introducing mas stephen fountain energy strand leader – mas north east
Post on 22-Dec-2015
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Introducing MAS
Stephen Fountain
Energy Strand Leader – MAS North East
Agenda
> What is MAS?> National Programme Results
> MAS North East Services> MAS North East Results
> The typical journey> MAS NE Approach to energy
management> Examples of opportunities identified
What is MAS?
> Created in 2002> Designed to give SMEs access to
consulting services normally out of their financial reach
> Primary remit is to help companies become more competitive through improvements in QCD
MAS in Numbers
In the year ended in November 2009, MAS nationally:> Handled 12,200 enquires> Performed diagnostics in
6,000 companies> Went on to assist 2,700 of
those companies > Generated £145m in
increased GVA
MAS NE Services
MAS North East has much wider remit than other regions!
MAS North East Services
Operational Excellence
Design Energy
MAS North East
ResourceEfficiency
Operational Excellence
Business process improvement Technical problem solvingOrganisational issues / systems Help in finding suppliers / productsFactory / process layout Supply chain optimisation / planning systemsWorking Capital Reduction Manufacturing Strategy & policy DeploymentKaizen blitz activities 2 year narrow and deep programmes
MAS North East Services
Operational Excellence
Design Energy
MAS North East
ResourceEfficiency
Design
New product introduction Cost down training / facilitationStructured design processes Product & Design strategy
MAS North East Services
Operational Excellence
Design Energy
MAS North East
ResourceEfficiency
Resource Efficiency
New & renewable energy feasibility Waste stream analysis / reductionEnvironmental management systems Water use and targeted reduction
MAS North East Services
Operational Excellence
Design Energy
MAS North East
ResourceEfficiency
Energy
Best practice advice and guidance Mapping, monitoring and targetingTariff/Contract reviews Cultural trainingTechnical energy reduction projects
MAS NE in Numbers
Locally, MAS NE:> Worked with over 600
companies> Created GVA of over
£30m> Identified potential energy
reductions of over £8m> Equates to potential
carbon savings of over 40,000 tonnes
MAS NE in Numbers
£2.3m (29%) of energy reductions were within process industry clients> £1.5m from structured
energy management> £0.8m from technical
energy reduction
MAS NE Customer Journey
Improved GVA
Increased Skills
Jobs created/safeguarded
Core Review
Diagnostic or gap analysis
Partially funded Interventions
} Subsidised support
MAS NE Approach
> Structured Energy Management> Get commitment
> Policy
> Allocation of Resources
> Responsibilities
> Understand> Why do we use energy?
> When do we use energy?
> How much do we use?
> What does it cost us?
MAS NE Approach
> Structured Energy Management> Plan & Prioritise
> Prioritise actions and set targets
> Implement> No cost solutions
> Low cost solutions
> Investment solutions
> Control & Monitor> Review and compare to initial benchmarks
etc
1st Stage - Diagnostic
> Step 1 – Get commitment> Cultural review against perceived best practice
> Step 2 - Understand> Analysis of available data> Physical review to identify opportunities
> Challenge established practices
1st Stage - Diagnostic
> Step 3 - Plan & Prioritise> Prioritise findings based on expected impact
Diagnostic fully subsidised to all NE Manufacturers!
1st Stage – Diagnostic (alternative)
> In addition to the energy review a MAS NE diagnostic can also be undertaken to:-> Carry out an initial assessment of renewable
energy opportunities OR> Review water and waste usage OR> Carry out an EMS gap analysis (14001 etc)
Diagnostic also fully subsidised to all NE Manufacturers!(can be and/or with energy review)
2nd Stage – Further Support
> Build on diagnostic> E.g. more detailed energy & resources
map
Energy & Resources Map
Node 1 Node 1 Node 6
Year: 2007 2756424 Cu.ft. x 100 Year: 2007 5683348 KWh Year: 2007 KWh Year: 2007 54802 Hu.c.m.2007 86914586 KWh 2007 363988 £ 2007 £ 2007 246848 £2007 1629129.3 £ Week: Week:
Week: 58990 KWh Week: 900 Hu.c.m.1788614 KWh £ Feeder1 1931 KWh £
£ £Feeder2 2018 KWh
£
6/2/08 - 12/2/08 6/2/08 - 12/2/08 Node 7 6/2/08 - 12/2/08 Node 7
Thermax 1 17968 KWh (est.) CHP1 458025 KWh CHPThermax 2 215234 KWh CHP2 467936 KWh Boiler17Bar 0 KWh CHP3 445712 KWhTOTAL: 233202 KWh TOTAL: 1371673 KWh
CHP1 147373 KWhCHP2 153163 KWhCHP3 150551 KWhTOTAL: 451087 KWh
KWh
Total: 42641 KWh Total: 331892 KWh Total: 60109 KWh
6/2/08 - 12/2/08 Node 1 6/2/08 - 12/2/08 Node 1 6/2/08 - 12/2/08 Node 4 6/2/08 - 12/2/08 Node 3 6/2/08 - 12/2/08 Node 8 6/2/08 - 12/2/08 Node 2 6/2/08 - 12/2/08 Node 9 6/2/08 - 12/2/08 Node 5
R&D Elec. 18436 KWh Admin Elec. 24205 KWh MCC1.1 31321 KWh MCC2.1 32553 KWh MCC3.1 35596 KWh MCC9.1 32072 KWh MCC4.1.2 12814 KWh B.H. Elec. 14464 KWhMCC1.2 39317 KWh MCC2.2 26106 KWh MCC3.2 43583 KWh MCC9.2 6277 KWh MCC4.1.3 32831 KWhMCC1.3 41134 KWh MCC2.3 23857 KWhE11A 1343 KWh E2-364 161 KWhMCC1.4 9163 KWh (est.) E20A 2241 KWhMCC1.5 7168 KWh (est.)
75435 KWh
? Kg
6/2/08 - 12/2/08 Node 1 6/2/08 - 12/2/08 Node 5 6/2/08 - 12/2/08 Node 5 6/2/08 - 12/2/08 Est. Fig.
R&D Steam 84704 Kg MPB1 139954 Kg MPB2 189070 Kg MPB2 252000 Kg (est.) 6/2/08 - 12/2/08 Node 6
E1009 143 m3
Kg (daily est.)
6/2/08 - 12/2/08 Node 6 6/2/08 - 12/2/08 Node 6 6/2/08 - 12/2/08 Node 6
Cond. Ret. 64800 Kg H2O Well 357 m3 E1025 N/A m3
MANUFACTURING
To AllManufacturing
MPB2
MPB 2
UTILITIES
Unmetered KWh?
Node 5 and 6
MPB 4Labs Admin Building
Boilers CHP
MPB 3
ADMINISTRATION
510077
Total Electricity to Site
(Total equals Feeder 1 and 2 combined)
351825 Kg
Waste Steam Recovery
Waste Steam Recovery
Labs MPB1 MPB2
Condensate Return
SI TE/ BOI LER STEAM106400010Bar Steam =
To STEAM
Areas
Gas
MISCELLANOUS Unmetered KWh?
MISCELLANOUS
Electricity
MPB1LABS
City Water to HOTWELL
Boiler House
From
MPB 1
KWh1446479179129446 84918
GAS
E1025 Water Supply
E1009 Water Supply
WATER
NI TROGENELECTRICITY (Import)
MPB3 MPB4
MPB3
Total:
ELECTRICITY (Export)
6/2/08 to 12/2/08
KWh Total: KWh4564538349
(Total equals Feeder 1 and 2 combined)
John Zink
6/2/08 to 12/2/086/2/08 to 12/2/086/2/08 to 12/2/08
Total: KWh Total: KWh Total: KWh Total:
2nd Stage – Further Support
> Implement> Design studies with cost benefit analysis> Implementation support to ensure benefits
achieved> Energy champion training and cultural awareness
> Control & Manage> Monitoring & Targeting system specification and
implementation> Before and after calculations
2nd stage partly funded by MAS NE
Examples of Opportunities
> Typical Low Cost Opportunities identified:-> Background equipment left running> Set-points to cover all eventualities> Too many cooling water pumps running> Efficiency compromised for convenience> Energy inefficient behaviour> Utility wastage e.g. compressed air or steam> Etc
Examples of Opportunities
> Typical Capital Opportunities identified:-> Heat recovery> Combined Heat & Power> Refrigeration upgrades> Lagging upgrades> Pumps and motors> Waste stream reuse options> Water usage reductions> Etc
Summary
> MAS NE wider remit than other MAS
> £2.3m potential energy savings in process industry clients> Structured approach to energy
management
> Fully subsidised diagnostics for energy & resource efficiency
> Partly funded further support
