Energy MAP

Plastics SectorWorkshop 3

Monday 11th December 2006

Port Laoise

Alan Ryan / Elizabeth Muldowney

SEI

Review of Workshop 2

• Workshop 1 Exercises• Energy Saving Opportunities

• Compressed Air• Air Conditioning and Refrigeration• Production Equipment

• Workshop 2

Homework for Session 3

• Finish Exercises from workshop 1 if outstanding• Prepare and bring to the next workshop a Register

of Opportunities• List of all potential energy saving

opportunities• Produce feasibility analysis on at least 3

energy saving opportunities

Register of OpportunitiesSample Energy Opportunities Register for XXXXXX LtdLast Updated xx/xx/xxxxAssumptionsAverage Elec Day Unit Price €/kWh 0.06000 CO2 per kWh elec x gCO2/kWhAverage Elec Night Unit Price €/Kwh 0.04500 CO2 per kWh gas x gCO2/kWhAverage Gas Cost €/kWh 0.01900

Energy Opportunity PersonEst YearlyEstimatedEst. Yearly Simple CommentResponkWh savingsC02 savings€ savings Payback

Housekeeping ActionsThermal Turn off boiler 1 at weekends Tech 1 Ongoingturn off boiler 2 at weekends Tech 2ElectricalAir HandlingTurn off AHU 1 at weekends Tech 1Turn off AHU 2 3rd Saturday off the month Tech 2Bills managementTender gas and electricity supply CompletedEnter the WPDRSTotalsCapital ActionsInstall Economiser Eng 1 1-JunReplace bucket trap on machine 7Replace process 1 with process 2 Eng 2 1-OctItems worth investigatingReplace bucket traps with thermodynamicEng 1 1-JunReplacing machine No.7 Prod EngCHP plant Eng 2 1-OctTotals

Feasibility Analysis

Copyright SEI 2005

Procedures & methods

Housekeeping

Technology & investment

Break

Session 3 Agenda

• Steps 10 – 12, • Programme Planning• Setting Targets

• Step 15• Prioritising Projects• Project Management Methods and Tools

• Resourcing the programme plan• Look again at pillar 1

• Introduction to Step 18 Monitoring and Measuring

Continual Improvement

Model

Take Action Plan

Review Identify

Commit

Energy Map Pillars

Continual Improvement

Model ReviewAppoint

Co-ordinator

Appoint senior

management sponsor

Energy Policy

Overview Energy

consumption

Identify significant

users

Identify key

factorsIdentify

opportunities

Establish a plan

Set goals and

targetsAppoint

resourcesCulture and

awareness

Training

Project prioritizati

on & manageme

nt

Operation &

maintenance design

procurement

Develop Key

performance

indicators

Monitor & measure

Corrective Action

Reporting

Take Action Plan

Review Identify

Commit

Energy Map Steps

Continual Improvement

Model ReviewAppoint

Co-ordinator

Appoint senior

management sponsor

Energy Policy

Overview Energy

consumption

Identify significant

users

Identify key

factorsIdentify

opportunities

Establish a plan

Set goals and

targetsAppoint

resourcesCulture and

awareness

Training

Project prioritizati

on & manageme

nt

Operation &

maintenance design

procurement

Develop Key

performance

indicators

Monitor & measure

Corrective Action

Reporting

Take Action Plan

Review Identify

Commit

Energy Map Support Programme

Complete

ReviewAppoint

Co-ordinator

Appoint senior

management sponsor

Energy Policy

Overview Energy

consumption

Identify significant

users

Identify key

factorsIdentify

opportunities

Establish a plan

Set goals and

targetsAppoint

resourcesCulture and

awareness

Training

Project prioritizati

on & manageme

nt

Operation &

maintenance design

procurement

Develop Key

performance

indicators

Monitor & measure

Corrective Action

Reporting

Take Action Plan

Review Identify

Commit

Energy Map Support Programme – Session 3

Session 3 Agenda

• Steps 10 – 12, • Programme Planning• Setting Targets

• Step 15• Prioritising Projects• Project Management Methods and Tools

• Resourcing the programme plan• Look again at pillar 1

• Introduction to Step 18 Monitoring and Measuring

Introduction to Pillar 3 - Plan

Why are some companies more successful than others

• If no strategic direction or commitment….

Operational Level

TechnicalEnergy ManagerFacilities MgrProduction Mgr

Strategic LevelCEO’sSenior Managers

CommitmentResources

People

Systems

Review/Set objectives

Introducing Steps 10, 11, 12Linking operations with strategy

Copyright SEI 2005

Operational Actions Capital Projects

Feasibility Projects

Register of Opportunities

(What could be done)

Programme Plan (Objectives and targets)

Energy Saving Register

Implement & Monitor Progress

- Energy Savings Wizard

- Energy Team/Staff

- From “Review”

If attractive and capital reserved in Programme Plan – do it!

InformationSystem

“Identify”

M & R, Corrective Action

FeasibilityStudies

Copyright SEI 2005

Heart of an EnergyProgramme

A good plan

Operational Level

Programme ManagementEnergy ManagerFacilities MgrProduction Mgr

Strategic LevelCEO’sSenior Managers

Sign off the planProvide resources

People Management

Project Management

Company targets

Programme Plan

Homework for Session 4

• Start to order and prioritise your Register Of Opportunities

• Develop a draft of a Programme Plan• Develop one Project Plan• Preparation for Workshop 4

• Read Pillar 4• Complete Energy Awareness Template

Example of a Programme Plan

XXXX Ltd Programme Plan 2005No Objective and target € SavingCO2 SavingBudget € Manager Responsible

EMAP general1 To train 40 key people in basic energy awareness Training MGr2 To continuously identify wastage and turn off Production and facilities manager3 To invest 100,00 euro on energy and Facilities manager

complete at least 20 energy saving projects4 To identify opportunities for saving every 6 months Facilities manager

instead of every yearEMAP Significant users

1 To reduce compressed air consumption by 5% by Facilities supervisora. installing a sequence controllerb. installing heat recovery on compressor 1c. agressively tackling leaks on machines

2 To reduce air handling units consumption by 5% by HVAC supervisora. reviewing production monthly and turn off if NIUb. installing energy efficient motors on 5 AHU's

3 To reduce production consumption by 2% by Production managera. replacing machine 7 with new process

4 To reduce gas consumption by 7% by HVAC supervisora. turning off AHU's (see 2a)b. installing air fuel ratio controllerTotals 57000 2500 84000

Signed ____________________ Managing DirectorSigned ____________________ EMAP Senior Manager Copyright SEI 2005

Session 4

• Pillar 4• Energy Awareness Campaigns• Energy Training Courses• Taking Action - the Energy Savings Register• Design, Procurement and Operating and

Maintenance

Alan Ryansei.i 01-8082536

www.sei.ie/energymap

Proof of global warming!!