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

Identify the sector that best represents your organization.

A. Commercial

B. Large Industrial

C. Small/Medium Industrial

D. Public

E. Other

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

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 Up Assessment Visit

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%

Has your organization established required payback periods for energy projects?

A. Yes

B. No

C. Don’t Know

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

Has your organization established energy-per-unit metrics?

(Ex: energy cost per pound of product)

A. Yes

B. No

C. Don’t Know

• 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

Does your organization have a formal written energy management plan or

energy policy?

A. Yes

B. No

C. Don’t know

• 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.

Has your organization had energy assessments done at its facilities

in the past?

A. Yes

B. No

C. Don’t know

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.

Do you use occupancy sensors? (warehouses, manufacturing areas, conference

rooms, copy rooms, etc.)

A. Yes

B. No

C. Don’t know

• 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.

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. Don’t know

• 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

Does your organization have a procedure for employees to suggest energy savings

opportunities?

A. Yes

B. No

C. Don’t know

Habit #6: Production Needs vs. Energy Reduction – Can’t 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.

Does your organization have an energy management team?

A. Yes

B. No

C. Don’t know

Habit #7: You Can’t Reduce What You Don’t Measure, and You Can’t Measure

What You Don’t 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

Are departments in your organization required to track energy usage?

A. Yes

B. No

C. Some, but not all

D. Don’t know

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.