Industrial Standards Framework and Energy Management

Aimee McKane,

Lawrence Berkeley National Laboratory

Industrial Systems

?

• Steam and motor-driven systems account for approximately for more than 50% of final manufacturing energy use worldwide

• Energy savings potential from cost-effective optimization of these systems for energy efficiency is estimated at 10-12 EJ of primary energy1

• A global effort to cost-optimize industrial systems for energy efficiency could achieve these energy savings through

• the application of commercially available technologies

• in existing and new industrial facilities

1 2007 IEA Statistics

Elements of System Optimization

• Evaluating work requirements

• Matching system supply to these requirements

• Eliminating or reconfiguring inefficient uses and practices (throttling, open blowing, etc)

• Changing out or supplementing existing equipment (motors, fans, pumps, compressors) to better match work requirements and increase operating efficiency

Elements of System Optimization

• Applying sophisticated control strategies and variable speed drives that allow greater flexibility to match supply with demand

• Identifying and correcting maintenance problems

• Upgrading ongoing maintenance practices

Why aren’t industrial systems more energy efficient?

• Most managers are unaware that these systems are inefficient

• System performance is not measured

• No data = no way to assess performance or performance improvement

Why aren’t industrial systems more energy efficient?• Technical skill is required to

optimize motor-driven systems- a one-size-fits-all approach misses most of the savings

• Although training and educational programs in the U.S., U.K., China and elsewhere have proven effective in teaching these skills

• these efforts are resource-intensive

• only reach a small portion of the market

Additional barriers to efficiency

• System optimization knowledge resides with the individual who has been trained- it is not institutionalized

• Trained individuals leave or transfer and take this knowledge with them

• Processes change over time and inefficiencies can re-occur

How can system energy-efficiency be maintained in this complex, changing environment?

Learning from Process Management Successful industrial processes are

also complex and changing, but they are:

• Consistent• Adaptable• Resource efficient• Continually improving

These goals are often achieved through widespread adoption of a management system to maintain and improve quality, such as:• International Organization for Standardization (ISO)• Six Sigma• Total Quality Management

What if system energy efficiency were fully

integrated into these management systems?

Learning from Process Management

Why ISO?Why select ISO as the management system of choice?

• Widely adopted in many countries

• Serves as an international trade facilitation mechanism

• Accepted as a principal source of standards for energy-consuming industrial equipment

• Well-established system of independent auditors to assure compliance and maintain certification

• By the end of 2004, more than 670,000 certified facilities in 154 countries participating in ISO 9001:2000 and 90,500 certified facilities participating in ISO 14001 *

* From The 2004 ISO Survey

Linking ISO and Energy Efficiency

Use a top-down, bottom-up approach to industrial motor system efficiency through implementation of an Industrial Standards Framework, which includes:

• Energy-efficiency standards (energy management, industrial systems)

• Energy efficiency policies (targeted agreements, incentives, recognition)

• Training (both awareness and expert level)

• Tools (system optimization library)

Why is a Standards Framework Needed?

A standards framework would:

• Provide achievable energy efficiency targets

• Be complementary to systems optimization training

• Offer technical guidance to factory personnel

• Require written procedures and documentation to ensure that energy savings will be sustained

Industrial Standards Framework

Goal:

integrate energy efficiency projects into

existing ISO management structures

for continuous improvement

Hire Experts to Conduct Initial Training Develop Supportive Policy Package Energy Management Standards, Voluntary Agreements, Recognition & Tax

incentives, Trading of Energy Efficiency Credits

Industrial Plant Engineers

Governments

Consultants/Suppliers/ESCOs

Certifying Organizations

(ISO, DNV, others)

Technical Educational Institutions

Develop standardized optimization

methodologiesIPMVP & ISO compatible

Provide System Optimization Training

Develop Highly Skilled Core of Practitioners

Capacity-Building Phase

(Outputs)

Develop and test tools to support sustainability System

Optimization LibraryDocumentation

Implementation Phase

(Outcomes)

Integration Phase

(Objectives)

Train future generations

of skilled practitioners

Team of International System Optimization

Experts

Recognize methodologies/

documentation & integrate into

certification process

Conduct plant assessments, train factory personnel, develop

& document projects

Promote standards, trading of EE Credits & other policies for system optimization

projects

Sell system optimization services

develop & document projects

Industrial System Energy Efficiency becomes “Business as Usual”

Industrial Plant

Managers

Use trained system optimization experts to

develop & document system projects as part of

certified continuous improvement process

Industrial Standards Framework

GovernmentsTrained System

Optimization Experts

Use training, library, & methodologies to develop projects

Hire Experts to Conduct Initial Training Develop Supportive Policy Package Energy Management Standards, Voluntary Agreements, Recognition & Tax incentives,

Trading of Energy Efficiency Credits

Industrial Plant Engineers

Governments

Consultants/Suppliers/ESCOs

Certifying Organizations

(ISO, DNV, others)

Technical Educational Institutions

Develop standardized optimization

methodologiesIPMVP & ISO compatible

Provide System Optimization Training

Develop Highly Skilled Core of Practitioners

Capacity-Building Phase

(Outputs)

Develop and test tools to support sustainability

System Optimization LibraryDocumentation

Implementation Phase

(Outcomes)

Integration Phase

(Objectives)

Train future generations

of skilled practitioners

Team of International System Optimization

Experts

Recognize methodologies/

documentation & integrate into

certification process

Conduct plant assessments, train factory personnel, develop

& document projects

Promote standards, trading of EE Credits & other policies for system optimization

projects

Sell system optimization services

develop & document projects

Industrial System Energy Efficiency becomes “Business as Usual”

Industrial Plant

Managers

Use trained system optimization experts to

develop & document system projects as part of

certified continuous improvement process

Industrial Standards Framework

GovernmentsTrained System

Optimization Experts

Use training, library, & methodologies to develop projects

Hire Experts to Conduct Initial Training Develop Supportive Policy Package Energy Management Standards, Voluntary Agreements, Recognition & Tax incentives,

Trading of Energy Efficiency Credits

Industrial Plant Engineers

Governments

Consultants/Suppliers/ESCOs

Certifying Organizations

(ISO, DNV, others)

Technical Educational Institutions

Develop standardized optimization

methodologiesIPMVP & ISO compatible

Provide System Optimization Training

Develop Highly Skilled Core of Practitioners

Capacity-Building Phase

(Outputs)

Develop and test tools to support sustainability

System Optimization LibraryDocumentation

Implementation Phase

(Outcomes)

Integration Phase

(Objectives)

Train future generations

of skilled practitioners

Team of International System Optimization

Experts

Recognize methodologies/

documentation & integrate into

certification process

Conduct plant assessments, train factory personnel, develop

& document projects

Promote standards, trading of EE Credits & other policies for system optimization

projects

Sell system optimization services

develop & document projects

Industrial System Energy Efficiency becomes “Business as Usual”

Industrial Plant

Managers

Use trained system optimization experts to

develop & document system projects as part of

certified continuous improvement process

Industrial Standards Framework

GovernmentsTrained System

Optimization Experts

Use training, library, & methodologies to develop projects

Industrial Standards FrameworkTop Down- Market Pull

National governments: • Issue energy management standard

• Provide access to training on how to comply with standard

• Provide access to tools (Industrial Systems Optimization Library) to document compliance

• Recognize companies that make outstanding efforts to improve the operation of their motor systems

• Develop agreements with industrial sectors that establish plant-specific energy efficiency targets

Industrial Standards FrameworkBottom Up- Market Push

• Build on existing industrial plant commitments to ISO certification

• Create an Industrial Systems Optimization Library with documentation that companies can easily incorporate into their QEM Manual

• Provide training to plant personnel and energy efficiency organizations- how to identify system improvement opportunities and use the library

• Engage existing supplier/customer relationships to promote greater energy efficiency

Industrial Standards Framework• Train consultants and suppliers to

support a system-based approach• Check results- regular audits by ISO

ensure that companies comply with their plans

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Time of Day on Wednesday 06/09/2004

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Air Receiver (6 bar) Air Receiver (8 bar) Air Receiver (10 bar) 3C2-11 (6 bar) Workshop 8 bar

Workshop 8 Bar 3C-06 (10 Bar) 3C-03 (8 Bar) Plant Header 10 bar

Phase 2 - Compressed Air System Pressure Profile - Test 3

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10 second Data Interval

• ISO 9000/14000 programs aimed at consistent operating culture and continuous improvement

• Audit requirements verify compliance to written procedures and policies

• Efficient operation becomes factory culture

Independent Verification of Compliance

Results

• More completed energy efficiency projects• Project results are periodically checked by

independent auditors• Improved energy efficient industrial systems• Sustainability

For more information

Aimee T. McKaneLawrence Berkeley National LaboratoryP.O. Box 790Latham, NY 12110USA518 782 7002atmckane@lbl.gov