EMS Implementation training

Energy Management System (EnMS) Implementation Training UNIDO International Energy Efficiency and EnMS Expert Day 1 Based on the contents of the UNIDO Practical Guide for Implementing and Energy management System 1

Housekeeping Emergency Exits Toilets Mobile Phones Breaks Lunch Please restrict email to break times 2

Today Topic Duration Exercise, Break Start End Time (mins) Interaction duration TimeDAY 1Registration 15 08:45 09:00 10 20Welcome and introductions 09:00 09:30 15Why are we here? 15 09:30 09:45Overview of EnMS 30 09:45 10:00Build management committment 10:00 10:30Break 15 10:30 10:45Develop energy information and plans 45 45 10:45 12:15How to create an energy efficient culture 30 12:15 12:45Lunch 12:45 13:45Interactive session - planning 60 13:45 14:45Break 60 14:45 15:00Energy Metrics and EnPIs 15:00 16:00Implementation and Operation 15 16:00 16:30Checking 30 30 30 16:30 17:00 30 3

Topic Today – Day 2 Start End Time Time Duration Exercise, Break (min) Interaction durationDAY 2Management Review 20 09:00 09:20Project Plan 10 10 09:20 09:40Financial Analysis 30 10 09:40 10:20 10:20 10:35Break 15 10:35 12:00Workshop on Implementation Plan 25 12:00 13:00Assignment presentation 60 13:00 13:25Small group discussion 13:25 13:35Group discussion/Feedback 25Next steps and closure 10 4

Welcome and introductions • Name • Company • Energy Management Experience • What do you expect to learn over these two days? 5

TodayTopic Duration Exercise, Break Start End Time (mins) Interaction duration TimeDAY 1 10 15 08:45 09:00Registration 15 20 15 09:00 09:30Welcome and introductions 30 15 45 09:30 09:45Why are we here? 45 09:45 10:00Overview of EnMS 30 60 10:00 10:30Build management committment 60 10:30 10:45Break 30 10:45 12:15Develop energy information and plans 60 15 12:15 12:45USAID Financing 30 12:45 13:45Lunch 13:45 14:45Interactive session - planning 14:45 15:00Break 15:00 16:00Energy Metrics and EnPIs 16:00 17:00Hardware and software (USAID) – part 1 6

Climate Change Policy Scenarios Source: IEA/ UNIDO 2010 Most emissions reductions possible through deploy- ment of existing best available EE practices and technologies 7

How to prioritize opportunities 8

Would you allow this man to make a $500 purchase on behalf of your company? What about $10,000? 9

What is being proposed?  Reduced operating costs  Reduced exposure to rising energy costs  Improved reliability and productivity  Reduced environmental impact  Improved corporate image  Alignment with ISO 50001 Initially based on low cost improvements 10

kWh/week What can be achieved? 1,600 1,400 Represent consumption VS significant 1,200 variables 1,000  See the trend 800  Set a target for next year 600 400  Check that the future consumption is below the target 200 y = 18.572x + 167.84 R² = 0.8926 0 0 10 20 30 40 50 60 CDD 9 11

What is energy management?It is how we propose to manage our use of energy!We want to be more systematicWe will combine the following: • Behaviour change among all employees • Behaviour change among management • Objective use of data to show performance • Technical improvement • Low cost operation and maintenance of existing equipment 12

What is an EnMS? Commit to changeCheck the results kWh Plan the changes (€ + CO2) 13 Make the changes

What can be achieved? 14

What sort of actions will we take?Operation and maintenance initially • Fix leaks • Fix insulation • Switch off • Run optimum equipment • Optimum settings • Check controls • Training • Maintain improvements 15

What do we do next?Make a decision to go aheadWe do not need financial investment until AFTER we start to show savingsViable investment projects may follow laterWe do need management commitment to improve • Some staff need to help • Some staff need to change behaviour • Some staff need training 16

Management Role – Commitment (Key Concept #1)Management Give commitmentparticipation Sign policy Allocate resources Management Yes Assign responsibility Responsibility Top management representativeManagement Policy Give support Review Make decisions Planning 17 Checking Implementation & OperationDay to dayoperations

Important Roles We want someone at the top level of the organisation to lead the energy management activities • Direct the activities • Represent energy management at senior level • Gain support for energy management • This is the management representative We want someone to run the EnMS on a daily basis • Know it in detail • Coordinate its development • Represent it at external audits • This is the energy manager In some cases both of these roles will be the same person, in others the duties may be split 18

Management representative responsibilities Implementing of the energy management system; Reporting to top management on the performance of the energy management system; Reporting to top management on the energy performance of the organisation; Formation of an energy management team; Plan and direct energy management activities; In a larger organisation, most of the day to day energy work may be completed by others, e.g. energy manager. 19

Energy ManagerIn some organisations, this may be the same person as the management representativeOften not a full time job; • For example, maintenance or engineering manager or engineer • Probably a technical person with energy engineering knowledgeRole • Implement the EnMS • Owns the EnMS • Manages energy use • Acts as auditee for the EnMSResponsibility • Varies with organisation • Implementation • Energy budget • Reporting 20

Energy management team Decide structure and membership based on size and complexity of your organisation Representatives from relevant departments • Production, finance, engineering, operations, senior management representative, energy manager or engineer, etc. Cross functional cooperation Common and shared goal 21

Sample energy management team (committee) Management Representative Chairperson Energy Manager Coordinator Company Production Environmental Production FacilitiesAccountant supervisor officer engineer engineer Financial perspective Production driver Env perspective Technical support Technical support Composition will vary with organisation and culture Size will vary The energy manager may deputise for the mgmt rep Teamwork 22

Roles, responsibility & authority (key concept #1)The above are required for each individual involved in the EnMS.Each person needs to understand their own role and responsibilitiesEvery needs to know each others authority levelsThis may seem like common sense but is often a source of ineffectiveness2 or 3 core people plus others to supportMUST be completed, accepted and communicated in advance of next steps 23

Roles and Responsibility (key concept #1) 24

PolicyManagement Management commitmentparticipation Not just a signature! Define scope of EnMS Management Yes Appropriate to scale Responsibility Commitment to continualManagement Policy improvement Review Make resources available Framework for target setting and Planning review organizations Checking Implementation & OperationDay to dayoperations 25

Energy Policy documentIt is an official document that demonstrates support and commitment to improving energy performanceDoesn’t need to go into detailScope and boundaries of the system • Which plant, buildings, energy sources (water?) are includedThe policy (and EnMS) should be appropriate to the nature and scale of the operations • Small organisation -> simple EnMS • Large organisation -> simple EnMS!Review and update regularly • Changes are usually minimalPrepare at an early stage • Possibly update after planning if required 26

Policy should includeCommitment to continual improvement of energy performance through the development and achievement of relevant objectives and targets.Commitment to provide the necessary information and resources to achieve its energy objectives and targetsCommitment to comply with all legal and other requirements that apply to its energy using activitiesSupport for the purchase of energy efficient products and services where economically feasible.Support the use of energy efficient design practices in new projectsThe policy should be communicated to all levels of the organisation. 27

ExampleAs an energy intense manufacturer of specialty glass, XYZ Company strives toreduce its energy consumption and costs and promote the long-termenvironmental and economic sustainability of its operations. We arecommitted to:Reduce energy intensity by 25% in 10 years in our manufacturing and distribution operationsEnsure continual improvement in our energy performanceDeploy information and resources to achieve our objectives and targetsUphold legal and other requirements regarding energyConsider energy performance improvements in design and modification of our facilities, equipment, systems and processesEffectively procure and utilize energy-efficient products and services 28

Scope Excluded Rationale for excluding any sourceIncluded LPG in the kitchen transport until next yearElectricityFuel OilWaterNatural Gas 29

BoundariesIncluded Excluded Rationale for excluding any areaProductionsystems remote warehouse facilityAll buildingsAll utilities 30

See you in 15 minutes! 31

Planning What are you going to do? Translating the commitment and energy policy into objectives, targets and action plans 32

Develop plans ER1. Energy bill and ER6. Review operational sub-meter data control for all SEUs ER4. Identify drivers, get data and analyze SEUs ER2. Analyze past, 33 ER5. Develop baselines present and future and performance energy use indicators for each SEUs ER3. Identify & quantify Significant Energy Users (SEUs) ER7. Technical energy audits ER8. Identify opportunities for improved performance, review and decide on action plans

How much energy am I using?How many people here know how much energy their organisation used in the 12 months ending last month?How much did it cost?How much did you use last year?How much are you going to use next year?How are you performing against your budget? • Why are there deviations?Are you using too much energy? • If so, how much should you be using? 34

ER2 – analyse trends ER1. Energy bill and ER6. Review operational sub-meter data control for all SEUs ER4. Identify drivers, get data and analyze SEUs ER2. Analyze past, 35 ER5. Develop baselines present and future and performance energy use indicators for each SEUs ER3. Identify & quantify Significant Energy Users (SEUs) ER7. Technical energy audits ER8. Identify opportunities for improved performance, review and decide on action plans

Quantify SEUs ER1. Energy bill and ER6. Review operational sub-meter data control for all SEUs ER4. Identify drivers, get data and analyze SEUs ER2. Analyze past, 36 ER5. Develop baselines present and future and performance energy use indicators for each SEUs ER3. Identify & quantify Significant Energy Users (SEUs) ER7. Technical energy audits ER8. Identify opportunities for improved performance, review and decide on action plans

Which systems? What is the single largest energy user in your organisation? How much energy does it use? What drives that use? • What causes it to increase or decrease? Which people affect the energy use of that item/system? 37

What is the second largest user? • We need to know the answers to the previous questions for all significant users (SEUs) • Ideally we keep working on the list until we know where at least 80% of our energy is going • This list of SEUs will be the basis of most of the rest of our system • Remember that a SEU can be either a large user or one with good performance improvement potential. 38

SEUs Estimated Equipment Contribution to Annual Energy Cost 0% 10% 20% 30% 40% 50% 39 Air Compressors - 75 kW Water Chillers - 17.5 kW Cooling Towers - 30 kW Refrigeration - 963 kW 2 x Dough Blender - 45 kW12 x Dough Sheeter - 1.5 kW Cheese Blender - 22 kW Extructor - 15 kW Grinder - 75 kW Vemag - 22 kW 2 x Oven Circ. Fan - 22 kW 2 x Oven Exh. Fan - 4 kW Lighting - 25 kW Other Equipment - 18 kW Baking Oven - 586 kW Baking Oven - 146 kW Electric Equipment Natural Gas Equipment

Quantify drivers ER1. Energy bill and ER6. Review operational sub-meter data control for all SEUs ER4. Identify drivers, get data and analyze SEUs ER2. Analyze past, 40 ER5. Develop baselines present and future and performance energy use indicators for each SEUs ER3. Identify & quantify Significant Energy Users (SEUs) ER7. Technical energy audits ER8. Identify opportunities for improved performance, review and decide on action plans

Establish energy variables Terminology: drivers, driving factors, variables, energy factors, etc. Can anyone give an example of energy use that does not vary and is not influenced by a variable? Each energy use should vary based on some factor(s) • What is it? • How do they interact 41

What is driving this use? Top level electricity and fuel Each SEU driver If you can’t quantify a variable is there a real reason • There rarely is a legitimate reason • Maybe you are simply out of control There are often indicators of significant savings from this step • Anomalies • Demonstrate with examples See tool Drivers 42

Significant energy users (Key concept #2)Which systems? Which people? Drivers? • Sub meters • Who • What is • Motor list influences driving use? • Estimation SEUs? • Calculation • Variables • Pie Charts • Training • Activity • Sankey needs • Weather • Regression Diagrams • Organisation charts analysis 43

Baselines and EnPIs ER1. Energy bill and ER6. Review operational sub-meter data control for all SEUs ER4. Identify drivers, get data and analyze SEUs ER2. Analyze past, 44 ER5. Develop baselines present and future and performance energy use indicators for each SEUs ER3. Identify & quantify Significant Energy Users (SEUs) ER7. Technical energy audits ER8. Identify opportunities for improved performance, review and decide on action plans

Establish energy performance indicators (EnPIs) (keyconcept #3)Varying levels of complexityAbsolute energy consumption • Simple but ignores activity levelsSimple Ratios • Easy to use but can be misleading • Take account of activity levels • Can only deal with single variablesRegression analysis • More complex • Quantifies driver effects • Allows comparison of actual against expected useTry to have an EnPI for each SEUTool EnPIs 45

Measurement PlanOnce SEUs are known • Including variables  Reporting requirements can be specified  What meters and measurements are required to deliver these reports?  How much can be achieved with existing instruments?  Manual vs. automated  List what new instruments are required • Each new instrument should be able to justify its cost • Don’t forget installation cost • Electricity and liquid flow meters can be good value • Gas flow meters tend to be expensive (steam, compressed air, etc) 46

Review operational control ER1. Energy bill and sub-meter dataER4. Identify drivers, get ER2. Analyze past, ER6. Review operationaldata and analyze SEUs present and future control for all SEUs energy useER5. Develop baselines 47and performance ER3. Identify & quantifyindicators for each SEUs Significant Energy Users (SEUs) ER7. Technical energy audits ER8. Identify opportunities for improved performance, review and decide on action plans

Review Operation control This is aligned with the review of training needs • It additionally checks operating and maintenance procedures Check operating procedures Are operators familiar with the energy impact of operations? Check maintenance procedures Check maintenance frequencies Are maintenance staff familiar with the energy impact of their work? This review will help to assess training needs 48

Types of people who impact energy consImmediate and direct impact • SEU Operators • Maintenance and external service personnelInfluencers • Managers, supervisors, leadersProduction peoplePeople who see things differently • Cleaners • Security • Safety Officers 49

Training Matrix Make a list of all people who need to be trained Make a list of potential training materials/courses Develop a training matrix • Who does what and when • Use it also to record completion of each course • If your organisation already has a training tracking system, use it. Develop training materials If external help is required identify potential training service providers 50