

Implementation of Criteria = Controls

How will significant deviations be handled? Will significant deviations be placed into the corrective

action system? What methods will be employed during the investigation? 5 whys IS/IS NOT Fishbone Other root cause analysis methods

What records will be kept?

Investigation of Significant Deviations

What will be considered a significant deviation?• Trend identified• Outside of control limits• Higher or lower than designated value• Percentage different from what is expected

Find out what happened Take appropriate action Keep a record

Identification of Significant Deviations

You determine what will be considered a significant deviation!

What type of data analysis methods will be used?– Absolute analysis– Control limit analysis– Trend analysis– Benchmarking

Analysis of Significant Deviations

• Clearly define requirements

• Conduct training for operations and maintenance

• Keep documentation current

• Remember, even technology-based controls require some training and documented procedures

• Ensure recommended practices are being followed & significant deviations handled

Operating Controls-Best Practice

May consider operational control requirements for energy performance during contingency situations

To plan contingent operational control, first define contingency to isolate potential effect on SEU

After contingency is defined, determine necessary changes to criteria and establish controls

Contingency, Emergency or Disaster Situations

Dual-fuel boiler operating normally on interruptible natural gas. An extended cold-snap will necessitate operation on #2 fuel oil during a gas interruption. What operational changes are anticipated?

What happens if there is an electrical power interruption?• Short outage• Long outage

Contingency Situation Example

Operational control

Procurement

Operational Controls & Monitoring and Measuring

Monitor & Measure

• Monitor = passive data acquisition: utility meters, panel meters

• Measure = active data collection: sub-meters, data loggers

Energy Performance

• Use M&M data to determine SEU performance

• Calculate efficiency, specific energy or input per unit output

Operational Control

• Is SEU energy performance as expected?

• Are controls working?

• How can they be improved?

Implementing controls that are not easy to use, understand or communicate (controls not user-friendly)

Forgetting to include maintenance criteria in addition to operating criteria

Infrequent communication of operational controls

Not checking control effectiveness regularly

Failing to improve ineffective controls

Barriers to effective operational controls

Promotes efficient, uninterrupted operation of critical equipment

Criteria for efficient operation can help identify actions that will support targets and objectives

Implementation of controls or refinement of existing controls can result in significant savings with no capital cost

Control energy spend by controlling highest cost uses

Improves uniformity of process

Provides continuity of processes during personnel changes

Allows operators to help with energy savings

Value to the Organization

Determine what operational and maintenance criteria it takes to run and maintain one of your SEUs in an efficient manner, and record these criteria on UNIDO tools.

Exercise

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Documentation

• Training

Communication

Action Plan

Procurement Can have a significant impact on your energy

performance You need to be able to assess the energy performance

and impact of items that you purchase Inform all vendors that you have an EnMS that requires

energy impact to be assessed as appropriate Need to move towards Life Cycle Costing (LCC)

If purchases affect significant energy use (singular) notifysuppliers evaluation partly based on energy performance

Designate how energy use over the lifetime of the product,equipment or service will be assessed for purchases thathave significant impact on energy performance• Significant energy use• Objectives and targets• Past improvement efforts• Maintenance of energy system

Procurement of Energy Services, Products and Equipment

Purchasing goods Many purchased items can impact energy performance

• Air compressors, motors, boilers, pumps, etc.• IT equipment, PCs, printers, photocopiers, etc.• Light bulbs• Maintenance materials, insulation, gaskets, bearings, lubricants,

Establish criteria for assessing energy use, consumptionand efficiency

Develop purchasing specifications for these items Need an analysis that incorporate life cycle costing

Purchasing services Energy service providers who will affect energy performance

need to be evaluated• Maintenance service contractors for SEUs• Project engineers/managers/architects• Energy consultants

Informed procurement partly based on energy performance Develop criteria for assessment Major component of assessment is competency

• Education• Training• Skills• Experience of previous similar services

Purchasing services Any service provider who will affect your significant energy

uses needs to be competent They include:

• Maintenance service contractors for SEUs• Project engineers/managers• Architects• Energy consultants

You need to be able to judge competence• Education• Experience of previous similar services• References• Curriculum vitae (CV) or resume

Notify suppliers that evaluation will be partially based on energy performance• Letter• PO• Specification• Training• Supplier open house• Email• Service letter agreements

Supplier Notification

What about purchasing energy saving technologies?

There are many vendors of energy saving technologies You need to be able to judge real saving potential from

what the sales person says. Try a sample as a test How do you verify savings? Nobody admits to buying the wrong thing Some good technologies are only good in the right

application, e.g. variable speed drives

Upfront expense Incremental cost Energy cost Maintenance cost Expected lifetime Disposal cost/Salvage value

Life Cycle Analysis

Life Cycle Costing Demonstrate using the tool Very important concept Useful in real EnMS

What if Procurement is a Corporate Function?

Is the purchase of the service, product, or equipmentrelated to a significant energy use?• Inform corporate that energy performance is

important in decision• Request energy be a criteria in evaluation• Request that corporate notify suppliers that energy

performance will be taken into consideration

If procurement is a corporate function:

Is there information that the facility can provide corporate purchasing to make their buying decisions more effective, for equipment or energy supply?

Is there energy supply price signal information that corporate can provide to the facility that might impact operational decisions?

Communication Ideas

Defined and documented energy purchasing specifications

Procurement of Energy Supply

Purchasing energy Increasingly complex area with competition Need to know who are the potential suppliers Need understanding of available tariffs Need understanding of specification of energy

requirements If significant energy savings are achieved through EE this

may affect best tariff structure Need each supplier to quote for the same thing and same

basis, need to be able to compare quotes

Quality• Moisture• Composition• Energy Content• Voltage• Amperage• Power Factor

Quantity• Amount supplied• Delivery period• Interruptible?

Reliability• Allowable variation in

quality• Allowable variation in

supply

Cost Factors• Cost per unit• Cost for non-interruption• Cost for demand• Cost for delivery

Energy Supply Specifications

Consider the procurement policies and procedures in your organization. Determine the gaps in your procurement procedures and the actions needed to fill those gaps.

This exercise is the start of the process. You will need to progress this over the coming months and years.

Exercise

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Documentation

• Training

Communication

Action Plan

Competence, Training and Awareness• Ensure those related to

significant energy uses are competent.

• Identify training needs related to the control of its SEUs.

• Provide training or take other actions.

• Maintain records of training.

Three Cogs

Competence

Training

Awareness

Education, training, skills, or experience Records How am I qualified to do this job? Related to significant energy uses

Competence

•Experience

•Boiler operator

•Education

New Maintenance Employee

•Certified

•Licensed

•Experienced

•Education

Certified Steam Specialist •Additional training and

Knowledge

•Experience

•Certified

Certified M&V Professional

Competence Process

Competence

Determine Categories of

persons

Determine education, skills, experience, skill combination for

categories

Review persons vs competence and determine training needs

The GAP

Competency process

Training Process

Competent

Training Needs

• Competency defines what is needed

• Training needs define what is missing or has changed

• Records of the training provided are required

Other OptionsReassign to another

activity Provide additional

trainingAssign a mentor Increase the training

opportunitiesRemove from the

situation

Training methodsClassroom trainingOn-the-Job trainingCertification programWork with a mentorWork with a supplier or

contractorWeb-based trainingTime in a job

Training Plan

Training

Employee ID Name Job Title Department Category Introductio

n to EnMS EnPIs SEU 1

Energy for Influencer

Energy for

Energy Vigilanc

eProduction Supervisor Influencer Y Y

Utilities Operator Direct Y YWWT Operator Direct Y

MaintenanceDirect YCleaner YSecurity YSafety Officer YManager Influencer Y YEnergy Engineer Direct Y Y Y Y Y Y Y Y

AwarenessThe organization shall ensure that persons working for or onits behalf are aware of:

• Energy policyImportance

• Procedures• Roles, responsibilities and authorities• Benefits of improved energy performance• Impact actual or potential, respect to energy use and

consumption,• How their actions contribute to achievement of energy

objectives and targets• Potential consequences of departure from procedures

Awareness – Behaviour Change – Social Norms

• Safety Belts in Cars• Smoking in public places• Smoking while Pregnant• Seat belts in cars• Safety glasses• Etc• Etc• Energy Waste?

• Increased energy awareness• Better decision making

capability of staff• Improved energy performance• Improved qualifications of staff• Increased understanding of

processes and energyrelationships

Benefits

Connections

Competence, Training,

Awareness

Policy

Management representative

Operational Control

Significant Energy Uses

Documents & Records

Documents Competency requirements Training needs

Records Competency records Training records

EXERCISE Consider one of the SEUs that you have identified

and the operational criteria required to operate theSEU in an efficient manner.

List those personnel who operate and maintain theSEU (don’t forget external contractors).

Review with the team different ideas on types ofcompetencies that may be necessary andexamples of how this is currently managed.

Update the training tab on the tools spreadsheet

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DAY 2Review competency, training and awareness exercise 15 08:30 08:45

Update Action Plans based on Op Control 20 55 08:45 10:00Communications 30 10:00 10:30Break 15 10:30 10:45Communications 30 10:45 11:15Document Control 20 25 11:15 12:00Design 30 15 12:00 12:45Lunch 45 12:45 13:30Design 30 13:30 14:00Record Keeping 20 20 14:00 14:40Exam discusion and help 15 14:40 14:55Break 15 14:55 15:10Monitoring and improving Baseline and EnPIs 30 50 15:10 16:30TOTALS 2.50 4.25 1.25

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Planning How much energy am I using?Where am I using it?Which are significant users?What is driving it?Who is influencing its use?Do I need to have an energy audit?What are the best opportunities?System OptimizationRenewable energy optionsAre there legal or other requirements?Develop baseline & indicatorsSet objectives and targetsAction Plans

Purpose:

• Review Objectives and Targets• Review Action Plans• Incorporate EnMS Implementation and

Operation considerations into Action Plans

Objectives, Targets and action plan

Objectives, Targets and action plans

Energy Policy

SEU list

Training needs

Energy Assessment

reports

ECO Database

Relationship

Energy Objectives

Improve performance Demonstrate policy Engage employees Engage stakeholders Focus resources

Objective: Reduce facility electricity costs by 20% over the next two years.

Objective: Reduce facility natural gas usage by 15% in 2012.

Objective: Reduce facility-wide energy usage by 25% by 2020

Examples

Targets

Specific

• What is the task to be done, use action words

• What are the details?

Measurable• How will we know if the task is complete and how well?

Achievable

• Is it possible and fair?• Is training or personal development

required?

Relevant• Which objective is it supporting?• In what way is it improving our energy

performance?

• When will it be completed or how often?• Does it need sub steps and are these

SMART?

Target: Reduce natural gas usage in boiler house by 25% in 2012.

Increase condensate recover rate to 90% in 2011.

Conduct 4 energy awareness training sessions in 2011.

Train boiler house operator on new startup / shutdown procedures by end of 2nd

quarter, 2011.

Examples

Action Plans

Responsibility (Functional level)

Time frame

ResourcesActions

Method of verifying results

ACTION PLAN

DocumentedUpdated at

defined intervals

Plans required for objectives and targetsPlan includes:

• Responsibilities (who)• Timeframe (when)• Resources • Actions (what)• How improvement in performance and

plan results will be verified

Documented Updated at defined intervals

Action PlanObjective: Reduce facility natural gas usage by 15% in 2012.Target: Reduce natural gas usage in boiler house by 25% in 2012. Project: Install heat exchanger to preheat combustion air 425 C above

ambientActions and Responsibilities:

Design – Mechanical department Installation – Acme Contracting Testing – Mechanical department and maintenance Results verification – Mechanical department

Time Table

Hierarchy in ISO 50001

PolicyObjectives

TargetsOpportunitiesAction Plans

Results

• Review the Energy Objectives foryour organization.

• Develop energy targets to meetyour objectives.

• Will the targets meet yourobjectives?

• Will your action plans meet yourtargets?

• Do you need to have an energyaudit?

Exercise

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Implementation & Operation Competence, training and awareness Documentation Operational control

• Key Area

• Training

Communication Design

• Energy Efficient Design (EED)

Action Plan

Internal Communication• EnMS• Energy performance• Commitment, awareness, and

understanding• Process for comments or suggestions

External Communication• Plant decision • Must be recorded• Plan for communication developed

Communication

Internal• Inside the facility• Between different levels, functions, shifts• Written procedures, newsletters, bulletin boards,

intranet, emails, communication screens, screensavers

External• Outside of the facility• Regulators, media, community members, etc.• Community meetings, newspaper, television, website

Types of Communication

• Policy• Significant energy uses• Objectives, targets, action

plans• Energy performance• Responsibilities• Suggestion process

Internal Communication

• Anyone can make suggestions• Employees• Temporary Workers• Contractors

• Need a means to collect suggestions

• Need a means to direct them to the correct person(s) for evaluation

• Need a means to respond and implement where appropriate

• Need evidence it is working

Suggestion Process

External Communication

Stakeholders Regulators Community Board

Others

Decision Needed Recorded

If Yes:PlanResponsibilities

and authorities

Communicate Energy performance EnMS Energy policy

Others

• Ignoring existing communication mechanisms• Not engaging facility personnel and contractors in the

suggestion process• Showing bias in considering ideas• Providing feedback slowly

Typical Barriers

Documents• Plan for external communication, if applicable

Records• Decision to communicate externally• Internal communication records• Suggestions from employees and contractors• External communication records

Documents & Records

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Exercise• What energy related information is important and to

whom should it be communicated?• What energy awareness topics should be

communicated?• What are some techniques for providing appropriate

EnMS and awareness information? (In addition to “standard” communication methods, think outside the box of unique ways for providing relevant EnMS information.)

• What are some techniques for providing/receiving suggestions and comments?

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• Key Area

• Training

Action Plan

Document Control• Identify changes and current revision

status • Approved• Reviewed and updated• Available where needed• Remain legible and readily

identifiable• Documents of external origin are

identified and distribution controlled• Obsolete documents are suitably

identified if retained to prevent unintended use

• Ensures correct information is available where needed

• Manages external information and obsolete information

Document Control—Value to the Organization

• Overly complex formats• Excessive controls• Too many levels of approval• Document

managers/coordinators• Lack of ownership

Typical Barriers

• Don’t make the process cumbersome• Align or integrate with existing document control

processes as appropriate• Allow stand-alone (but controlled!) documents

Success Factors

Exercise

• Review your document list• Did you use the document tab in the tools?• Or did you use the RnR tab?• Develop the list further based on what you have heard

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• Key Area

• Training

Action Plan

Design – Energy Efficient Design (EED)Major opportunity to improve

Technical Changes

• Expansion, refurbishment, replacement

• Facilities, equipment, systems and processes

Energy Efficient Design

• Challenge user specification, use, distribution, generation

Design may occur as a part of an action planDesign may occur as a part of a preventive or corrective

actionDesign may occur as a part of a process change

• To improve energy performance• New product introduction• New technologies• Energy supplies• Change in materials, regulations, customers• For some other reason

When Does Design Occur?

Energy Efficient Design (EED)Confirm real user requirements first

• Pressure, temperature, flow, humidity, air changes, etc.• Integrate with other systems, e.g. use waste heat for space

heatingDesign in user optimization features

• Facilitate operational control in operationDesign distribution system to minimise lossesDesign and size generation equipment LAST

• It is often purchased first due to longer lead times• Include best available technology (BAT) and control

EED will often reduce capital costAllow for future expansion only if realistically expectedConsider energy metering

Challenge energy service

Ensure operational control is facilitated

Design and challenge

distribution system

Design and challenge generation

system

Design and challenge controls

Pump system example1. Minimise user

requirement2. Shut bypasses3. Determine actual

flow and pressure requirement

4. Reselect motor and pump

5. Replace 150m3/h with 25m3/h

6. Save 75% or 176MWh p.a.

The importance of commissioningIt is common to find well designed buildings and processes

that are not energy efficient in operationThe commissioning team need the following:

• Understanding of the design intent of energy saving features

• They need the expertise to be able to commission properly• They need the time to be able to do it properly (the lowest

bidder may not have enough time)• The project schedule needs to allow enough time for correct

commissioningThe design intent and commissioning learnings need to be

communicated to the operational team (training)

• What is the right energy source?• What specific items or operations can be changed to

improve the consumption of energy?• What technology options are available?

Considerations

• Determine what types of new or modified equipment,systems, facilities or processes can have a major impacton energy performance

• Ensure design review includes appropriate stakeholdersfrom the very beginning - including operators from anyaffected areas

• Consider developing procedures, checklists and/or formsto ensure that the design process consistently considersenergy improvement opportunities

Design Review (EED) Process

• Consider building energy performance evaluation andopportunity consideration into the existing design andreview process.

• Ensure the loop is closed between design andprocurement.

• If the existing design and review process does notensure appropriate design records are being kept,modify the process.

Design Process

• Consider 2 upcoming design opportunities in your team• One large and one small• How will you implement energy efficient design for

these?• What tools do you need?• What decisions will you make?

Exercise

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• Continue with the design exercise

Exercise

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RECORDSRecords support the

CHECKING processes by providing evidence that you are doing what you said you would do.

Controlling records means controlling the data and other evidence that your system is implemented and effective.

Records

• Provide evidence of activities performed

• State results achieved

Records that demonstrate Conformity to EnMS requirementsEnergy performance results achieved of performance

Some specific records are required, for exampleEnergy reviewBaselineMeasuring and monitoring resultsManagement reviews

What records are needed?

What record controls are needed?

Define and implement controls for • Identification• Retrieval • Retention

Ensure records are legible, identifiable and traceable (and stay that way)

• Ensures that you can tellwhat the recorded data orinformation is related to

• Ensures that records can belocated and retrieved

• Expectations for retention ofdata and information areclear

Records Control—Value to the Organization

Consider• using a records table or

index• assigning record owners

(by responsible position)• legal requirements in

setting retention times

Exercise - Documents and Records

During your Phase 1 implementation efforts, what documents and records have you generated?

How are you controlling your energy data to ensure that it is identifiable, retrievable and kept for a specified period of time?

Based on your discussions with your team members, are there any “back at the office” actions you need to address to ensure both control of records and control of documents?

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Module 2 test

• Same format as module 1• 75 minutes• Focus on module 2 topics• Possibility of a few questions from module 1 also.

Especially in generally weak areas.

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Update Action Plans based on Op Control 20 55 08:45 10:00Communications 30 10:00 10:30Break 15 10:30 10:45Communications 30 10:45 11:15Document Control 20 25 11:15 12:00Design 30 15 12:00 12:45Lunch 45 12:45 13:30Design 30 13:30 14:00Record Keeping 20 20 14:00 14:40Exam discusion and help 15 14:40 14:55Break 15 14:55 15:10Monitoring and improving Baseline and EnPIs 30 50 15:10 16:30

TOTALS 2.50 4.25 1.25

Planning How much energy am I using?Where am I using it?What Legal requirements are related to my

energy use?What Other requirements are related to my

energy use?Which are significant users?What is driving it?Who is influencing its use?Are there opportunities for improvement?What is my future energy picture?

System OptimizationRenewable energy optionsAre there legal or other requirements?Develop baseline & indicatorsSet objectives and targetsAction Plan

Energy Planning

Legal and other

requirements

Energy Review

Energy Performance

Metrics

Objectives, Targets,

Action Plans

It’s all about improving energy performance

Energy Performance

Energy Consumption

Energy Efficiency

Energy Intensity

Energy Use

Others

Source: ISO 5000165

Energy PerformanceEnPIs & Baseline

Measurement & Verification (M&V) protocols provideguidance on how to calculate energy savings (usually forimprovement opportunities).

EnPIs are used to measure energy performance

Baselines are established to provide a reference or starting point for measuring energy performance

Purpose of energy metrics

Objective support for decision makingOften subjective reasons

We need to know how much energy we are usingWe need to know if performance is improving or notWe need to know if we are meeting targetsWe need to be able to verify savings of improvementsWe need to establish the following:

• Baseline• Baseload• Performance indicators (EnPIs)

Numerical basis

Energy MetricsVarious levels of complexitySimple:

• Simple: consumption last month v same month last year

• Simple: compare actual consumption with budget• Simple: annualised trend of cost and consumption

More complex• Energy use per unit output• Cooling energy per cooling degree day• Specific energy consumption (SEC)

Same principles apply to EnPIs and verification of savings68

Electricity Use and cost (monthly)

Did the plant start using energy more inefficiently?Or, did other variables impact energy consumption?

What Caused Increase in Energy Intensity (kWh/Kilogram)?

kWh/Kilogram

To answer these questions, we need to understand whatvariables impact energy intensity. Often there arecomplicating factors in 3 broad areas:

■ Production

■ Energy types/uses

■ Other

Complicating Factors

Example:

Example: Determine drivers

Scatter plot

Utilize Energy ReviewEstimated Equipment Contribution to Annual Energy Cost

0% 10% 20% 30% 40% 50%

Air Compressors - 75 kWWater Chillers - 17.5 kWCooling Towers - 30 kWRefrigeration - 963 kW

2 x Dough Blender - 45 kW12 x Dough Sheeter - 1.5 kW

Cheese Blender - 22 kWExtructor - 15 kW

Grinder - 75 kWVemag - 22 kW

2 x Oven Circ. Fan - 22 kW2 x Oven Exh. Fan - 4 kW

Lighting - 25 kWOther Equipment - 18 kW

Baking Oven - 586 kWBaking Oven - 146 kW

Electric Equipment Natural Gas Equipment

• Not identifying all energy sources from the very beginning• Neglecting any significant changes that have occurred

during the baseline development period and since thattime

• Not identifying driving factors• Dedicating resources to EnPI development who are not

familiar with processes or understand EnPIs• Not using the EnPI to report improvement to management

Typical Barriers for EnPI & Energy Metrics

Energy BaselineBasis of comparison for evaluating energy performance

• Facility wide• System• Equipment • Significant energy uses

Uses pieces of initial energy review • Energy use data• Energy consumption data

Facility-determined time period• Point in time• Period of time

Measure energy performance improvement against the baseline

Cumulative savings can be tracked

Adjust Energy Baseline Major process changes Major operational changes Major energy system changes When EnPIs no longer reflect organizational use As determined by the organization (predetermined

method)

Typical Barriers for Baseline• Failure to collect appropriate

data for baseline• Identifying inappropriate

baseline for energy performance measurement

• Failure to identify appropriate time frame

• Failure to identify baseline during initial energy review

• Failure to record baseline(s)• Failure to adjust baseline(s)

based on changes80

Documents• Identified Energy Performance Indicators (EnPIs)• Method for determining and updating EnPIs• Energy management baseline

Records• Baseline (data pieces of initial energy review)• Review and comparison of EnPIs to baseline

Documents & Records

Exercise

• Review your organization’s EnPIs and SEUs.• How are you measuring energy performance of SEUs?• How are you measuring energy performance of the entire

EnMS?• Do you need additional data or metering?• What are the limitations of your EnPIs?• Do you need to modify them?

Agenda – day 3Topic Duration

(mins)Exercise

(mins)Break

durationStart Time

End Time

DAY 3Develop measurement plan 15 45 08:30 09:30Measurement and Verification of savings from action plan items 30 30 09:30 10:30

Break 15 10:30 10:45Measurement and Verification of savings from action plan items 30 10:45 11:15

Discussion: linkages of module 2 and overall EnMS 5 45 11:15 12:05Preview of checking and module 3 20 12:05 12:25Lunch 45 12:25 13:10Test on module 2 5 75 13:10 14:30Workshop to work on specific issues raised by national experts 60 14:30 15:30

Break 15 15:30 15:45Closing remarks 15 15:45 16:00TOTALS 1.25 5.00 1.25

For each SEU where practical– Energy consumption– Driver data (relevant variables)– Consider proxies for variables, e.g. meals served for occupancy

For each SEU– Critical operating parameters

What needs to be measured?

Billing data Energy meters Automation control systems, e.g. BMS Local instrumentation Internet, e.g. degree days Security systems, e.g. for occupancy

Data Collection Sources

Define measurement needs What must be measured/monitored? What degree of accuracy is required? What is required to provide this accuracy? What is already in place? What are the calibration requirements? How often should the measurement needs be reviewed?

What has to be done

A measurement plan is developed.

The plan is implemented.

Used to manage the monitoring and measurement of the key characteristics

Ways it might be done

Maintenance software Checklist Work Instructions Schedules Charts Others

Energy Measurement Plan

Ensures accuracy and repeatability of data

Allows data to be compared over time

Is required for equipment used in key characteristic measurements

Typically a calibration form or record is used

Calibration

Consider your measurement needs

Critical operating parameters

Exercise

(mins)Exercise

(mins)Break

durationStart Time

End Time

M&V of savings from action plan items Has each item achieved its intended savings? Actual savings are always different to estimated M&V plan recommended in advance of implementation

Worked example of a simple M&V - 1

Replacement of light fittings 100 units with 100 W lamps replaced with 75 units of 30 W

lamps What are the annual savings? Make any assumptions needed

Worked example of a typical M&V - 2 Fitting a variable speed drive to a centrifugal pump 30 kW motor What are the annual savings Make any assumptions needed

Worked example of a typical M&V - 3

Training operators in reducing temperature lift of a refrigeration system

50 kW motor on compressor What are the annual savings Make any assumptions needed

Worked example of a regression based M&V - 4 Show the effect of a project on a CUSUM chart How to interpret the savings What assumptions are made?

M&V exercise Consider some of your action plan items. How can you verify the actual savings? What additional instrumentation is required and

economically practical? What duration of monitoring is appropriate?

(mins)Exercise

(mins)Break

durationStart Time

End Time

(mins)Exercise

(mins)Break

durationStart Time

End Time

Discussion: linkages of module 2 and overall EnMS 5 45 11:15 12:05

Preview of checking and module 3 20 12:05 12:25Lunch 45 12:25 13:10Test on module 2 5 75 13:10 14:30Workshop to work on specific issues raised by national experts 60 14:30 15:30

Break 15 15:30 15:45Closing remarks 15 15:45 16:00TOTALS 1.25 5.00 1.25 18

Discussion SEUs are central to everything Operational control, competence and training Roles and responsibilities

– Procurement– Design (Projects People)– Document control

(mins)Exercise

(mins)Break

durationStart Time

End Time

Preview of checking and module 3

Module 3 – Checking – Day 1Topic Duration

(mins)Exercise

(mins)Break

durationStart Time

End Time

Registration 15 8:30 8:45Welcome and opening remarks 10 8:45 8:55Review targets, action plans, improvements using EnPIs 5 45 8:55 9:45Review Operations 5 45 9:45 10:35Break 15 10:35 10:50Overview of checking 15 10:50 11:05Performance Checking: EnPIs and Action plan savings total 20 30 11:05 11:55Checking of Operational control 10 30 11:55 12:35Lunch 45 12:35 13:20Internal Auditing: Purpose, Driver and Types 45 60 13:20 15:05Break 15 15:05 15:20Non Conformances 30 15:20 15:50Reviewing and sustaining the system 20 15:50 16:10Certification to ISO 50001 20 16:10 16:30

(hours)Exercise

(mins)Break

durationStart Time

End Time

DAY 2Opening Remarks Company Representative 15 9:00 9:15Internal Audit Schedule review 5 9:15 9:20Commitment 30 9:20 9:50Break 15 9:50 10:05Planning 45 10:05 10:50Implementation and Operation 45 10:50 11:35Lunch 45 11:35 12:20Site Tour to review operational control 90 12:20 13:50Checking and Management Review 30 13:50 14:20Break 15 14:20 14:35Review the Audit in group 30 14:35 15:05Prepare Audit report 60 15:05 16:05Daily Wrap up 5 16:05 16:10

(hours)Exercise

(mins)Break

durationStart Time

End Time

Team 1 Audit Review presentation 15 5 09:00 09:20Team 2 Audit Review presentation 15 5 09:20 09:40Q&A on internal audit process 40 09:40 10:20Break 20 10:20 10:40Review of a whole EnMS 35 10:40 11:15test on module 3 75 11:15 12:30Lunch 45 12:30 13:15Optional review of any topic required by national experts 90 13:15 14:45

Closing remarks 15 14:45 15:00Refreshment and celebration 90 15:00 16:30Total 2,83 2,08 2,58

(mins)Exercise

(mins)Break

durationStart Time

End Time

Discussion: linkages of module 2 and overall EnMS 5 45 11:15 12:05Preview of checking and module 3 20 12:05 12:25Lunch 45 12:25 13:10

Test on module 2 5 75 13:10 14:30Workshop to work on specific issues raised by national experts 60 14:30 15:30

(mins)Exercise

(mins)Break

durationStart Time

End Time

Discussion: linkages of module 2 and overall EnMS 5 45 11:15 12:05Preview of checking and module 3 20 12:05 12:25Lunch 45 12:25 13:10Test on module 2 5 75 13:10 14:30

Workshop to work on specific issues raised by national experts 60 14:30 15:30

(mins)Exercise

(mins)Break

durationStart Time

End Time

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