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The Road to Sustainability

Master Thesis Report

Sahana Naganathan

ME3 2011 -2013

ENVIRONMENTAL BASELINE PROJECT – PHASE 2

Alstom Switzerland Ltd.


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INDEX NOTE

Report title: The Road to Sustainability – Environmental Baseline Project Phase 2

Curriculum International Master ME3

Placement title: Intern

Year: 2013

Author: Sahana Naganathan

Company: Alstom Switzerland Ltd.

Address: 7 Brown Boveri Strasse, Baden. Switzerland

Number of employees: 96,000 (Corporate)

Company tutor: Raul Mora

Function/position: Environmental specialist at Thermal Services

School tutor: Dr. Pal Szentannai

Keywords: Environmental Strategy, natural resources, water management,

energy management, waste management, Space Heating

Assessment

Summary: Alstom Thermal Services business provides cradle to grave

operation, maintenance and service components to power plants

belonging to Alstom and clients. The Environmental Baseline project

aims at measuring and improving the resource efficiency of

Thermal Services. Phase 2 of the project aims at deployment of the

strategy, through site assessments, communication and training kits

and development of space heating assessment tool.


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1.

1. Table of Contents .......................................................................................................................... 2

2. Abstract ............................................................................................................................................ 3

3. Company Description .................................................................................................................. 4

3.1 Alstom Group ....................................................................................................................................... 4

3.2 Alstom Thermal Services ................................................................................................................ 5

4. Introduction ................................................................................................................................... 6

4.1 Background – Project Context ....................................................................................................... 6 4.1.1 EHS Environmental Tools ................................................................................................................................... 7 4.1.2 Phase 1: Development of Environmental Strategy .................................................................................. 7 4.1.3 Phase 2: Deployment of Environmental Strategy ..................................................................................... 7

5. Objective & Methodology ........................................................................................................... 8

5.1 Objective ............................................................................................................................................... 8

5.2 Methodology ........................................................................................................................................ 8

5.3 Project Planning and Management ............................................................................................. 9

6. COMMUNICATION MODULE- Development of Guidance Kits ...................................... 10

6.0 Background ....................................................................................................................................... 10

6.1 Results ................................................................................................................................................ 10

6.1.1 Waste Management Program ................................................................................. 10

6.1.2 Water Management Program ................................................................................. 14

6.1.3 Energy Management Program ............................................................................... 16

7. PROJECT MANAGEMENT MODULE- Environmental Baseline Visits .......................... 21

7.0 Introduction ...................................................................................................................................... 21

7.2 Wroclaw Site Assessment ............................................................................................................ 21

7.2.1 Lighting Assessment ............................................................................................... 21

7.3 Charleroi Site Assessment ........................................................................................................... 22

8. TECHNICAL MODULE – Development of Heating Assessment Tool ........................... 23

8.0 Background ....................................................................................................................................... 23

8.1 Methodology ..................................................................................................................................... 23

8.1.1 Literature Review ................................................................................................... 23

8.1.2 Software Evaluation ................................................................................................ 23

8.1.3 Designing the tool ................................................................................................... 24

8.1.4 Proof of Concept ...................................................................................................... 28

8.2 Results ................................................................................................................................................ 29

9. Conclusion ..................................................................................................................................... 30

9.1 My contribution to the project ................................................................................................... 30

9.2 My Learning Outcomes ................................................................................................................. 30


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2.

Alstom Thermal services EHS (Environment, Health and Safety) launched the Environmental

Baseline Project to keep in line with the sustainability efforts of Alstom Power and specifically

to improve environmental management at various workshop sites of Thermal Services. This

document details the methodology and results of phase 2 of the project. Phase 2 was divided

into three main modules The first, ‘Communication Module’, which was set up to increase the

understanding and awareness of concepts underlying the environmental baseline project,

involved the development of guidance kits for each, water, energy and waste management. The

second, ‘Project Management Module’ consisted of monitoring and applying the results of Phase

1 to more sites; Wroclaw (Poland) and Charleroi (Belgium) sites in particular. This involved the

drafting of lighting & water consumption and waste generation review documents in order to

facilitate the generation of the report document. The third, ‘Technical Module’ comprised of the

development of a heating assessment tool. The tool is designed to calculate the heat losses and

to assess if the installed heating system is sufficient to attain thermal comfort within the site.

The tool further aims to generate a preliminary action plan suggestions from the results of the

assessment. Each module of phase 2 intends to sustain, improve and develop (respectively)

results of phase 1 and sets a path with the same intention for the next phase of the project.


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Steam

Gas Power

Automation and Control

Nuclear

Thermal Services

Thermal Power

EHS and

Quality

Strategic

Planning

3.

3.1 Alstom Group Alstom group is a multinational company consisting of 92,600 employees in over a hundred

countries. The Alstom group is involved in four main sectors; Thermal Power, Renewable

Power, Grid and Transport. A brief description of each is shown in Figure 1.

Alstom Thermal Power is the largest

business of the group with 37,500 employees

and was responsible for 43.7% of the total

sales in FY2011/2012 (Alstom Acitvity Report

2011/12). Thermal Power is divided into 5

businesses: Steam, Gas, Power Automation and

Control, Nuclear and Thermal Services.

EHS (Environment, Health & Safety) and

Quality and Strategic Planning are placed at

sector level, and belong to every business.

Figure 2 shows an illustrated representation of

the organization of Alstom Thermal Power,

shown in no particular hierarchical order.

Figure 1: Alstom Group – Businesses

Source: (Alstom Acitvity Report 2011/12)

Figure 2: Thermal Power Organization

Source: Adapted from https://online.alstom.com/Alstominbrief/Pages/Alstom-

in-brief.aspx


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Figure 3: Thermal Services Structure

Source: Adapted from https://online.alstom.com/Alstominbrief/Pages/Alstom-in-brief.aspx

3.2 Alstom Thermal Services

Thermal Services provide power generation services worldwide, from repair and

reconditioning, performance improvement, on site field services to full-operation and

maintenance solutions. The business consists of 15,000 employees; Thermal Services is

organized by Product Lines, Service Network areas and Integrated Solutions. The six Product

Lines are responsible for establishing the technology and strategy of the business, and the

Service Networks are defined by 12 areas that are responsible for project execution. Integrated

Solutions combines and coordinates projects that involve more than one business with

technology.

The scope of this Master Thesis project covers all 33 Thermal Services Sites which are spread

across a combination of Product Lines and Service Networks. The sites are categorized by two

types: Field Services, which are sites that belong to the client, and workshop sites which belong

to Alstom.

EHS and quality are placed at the business level and support the activities of this complex

organization and have an influence over the whole business. EHS, Thermal services at

Switzerland, is where this internship was conducted. A visual representation of organization

of Thermal Services and explanation of its structure is shown in Figure 3.

Thermal Services

Product Lines

Gas Turbine OOEM

Gas Turbine

OEM

Generator Boiler Steam

Turbines

AQCS

North America

South West Europe and

America North Europe

Central Europe

East Asia Middle East

South East Europe

South African Countries

Oceania

Latin American

India China

Integrated

Solutions

Service Network

Thermal Services Workshop Sites

EHS and Quality

Internship

Geographic Location Technology


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“Economic growth and resource efficiency are two sides of the same coin. They are both

prerequisites for the sustainable growth of our modern societies and are essential to face the

current environmental, social and economic challenges. “ (K.Rademaekers, 2011)

It is important to understand that resource efficiency is defined by all material resources

including water, soil, air and the overall ecosystem; and how effectively and efficiently we use

these resources. This means, using less to produce more and reducing the impact from using

these resources. (K.Rademaekers, 2011)

Sustainability and resource efficiency need to be measured in order to understand clearly the

progress of an organization and consequently put in place measures and strategies in order to

achieve effective management and improvements. (K.Rademaekers, 2011). This is the goal of

the Thermal Services’ Environmental Baseline Project; to make a baseline assessment on

where Alstom Thermal Services stands with respect to being sustainable and to identify the

potential improvements towards a more sustainable future.

4.1 Background – Project Context

Alstom Power has over the years, worked on improving its resource efficiency and

environmental impact (energy, water and waste management specifically) through continued

sustainable efforts. Alstom, being one of the leading organizations in the power sector, has

committed to its stakeholders to reduce its overall environmental impact. The company forms

part of global sustainability initiatives like GRI (Global Reporting Initiative), DJSI (Dow Jones

Sustainability Index) and the CDP (Carbon Disclosure Project)

In 2010 corporate EHS (Environment Health and Safety) committed to targets in energy, water

and waste management to keep in line with the EU “20-20-20” targets.

Reduction in Energy Intensity and GHG (Green House Gases) Intensity of 20% by 2015

Waste reduction with 80% Recycling by 2015

20% water reduction in water stressed areas

(Alstom Annual Report, 2013)

With this as a basis each business was encouraged to establish its own strategy in line with its

core business.

The actual actions of strategies are taken at the lowest levels of the organization and therefore

establishing how to bring the strategy down to the lower levels is the key to achieving targets.

The Environmental Baseline Project was established for this purpose; to provide a focus at the

site level, where assessments are to be made, reduction potentials identified and measures can

be taken. The aim is to act local, keeping in mind one global vision or strategy. With the support

from senior management of Thermal Services, the project was initiated at EHS in the beginning

of 2012 and its scope influenced all Thermal Service Sites.


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• Assess reduction potential

• Set actions and projects

• Set indicators • Assessment

• Vision • Time

framework

1. Commitment

2. Indicators

3. Targets 4. Action Plan

4.1.1 EHS Environmental Tools

Environmental performance of Alstom Power is periodically (monthly, quarterly and annually)

assessed, using certain global IT tools. Thermal Services workshop sites are reviewed through

reporting of certain environmental indicators. Total water consumption (in m3), Total Energy

Consumption (kWh), total CO2 emissions, total waste production (in tonnes) are some examples

of about 70 environmental indicators which were externally verified by

PricewaterhouseCoopers. (Alstom EHS Reporting Manual, 2012)

Environmental performances of all Thermal Services sites are also internally audited using the

EHS Roadmap Standard. The EHS roadmap standard for the environmental chapter is divided

into various initiatives that cover water, energy and waste resources, amongst others, and then

further divided into various themes under each topic. Assessors perform a maturity assessment

based ISO 4001 requirements and on how well the site is performing with respect to each

theme.

4.1.2 Environmental Baseline Project Phase 1: Development of Environmental Strategy

The first phase of the project commenced in Feb 2012 and involved the development of the

Thermal Services environmental strategy. During this phase the four main pillars of the

environmental strategy were identified: The

first step involved making a commitment and

included setting a vision and time framework

for the strategy. The second pillar was

identifying a set of indicators that allowed

analysis and consolidation of results. The third

pillar consisted of a developing a procedure for

establishing targets and included using the

questionnaire tool that was developed in order

to measure the various indicators such as total

water or energy consumption. The fourth pillar

involved a suggested action plan in response to

achieving the targets that were set. Figure 4

Shows the four pillars of the environmental

strategy.

The first phase concluded in Jan 2013 with the release of the questionnaire assessment tool for

waste, water and electricity consumption, details of which can be found in the Phase 1 master

thesis report. (Izquierdo, 2012). The proof of concept for the first phase was achieved through

two key Thermal Service workshop sites: La Courneuve, FR and Charleroi, BE.

4.1.3 Environmental Baseline Project Phase 2: Deployment of Environmental Strategy

The second phase commenced in Feb 2013 and is what defines the activities of this internship.

Three main modules with specific objectives were designed to form the pillars for this next

phase:

Improving certain modules that were developed in phase 1

Sustaining the outcomes of phase 1

Develop: Developing certain modules for the next phase of the project.

The next chapter gives a detailed explanation of contents of each module and the methodology

of how the internship was conducted.

Figure 4: The four pillars of environmental strategy

Scource: (Izquierdo, 2012)


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Improve • COMMUNICATION

MODULE • Guidance Kits

Sustain • PROJECT MANAGEMENT

MODULE • Environmental Baseline Visits

Develop • TECHNICAL MODULE

• Heating Assessment Tool

5.

5.1 Objective The objective of the environmental baseline project is to measure and improve resource

efficiency within Thermal Services fixed through optimization of activities and minimizing

resource consumption, thereby resulting in cost reductions, environmental impact

minimization, improving social aspects and thus leading the company into a more sustainable

future.

With this as underlying aim, the project moves into its second phase, and described below is a

more detailed understanding of the specific modules and methodology adopted in order to

achieve those specific objectives and targets.

5.2 Methodology The three main modules that define the activities of this internship covered developing three

major skills; project management, communication and applying technical concepts. Each of the

modules were aligned along the three pillars or objectives for the environmental baseline

project; Improve, Sustain and Develop (as described in the previous section). Figure 5 given

below are details of each module.

Improve

The improvement module was established in order to

further develop and refine the communication and

training part related to the project. It involved

developing guidance or training kits related to

environmental management. The awareness training

kits provide with guidance and suggestions on

establishing reduction programs, different types of

technological improvement options and how to better

manage the environmental systems within a site.

Sustain

The sustain module also known as the ‘Project

Management Module’ was set up with the intention of

executing the site visit programs (attached as ANNEX

13) which involved continuing the site assessments

using the questionnaire tools for water, waste and

electricity, developed in Phase 1. The Thermal Service

sites at Wroclaw, Poland and Charleroi, Belgium were

chosen as the sites to perform the assessment as part of

this module

Develop

Space heating was identified to be a major contributor to energy consumption within sites that

require indoor heating due to their location. In order to achieve reductions in consumption, it is

Figure 5: The modules of Phase 2


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necessary to first assess current energy consumption related to heating and make a preliminary

analysis of the degree of improvement that can potentially be achieved. A software specification

evaluation was performed to choose the best option to perform the heating load assessment. It

was concluded from the evaluation that a tool was required to be developed using Microsoft

excel as it would be the preferred option to make a preliminary assessment. This development

of this heating assessment tool formed the technical module of phase 2 of the project.

5.3 Project Planning and Management The planning of the internship was performed by using methods and skills learnt through from

the project management course of the master’s program. The Project was executed with the

help of organizing each module into various work packages and each work package was further

divided into tasks and subtasks. A time frame was aligned against each task and subtask. The

project schedule and deliverables were monitored weekly and the chart was revised bi-weekly.

Gate reviews were held every month to review the outcomes and deliverables for that month.

Given below in Figure 6 is the first version of GANT CHART developed for project the schedule.

The original chart is provided in ANNEX 1.

WO

RK

PA

CK

AG

ES

RESOURCES

Figure 6: GANT CHART for Project Planning


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6.

6.0 Background

The communication module was set up with the intention to increase awareness and provide

with guidance on how to achieve reductions and better manage the environmental systems,

within Thermal Services workshop sites. It involved the development of guidance kits that could

be used by people in all levels of the organization. The three main focus areas of water, waste

and energy management were selected to form the basis for this module.

Each of the three guidance kits (water, energy and waste management) was approached in the

same way and was designed with a common backbone that addressed the following:

Why : The necessity

The documents establish the need of implementing environmental

management techniques; by illustrating its positive effects on the site’s

overall resource efficiency and environmental impact and hence cost.

What : Current (consumption or generation) categorization tree

This section provides with a visual representation of what the current

energy / water consumption or waste categorization system looks like for

any particular site

How: Reduction and Management suggestions

Each document finally provides with suggestions and measures i.e, real,

applicable examples that can be adopted to implement better management

techniques or achieve reductions.

Given below are the steps followed for this module and results of the guidance documents

developed.

6.1 Results

6.1.1 Waste Management Program

6.1.1.1 Waste Management – A Necessity

The first step to waste management was to understand that all waste produced, has some level

of impact on the environment. Introduction of an effective waste management system results in

reducing this environmental impact. Shown below in Figure 7 is a visual illustration that was

developed to convey the same message (please refer to ANNEX 2 for the full version). The first

part of the diagram shows the effects of Alstom’s activities on the environment without any

waste management techniques in place. The second conveys how waste minimization can be

achieved through alterations in design (eg: eco-design) or reuse opportunities. Finally, the last

diagram shows how combination of waste minimization with waste management practices (Eg:


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Recycling and Energy Recovery) can achieve considerable reductions in waste production and

thereby increase resource efficiencies and environmental impact.

Four main steps were defined (McDougall, 2001)

to achieving an effective waste management

system as shown in Figure 8.

One of the key challenges that were encountered

during the initial development of the project was

that sites were struggling with the identification

of all possible waste streams. This could be due to

the misinterpretation and absence of clarity on

what exactly defines waste. Therefore the first

step is identifying and understanding the basic

definitions and mapping all possible waste

streams.

The second step is to identify waste

minimization opportunities through alterations

in design or reuse. Alteration in the design of processes, also known as Ecodeisgn, is an

approach to design of a product with special consideration for the environmental impacts of the

product during its whole lifecycle. (What is Ecodesign, 2013) This would in turn reduce the

Waste

Generation

1. Understand the basis (definitions and teranga

reporting)

2. MInimize waste (prevention and reuse, an approach to LEAN)

3. Waste segregation (prepare for

specific treatment)

Handling waste to

contractors

Figure 7: The effects of proper waste management

Figure 8: Steps to Waste Management


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consumption of raw materials or natural resources, thus leading to a more efficient system

overall.

After minimization and reuse, waste segregation projects are recommended. Segregation of as

many streams as possible are encouraged. In Europe, countries need to ensure collection of

certain streams in accordance with the EU waste framework directive. (Commission, 2008) The

Alstom Thermal Services Benchmark is that all sites segregate as many streams as possible or at

least those required in the corporate reporting manual, whenever collection of specific streams

is available.

Finally, it is made a requirement by Alstom Thermal Services that waste contractors are to be

chosen by sites to treat and dispose waste responsibly. Thus, ensuring that all non-hazardous

segregated waste follow a preferred treatment. For non-segregated waste, waste incineration

with energy recovery is preferred over waste incineration without energy recovery. Landfill of

waste is the least preferred option. The next section focuses in more detail, the methods to

segregate and dispose waste.

6.1.1.2 Categorizing and Disposing Waste

In 2010, the European Union released a directive that provided the legislative framework and a

detailed guidance on segregating and managing waste. However the directive was found to be

complex and difficult to use by sites. Therefore it was necessary to find a way to convert a

complex concept into an easy ‘one pager’ that conveyed the contents of the directive.

For this purpose, a decision tree flowchart shown below in Figure 9 was developed in order to

help the user conclude if the waste is hazardous.

Figure 9: Waste Decision Flow Chart


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Once the waste is categorized the tree shown below in Figure 10 was developed to enable the

user to understand the various disposal options under each category. A full version of the tree is

available as ANNEX 3.

One of the key challenges during the course of this module was to develop a single document

that could be usable by all sites globally. However, waste related legislation varies from one

country to another. Therefore, a decision was taken to use EU regulations related to waste

segregation and disposal as the basis.

In Europe, countries have an obligation to introduce separate collection of the following waste

streams to facilitate recycling or recovery of the following streams shown in Table 1: European

legislation on segregation of waste streams (Union, 2010):

Table 1: European legislation on segregation of waste streams

Waste Disposal Method

Paper Recycle

Metal Recycle

Plastic Recycle

Glass Recycle

Figure 10: Waste Segregation Tree


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Waste Oils Recycle and energy recovery are possible

Bio Waste Recycle

Directives such as the WEEE (Waste Electric and Electronic Equipment) Directive or EU

directive on batteries and accumulators bans the disposal of many wastes such as electric and

electronic equipment or industrial batteries. This includes Lamps, IT, electric tools, gadgets, etc.

Recycling of these wastes are recommended due to the environmental impact of these

hazardous materials. Recycling also enables the extraction and reuse of the rare metals found in

electronic waste.

The EU Directive on disposal of waste oil also bans:

• Any discharge into inland surface water, ground water, territorial sea and drainage

systems;

• Any deposit and/or discharge of waste oils harmful to the soil and any uncontrolled

discharge of residues resulting from the processing of waste oils;

• Incineration with energy recovery / Recycling recommended

A detailed guidance document on waste management was formulated. This guidance chart lists

out all possible types of waste that could be present at any Thermal Services site and provides

with recommendation of the best treatment or disposal method for each. A screen shot of this

guidance is chart shown below in Figure 11 . The original document can be found as part of

ANNEX 4: Waste Management Guidance Document.

6.1.2 Water Management Program

The same approach as that followed in waste management guidance, was used in developing the

water management guidance document.

One of the challenges observed during phase 1, was that the way water was being used within

the site was not being perceived as important due to the fact that the reporting tool

requirements only focused on the total water consumption before entry into the site. Therefore,

it was necessary to convey the message that water usage was process intensive. Figure 12 is a

screen shot of Sankey flow diagram that was designed to clearly show the flow of water through

Figure 11: Guidance Chart on Waste Management


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the site. Four major categories of consumption were identified as Processes, Amenities, Others

and finally losses. The flow diagram also visually conveys (through the reduction of the width of

the arrows) how employing water management techniques would result in an overall reduction

of water resource consumption. The original sankey water flow diagram can be found as ANNEX

5.

As mentioned before, sites were required only to report quantity/quality of water entering and

leaving the site. Therefore, the key performance indicators were analyzed before the water

entered and after it left the site. However it was a key realization that the real potential for

reduction lay within the site and in how efficiently water was being used. Thus, establishing the

need to map and quantify water uses within the site boundaries. Reduction measures were

not possible without measuring the current consumption. By mapping and measuring

water usage in all categories it would enable the site to identify amount of water losses and

therefore take measures to reduce losses and increase efficiency. Shown below in, is a water

consumption tree that was designed to convey how water is used in a typical Thermal Service

Site and to help sites see that the reduction potential lay within the site boundaries. A full

version of the tree is available as ANNEX 6.

Figure 12: Sankey Water Flow Diagram


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6.1.3 Energy Management Program The Energy Management guidance document was approached in a slightly different way

compared to the waste and water documents, owing to the complexity of the energy

consumption system within a site. Energy is consumed through different fuels and for varying

categories of uses. Therefore in order to identify ways to reduce overall energy consumption, it

was necessary to deal with energy management in parts. As a first step, energy management

within a household was chosen to analyze in order to better understand a complex energy

consumption system. A mind map was constructed on the different consumption categories, and

fuels used under each category within a household. Figure 14 shows a screen shot of the mind

map for the household.

Figure 14: Energy consumption mind map for a household

KPI’s

KPI’s

Reduction Potential

Figure 13: Water Consumption Tree that shows reduction potential lies within site boundary


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With this as a basis, a similar mapping was done for a Thermal Service site. Six major categories

of consumption were identified (Saidur, Rahim, & Hasanuzzamana, 2010) and possible fuels

used were mapped against each category. This map formed part of the energy management

guidance document, and is shown below in Figure 15. The idea of the energy management part

of this module was to develop a guidance document for each of the six categories separately that

would provide with guidance on how to measure and reduce consumption of each. An

introductory guidance document consisting of the basic concepts, impact of energy

consumption and the need for energy management, and bringing together all the guidance

documents was developed. A full version of the energy consumption mindmap for a site is

available as ANNEX 7.

Given below is an introduction to each of the six categories that were covered in the energy

management guidance document.

6.1.3.1 Lighting

Lighting accounts for nearly 10% of the end energy use within a manufacturing facility and

provides with a good potential for

energy savings. (Manufacturing End-Use

Breakdown, 2010)

Lighting retrofits proves advantageous

for both reduction in energy

consumption and a quick return on

investment. Retrofitting also improves

the visual environment and working

productivity. The IES (Illuminating

Engineering Society) sets minimum

14%

13%

11%

9% 8%

7%

6%

17%

15%

HVAC

Process Heat

Lighting

Compressed Air

Process Fans

Material Handling

Process Refrigeration

Material Processng

Process Pumping

Figure 15: Mind mapping of total energy consumption within a site

Figure 16: Energy end use breakdown in a manufacturing site

Scource: http://www.fypower.org/images/ind/ind_index_chart.png


18

lighting quality standards for various types of activities. The recommended guideline luminance

range for industrial interiors has been set to about 500 luxes for ordinary tasks and 1000 luxes

for more difficult tasks. Luxes are a measure of amount of light emitted per unit area. (Wayne C.

Turner, 2007)

The first step to a lighting retrofit program is to perform a current lighting assessment to

measure the electric consumption and luxes within the site. The assessment can be performed

using the lighting tab of the environmental baseline questionnaire assessment.

6.1.3.2 Water Heating – Boilers

Water heating systems like boilers, are one of the most significant energy consuming areas

within a site. They are also highly fossil fuel intensive. Thus boilers pose very high potential for

energy reductions and management measures.

The main categories for energy and cost reduction measures are

Load reduction Waste heat recovery Efficiency improvement Fuel cost reduction, Other opportunities

6.1.3.3 Electrical Equipment and Machines

Efficient use of electricity enables industrial facilities to reduce operation costs and thereby

increase profits. It also reduces the overall electric consumption. Electric motor driven systems

such as equipment and machines contribute to the majority of electricity consumption for any

site. Therefore any reduction measures taken will heavily impact the overall energy

consumption.

The function of a motor is to convert all electrical energy into mechanical energy. There are

several ways to improve the electrical efficiency of the driven system. The cost effective way is

to check each component of the system for an opportunity to reduce electrical losses (Wayne C.

Turner, 2007).

The first step in identifying reduction potentials is to perform a machine electrical consumption

analysis (audit) to understand the electric sizing of machines. One way to do this is to use the

Machines CV or inventory tool that has been developed which gives details of every machine

used within the site. Another way is to use the electrical questionnaire tool that enables the user

to input and calculate the overall consumption of electricity of machines as per usage energy

management guidance also lists out steps that could be taken to improve the drive system

efficiency.


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0

20

40

60

80

100

120

Natural Gas Steam Electricity CompressedAir

Eur/mWh

6.1.3.4 Compressed Air

Compressed air systems accounts for almost 10% of the total industrial energy use for many

countries and are considered to be one of the most expensive utilities within any industrial

facility. Compressed air generation is highly energy intensive and energy costs accounts for

majority of the total costs that go into compressed air systems. Operation and maintenance

costs represent only a small portion of the overall costs. However compressed air equipment

and power needed for them contribute to almost 80% of the total costs.

Two of the most important factors influencing the cost of compressed air are the type of

compressor control and the proper compressor sizing. Oversized compressors and compressors

operating in inefficient control modes have the highest unit energy and the highest annual

operating costs. (Saidur, Rahim, & Hasanuzzamana, 2010). Therefore paying attention to

compressed air systems and employing conservation measures can save considerable energy

and cost.

The first step to implementing any energy

reduction program for compressed air is to

perform an energy audit. Measures such as

introduction of energy-efficient motors, use of

VSD(Variable Speed Drive), preventing

leakages, use of intake air temperature,

reducing pressure drop, use of water heat and

use of efficient compressed-air systems can

be taken to reduce the overall energy

consumption of compressed air systems. .

Figure 19 shows the energy saving

opportunities for different measures. The

energy management Guidance provided with

details of the different energy conserving

measures. (Saidur, Rahim, & Hasanuzzamana,

2010)

10%

10%

12%

4%

42%

22%

Other Measures

Optimized DriveSystems

Heat Recovery

Otimization ofoverall process

Pressure Drop

Leakages

78%

6%

16% Energy Cost

Maintenance Cost

Investment Cost

Figure 18 : Cost of different types of Energy Conversions

Source: (Saidur, Rahim, & Hasanuzzamana, 2010)

Figure 17: Cost Distribution for Compressed Air Systems


Figure 19: Energy Saving Opportunities for Different Measures



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6.1.3.5 Heating, Ventilation and Air-Conditioning (HVAC)

HVAC requirements for any building can account for upto 35 - 45 % of the total building energy

requirements (Energy Use Data Handbook, 2002). Therefore HVAC is identified to have high

potential in energy reductions.

The main purpose of HVAC systems is to control the indoor temperature, humidity and air

quality and ensure that thermal comfort is reached. The mechanical heating or cooling load in

any building is determined by heat gains (eg: solar heat gains or internal heat gains) and by heat

losses ( eg: transmission heat losses, ventilation heat losses, infiltration heat losses). Reduction

or optimization of heat losses from the building envelope under consideration can considerably

reduce the heating or cooling load requirements.

The first step in increasing the overall HVAC energy efficiency of a site is to make an assessment

of the performance of the existing HVAC systems and to assess if the installed heating system is

operating as per design conditions. The technical module of this internship includes the design

of an assessment tool that measures the heating load within a site and enables to perform a

Space Heating energy audit, followed by preliminary suggestions on actions that can be taken to

minimize losses. Details of the development of this tool can be found in Chapter 8.

6.1.3.6 Transport

Transport refers to any forklifts that are used within the site boundaries. Forklifts are usually

run by gasoline, propane/butane and electricity.


21

7.

7.0 Introduction The objective of this module was to continue implementing and monitoring the outcomes

achieved in phase 1 of the environmental baseline assessment and to execute the site visit

program. This meant performing the assessments using the water, energy and waste tools that

were developed during Phase 1 concluded with the development of the water, electric and

waste assessment The next site that followed in the environmental baseline site visits plan was

the Wroclaw Site. Additionally Charleroi site, Belgium was chosen for monitoring the results

from the assessment during phase 1 and to re-perform the waste management assessment.

7.2 Wroclaw Site Assessment Electric and water consumption assessments were performed at the Wroclaw site in Poland.

Given below are details on the methodology followed and results obtained from the lighting

assessment. Electrical and water assessments were performed in a similar way.

7.2.1 Lighting Assessment The first step to the lighting assessment of the site was to learn how to perform a lighting

energy audit. The site was divided into various zones (process and equipment based) and the

lighting usage was mapped and sized throughout the site along each zone by collecting data on

the rated power of each lighting appliance. Measurements were also made to determine the

quality of light in each zone, as quality of light had an impact on the safety aspects of the site.

Therefore, although it was an environmental assessment, it had a holistic approach. Lighting

quality assessments were made through measurements in available luxes in each zone.

The lighting review document is a visual representation of the lighting system of a site and is

available as ANNEX 8. All raw data collected during the energy audit is mapped against each

zone along with pictures, to get an idea of what the site looks like. The lighting review document

enables easy transfer of the data into the questionnaire assessment tool. The tool then generates

the report, which details the lighting electric consumption of the site. The total consumption is

Figure 20: Lighting Review Document for Wroclaw Site


22

then mapped against the benchmark value and against the best practice value, to show the

potential for improvement. The report then lists out a set of suggested action plan that the site

could adopt to improve its lighting efficiency. Figure 20 shows a screen shot of the lighting

review documents and in Figure 21 the screen shot of the Assessment report.

7.3 Charleroi Site Assessment During the site assessment of Charleroi, Belgium in phase 1, it was observed that the waste

management was a more complex system than it seemed. It was learned that many of the waste

streams had not been identified and monitored. Therefore the second site visit to Charleroi

during this internship was used to re-perform the waste assessment. A waste review

document(shown as ANNEX 9) similar to the one designed for lighting assessment at Wroclaw

site, was formulated. Figure 22 shows a screen shot of the different types of waste bins mapped

against a selected zone.

Figure 21: Lighting Assessment Report

Cardboard/paper

Used Rags/Absorbents

General Waste

Non Ferric

Ferric

Necessary for

Questionnaire

tool

Figure 22: Waste Review Diagram


23

8.

8.0 Background

Space heating energy requirements can account to up to 40% (Energy Use Data Handbook,

2002) of the total energy consumption for industrial manufacturing facilities and therefore

poses a high-energy savings potential. This module was set up in order to develop a tool that

would assess the potential degree of improvement that is possible within a site (that requires

space heating) in relation to the heating demand.

Described below, is the methodology followed and results of the heating assessment tool.

8.1 Methodology

8.1.1 Literature Review A preliminary literature review was performed on heating demand calculations for buildings

and different types of heating systems to achieve an understanding on the elements to be

considered for the development of this module. The theory and concepts reviewed during the

literature study were later used in the documentation of the calculation logic.

8.1.2 Software Evaluation In order to arrive at the best available solution for performing the heating assessment, a

preliminary software evaluation was performed. A list of available software was obtained from

the Buildings Energy Software Tools Directory (Building Energy Tools Directory, 2011). After

analysis of all the available software, three (CASAnova, BuildingSim and TRNSys) were chosen,

that provided the closest match to the requirements of this module. The availability of a free

trial was an important criterion for selection from the directory. The criteria for evaluation

were then chosen (shown in Figure 23) and defined based on the detailed requirements of the

module. A screen shot of the project requirement criteria definitions are shown below in Error!

Reference source not found..

Project Requirement

Criteria Functionality

User Interface

Detailing in Design

Customizability Effort to

Generate Results

Flexibility

Cost

Figure 23: Criteria for evaluation


24

Once the requirements were defined, each of the software was evaluated with the help of a

scoring system, in comparison to Excel (as one of the options). The results of the evaluation

concluded that the tool TRNsys would serve as the best option for a 2nd stage of the assessment,

i.e. a more detailed heating assessment of a site. However for the purpose of performing a

preliminary assessment, that would give a value in the order of magnitude of potential for

improvement, Microsoft Excel was chosen as a suitable option. Shown below in Figure 25 is a

Table of the evaluation performed. The detailed evaluation document can be found as part of

ANNEX 10.

8.1.3 Designing the tool The first part of developing the tool was to clearly define the objectives and to document the

logic to be followed while designing the calculation module. The aim of the tool was to perform

a preliminary assessment that would measure the heat load within the building. This would be

Figure 25: Evaluation of Software

Figure 24: Project Requirement Criteria for Heating Tool


25

done through the calculation of the real indoor temperature and compare this value to the

design conditions. It was important to understand the various scenarios that would result from

the calculation. Table 2 shows the possible scenarios along with the suggested actions that could

be taken in response to the result. With the aim of the tool and required output decided, the

calculation logic to be followed while programing the tool was documented.

8.1.3.1 Aim of the tool – To Assess if comfort temperature has been reached

ASHRAE and ISO 7730 define thermal comfort as “The condition of the mind that expresses

satisfaction with the thermal environment”. The ideal standard for thermal comfort is a

combination of dry bulb temperature, relative humidity (wet bulb temperature) and other

factors. It can be defined by the operative temperature. ASHRAE 55-1992 sets the optimum

operative temperature in winter as 22.7 oC.

The main objective of the heating module is to calculate actual indoor temperature of the

workshop based on the design conditions and to assess if the comfort temperature has been

reached. The indoor temperature is calculated by calculating the actual heat within the

workshop using the installed heating system and the overall heat losses through the walls of the

building. Heat losses are determined by transmission and ventilation losses. Figure 26 shows

the concept followed while designing of the tool.

Table 2: Outcome scenarios of assessment

With this as a basis, all calculations required to determine the indoor temperature were

documented as well and can be found as part of ANNEX 11.

Scenario Ti design vs Ti calculated Conclusion Suggested solution

Scenario 1

Ti calculated > Ti design

example: Ti calculated is 28 C

Heat going inside the place is more than required, thus overheating the place; Employees react by open to allow outside ventilation, thus T measured is inaccurate.

Reduce heating; Improve control options Ti design – defined by comfort zone definition, i.e. 22.7 C Ti calculated – based on the questionnaire, the calculated final temperature after accounting for Q going into the system and Q losses

Scenario 2

Ti calculated = Ti design Heating is appropriate and achieves the comfort zone.

If Q losses are significant, cost of heating is high. If Q losses are reduced, then Ti calculated will be greater than Ti design. Improvements in technology/efficiency; If improved, Ti calculated will most likely be higher than T design.

Scenario 3

Ti calculated < Ti design Installed heating is not enough and comfort temperature cannot be achieved with the current configuration.

Increase heat supply Reduce heat losses by improving insulation Increase heating efficiency (replacing technology for example)


26

8.1.3.2 Documentation of Calculation Logic

Total Heat Losses from a building (H.Havtun, 2011):

Where

is the total heat losses through surface under consideration, Watts

is the transmission heat losses : Heat losses due to transfer of heat

through any surface, Watts

is heat loss due to ventilation or infiltration through open

windows/doors/ cracks/ mechanical ventilation systems, Watts

Heat Transfer through any surface

Where

Figure 26: Visual representation of heat flows through a site


27

U – Coefficient of heat transfer through any surface, W/(m2 K)

A – Area of surface, m2

– Indoor air temperature near surface, oC - Outdoor air temperature or temperature of adjacent unheated space, oC

Heat Transfer through a Wall

Where is Heat transfer coeff. for each component of wall =

For example, consider a wall made partly of brick, partly cement, and consisting of a door and

window

If wall consists of different layers, then U or resistance values should be treated as if in series

U is a measure of how easily the material/surface transfers heat

U=

Where R is a measure of resistance offered by material /surface to

heat transfer, (m2 K)/W

Higher U – Higher Heat losses

R1

R2

T

i

To

R3

R4

R1,R2,R3 & R4 are the resistance values of each

component to heat transfer

R brick

R

cement

R

window

R door

Overall U value =

*

Ti To


28

T

i R3 R2 R1

To

Overall U value =

Example , consider a brick wall that has a layer each of insulation, plaster and render

Note:

If U values not given directly, R value of any material can be calculated by

or

(W/m2 oK) and (W/m oK) are conductivity and conductivity per unit length (respectively)

values of various materials. (Transmittance or U-Value, 2013) (U values, R Values and K Values -

Basic Explanation, 2012)

8.1.4 Proof of Concept

As part of this internship, a site visit was performed, to a Thermal Services site at Charleroi,

Belgium. One of the objectives of the site visit was to collect information needed for the proof of

concept of the tool. During the site visit, detailed information was collected related to the

construction of the site building as well as the installed heating system. A preliminary design of

the tool had been started based on literature review and formulating the logic behind the tool.

This information collected during the visit helped with further developing the design of the tool

as it provided a practical understanding of an existing heating system. The data collected from

the site visit would be used as proof of concept for the tool.

Total Resistance of Wall =

Overall U value =

Figure 27 : Layers of a wall

(Source: retrofit masonry walls: www.greenspec.co.uk)


29

8.2 Results

With the logic documentation as a basis, and the information collected during the site visit to

Charleroi, the questionnaire tool was developed. The tool consisted of three main tabs. The first

was the input tab, which was designed to collect information related to the different

components of the building in order to calculate the theoretical heat losses (Qlosses) owing to the

construction of the site. The development of input tab for installed heating system followed

next. The tab was designed with the intention that multiple types of heating systems would exist

at a particular site (as seen from the site visit to Charleroi site) and would provide information

to calculate the overall installed heating capacity (Qinstalled). Finally, the tool was programmed to

generate the calculated indoor temperature and to obtain a comparison with the design

conditions. The results from this comparison would generate a set of preliminary actions or

measures. A Screenshot of the results of the tool is shown below in Figure 28. (Read from top to

bottom, left to right, the screenshots for Input tab for site construction, Installed heating

capacity, Calculation chart and Results tab). For a detailed view of the heating assessment tool

refer to ANNEX 12.

Figure 28: Results of Heating Tool


30

9.

9.1 My contribution to the project

9.1.1 Improve Module The objective of the improve module was to develop and create guidance or awareness kits for

the three main topics of waste, energy and water management within Thermal Services sites,

that would be usable by people in all levels of the organization. The documents establish the

need to measure and map consumption/generation in order to achieve reductions and provides

with an understanding and clear message to people without a technical background. It

summarizes visually a typical site’s current consumption/generation system and finally

provides with suggestions on the steps that can be taken to achieve reductions, keeping in

consideration the legal aspects of environmental management. My contribution was in

converting complex concepts and ideas to a visual and easily understandable document that

conveyed the various aspects that go into a better environmental management system within

sites.

9.1.2 Sustain Module Through the sustain module, I aided in the execution of the environmental baseline site visit

plan. This involved the site assessment of the next site in the plan for the year 2013: Wroclaw

site at Poland. The assessments involved performing water, waste and energy audits through

the procedure of zoning and measuring, and then converting the raw data into inputs for the

questionnaire tool, which then enabled to generate the report and make preliminary suggestion

to the site.

9.1.3 Develop Module The develop module involved the design and development of a space heating assessment tool

that would enable an assessment on the possible degree of improvement for a site’s heating

system. The module begins with a software evaluation that can later be used to choose

appropriate software for detailed assessment. However for this phase, a tool was developed

using excel, to make a preliminary assessment. The tool was programmed to calculate the

indoor heating load within a site (accurate to the same order of magnitude), and compares it

with design conditions, allowing to understand the necessary actions to be taken. Through the

module, a conclusion can be made on the significance of space heating energy efficiency for

sites. The development of the module enabled me to use the technical knowledge gained

through my masters program and converted that to a real and practical business case that could

be used by the company.

9.2 My Learning Outcomes

9.2.1 Improve Module The creation and development of the guidance documents enabled me to improve the visual

aspects related to communication and let me explore my creative side. It taught me to use the

environmental management knowledge and skills learnt during the ME3 masters program and


31

apply them practically in a multinational organization. It improved my communication skills to

be able to reach out and convey ideas to people of different backgrounds

9.2.2 Sustain Module Through this module, I applied the project management and execution concepts learnt. I learnt

how to perform an energy audit and was trained on the various aspects that go into performing

an environmental baselines assessment. It gave me the opportunity, through the site visits, to

see what a manufacturing workshop looks in reality.

9.2.3 Develop Module The development and design of the heating assessment tool enabled me to use the technical

knowledge gained on energy management systems of buildings. It taught me how to approach

designing and programming of tools that could be usable by the company.

This master thesis project was an exercise that integrated project management, communication

and environmental engineering learned during the ME3 masters program to deliver outcomes

that contributed to the deployment of the environmental baseline project and that helped

improve the resource efficiency of the Alstom Thermal Services business.


32

Bibliography

Manufacturing End-Use Breakdown. (2010, 13 09). Retrieved 2013, from World resources sim

center: http://www.wrsc.org/attach_image/manufacturing-end-use-breakdown

Building Energy Tools Directory. (2011). Retrieved 2013, from US Deopartment of Energy.

Alstom EHS Reporting Manual. (2012).

U values, R Values and K Values - Basic Explanation. (2012). Retrieved 2013, from Holden

Management Services: http://www.holden-management.co.uk/u-values-explained

Transmittance or U-Value. (2013). Retrieved from educate-Sustainability.eu:

https://www.educate-sustainability.eu/kb/content/transmittance-or-u-value

What is Ecodesign. (2013). Retrieved from Ecodesign Infoknoten:

http://www.ecodesign.at/einfuehrung/allgemein/ecodesign/index.en.html

Alstom Acitvity Report 2011/12. (n.d.).

Commission, E. (2008). Waste Framework Directive.

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Izquierdo, L. (2012). Development and Deployment of an Environmental Strategy.

K.Rademaekers, S. M. (2011). Sustainable Industry:Going for Growth and Resource Efficiency.

McDougall, F. (2001). Integrated Solid Waste Management : A Life Cycle Inventory.

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energy savings. Renewable and Sustainable Energy Reviews.

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