seven habits of highly effective energy managers

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  • 1. 7 Habits of Highly Effective Energy Managers & Real Time Survey Energy Checkup Dr. Ken Currie, Director Center for Manufacturing Research Tennessee Tech University Associate Director of Industrial Assessment Center

2. Identify the sector that best represents your organization. A. Commercial B. Large Industrial C. Small/Medium Industrial D. Public E. Other 3. Shameless Advertising Tennessee 3-Star Industrial Assessment Center FREE!!! Energy Assessments to Small & Medium-Sized Facilities Within SIC Codes 20-39 Gross Annual Sales < $100 Million Employment < 500 $100K < Annual Energy Bills < $2.5 Million No Permanent Energy Professional Primary Focus is Workforce Development In Partnership with University of Memphis and ETSU Unique capabilities to assisting TN Industry in ISO 50001 Implementation and Certification 4. Shameless Advertising Industrial Assessment Components Gather plant data including product type, annual sales levels, production levels, operating hours Study processes and plant layout Analyze utility billing data Identify key energy systems Develop assessment day strategy To be completed before assessment visit Pre-Assessment Meet with plant management team Present details of pre- assessment analysis Tour plant Collect operating data Conduct diagnostic testing Discuss preliminary assessment findings with plant management Prioritize potential recommendations for further analysis Duration: One Day Conduct engineering and financial analyses of priority recommendations Develop first order estimates of implementation costs Document results in GOLD Standard format assessment report Upload report data into IAC database Deliver report to plant within 60 days from plant visit Conduct follow up discussions with plant, 6- 9 months following assessment visit Identify implemented energy savings Upload implementation data into the IAC database Analysis & Reporting Follow UpAssessment Visit 5. Shameless Advertising Tennessee 3-Star IAC Performance ASSESSMENTS 70 Completed FOLLOW-UPS AT 6 9 MONTHS 50 Completed (Of those, 1 plant had closed) Recommendations Made Recommendations Made Recommendations Implemented Percent # of Recommendations 443 335 134 40% Energy Dollar Savings $8,730,665 $7,022,291 $2,084,081 30% Electric Usage Savings (kWh) 74,146,120 kWh 59,041,051 kWh 17,754,813 kWh 30% Electric Demand Savings (kW) 680,189 kW 72,832 kW 40,041 kW 55% Natural Gas / Liquid Propane Savings (MMBtu) 529,499 MMBtu 450,752 MMBtu 193,742 MMBtu 43% 6. Has your organization established required payback periods for energy projects? A. Yes B. No C. Dont Know 7. Shameless Advertising Implementing ISO 50001 Energy Management Systems Requires an organization to establish, implement, maintain, and improve an energy management system, enabling continual improvement in energy efficiency. Imposes requirements on energy supply and consumption: Measurement Documentation and reporting Design and procurement practices for energy-using equipment and systems Processes and personnel TTU has capabilities for coaching, mentoring, and training organizations seeking certification. Successfully coached Schneider Electric, Smyrna to achieve ISO 50001 certification and Superior Energy Performance Platinum. Two Certified Practitioners in EnMS, ISO 50001 Lead Auditor, and CP in SEP Verification 8. Has your organization established energy- per-unit metrics? (Ex: energy cost per pound of product) A. Yes B. No C. Dont Know 9. Fans & Pumps are usually oversized to consider worse case scenarios. Variable speed drives allow for a throttled output with a corresponding variable electrical load to reduce flow. Furnaces are designed for peak product flow but typical flow may only require a subset of the burners to be in service. Habit #1: Engineers Design for Just- In-Case NOT Energy Efficiency 10. Does your organization have a formal written energy management plan or energy policy? A. Yes B. No C. Dont know 11. Compared to electric motors, the work that is conducted by compressed air is 7 times more expensive. Inappropriate uses and leaks are common losses in a compressed air system resulting in significant wasted energy i.e. In a system that is running a 200 hp compressor, 30% represented by inappropriate uses and leaks can cost approximately $4,500/yr in a single shift operation. Habit #2: Air is Free, but Compressed Air is Very Expensive Poor management of air supply can yield inefficiencies for costs and also in meeting demand events. 12. Has your organization had energy assessments done at its facilities in the past? A. Yes B. No C. Dont know 13. Habit #3: Motel 6 Got it All Wrong They Should Not Have Left the Lights On Changing bulbs is a good first step, but all light is not created equal and replacing one fixture for another fixture may yield more lumens than what is needed. Consider reducing the number of bulbs to reduce lighting levels as appropriate for the task. Sensors and controls allow for occupancy sensors, daylighting, and timers. 14. Do you use occupancy sensors? (warehouses, manufacturing areas, conference rooms, copy rooms, etc.) A. Yes B. No C. Dont know 15. Few industrial operations are truly 24/7 One company assumed that these compressors were being turned off when in fact there was a perceived production requirement that they be left on reality was quite different. Improper compressor sequencing and controls can adversely affect energy efficiency. Habit #4: Reality is Usually Somewhere Between our Expectations and Total Chaos. 16. Are fixtures or equipment turned off during extended unoccupied periods? (Ex: evenings, weekends, plant shut-downs) A. Yes B. No C. Some, but not all D. Dont know 17. Air & steam leaks, HVAC efficiency losses, results of poor maintenance, equipment degradation all result in the need for a continual management process. Habit #5: Low Hanging Fruit Always Seem to Grow Back 18. Does your organization have a procedure for employees to suggest energy savings opportunities? A. Yes B. No C. Dont know 19. Habit #6: Production Needs vs. Energy Reduction Cant We Just All Get Along! Perceived needs for quality, production throughput, and refusing to change anything that may cause a production perturbation often conflict with changes to reduce energy. Energy Management Systems create a cross- functional energy management team working to analyze and improve processes at the lowest possible energy consumption. 20. Does your organization have an energy management team? A. Yes B. No C. Dont know 21. Habit #7: You Cant Reduce What You Dont Measure, and You Cant Measure What You Dont Meter This project is funded under an agreement with the State of Tennessee. This material is based upon work supported by the Department of Energy under Award Number DE-EE0000160. CFDA 81.041. Sub-metering helps to align energy consumption with significant energy uses allowing for concentration of effort. Measuring energy performance should be calculated as a basis of production (energy intensity) without consideration for rate changes MMBtu/unit production 22. Are departments in your organization required to track energy usage? A. Yes B. No C. Some, but not all D. Dont know 23. Thank You for Participating in Our Survey! This project is funded under an agreement with the State of Tennessee. This material is based upon work supported by the Department of Energy under Award Number DE-EE0000160. CFDA 81.041.