APPLIED INDUSTRIAL ENERGY AND ENVIRONMENTAL MANAGEMENT

Z. K. Morvay, D. D. Gvozdenac Part III: FUNDAMENTALS FOR ANALYSIS AND CALCULATION OF ENERGY AND ENVIRONMENTAL PERFORMANCE

Applied Industrial Energy and Environmental Management Zoran K. Morvay and Dusan D. Gvozdenac John Wiley & Sons, Ltd

Toolbox 1 AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE Guidelines on how to evaluate existing energy and environmental management practice in an industry Table of Contents Part A: Energy Management 1. Awareness and Motivation for Energy Performance Improvements Checklist 2. Analysis of Energy Management Practice Questionnaire for Energy Management Audit Checklist for Metering And Control Checklist for Housekeeping Needs for Industrial Plants Questionnaires for Training Needs Assessment Questionnaire for Line Managers Questionnaire for Technical Personnel Questionnaire for Maintenance Staff Training Recommendations Part B: Environmental Management 1. Motivation for Environmental Management 2. Company Commitment 3. Key Environmental Issues Associated with Company Operations 4. Water and Wastewater Management 5. Air Emissions 6. Solid Waste Management 7. Effective Spill Prevention and Response Program 8. Hazardous Materials Management 9. Package 10. Measuring Environmental Performance 11. Environmental Risk Prevention Program

2 2 2 2 2 5 6 7 7 8 10 11 12 12 13 14 15 15 16 17 18 18 18 19

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

Part A: Energy Management 1. Awareness and Motivation for Energy Performance Improvements

Energy management starts with awareness of WHAT is the potential and significance for energy performance improvements, and follows by providing motivation to harvest that potential. 1.1 Checklist AWARENESS examines the WHATS: What is energy? What is the organizations energy policy? What different types of energy are used? What does energy cost? What is the potential for saving energy? What can be saved? MOTIVATION examines the WHYS: Why save energy? Why is it important? Why should I bother when others dont? 2. Analysis of Energy Management Practice

2.1 Questionnaire for Energy Management Audit Name of company Location Official(s) interviewed 1. Is there an energy policy in place? Yes No Who is responsible for energy management? Name: Position in organization: Who does he/she report to: Full time or part time: Qualifications, relevant experience: Number of staff in energy section:

2.

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

3.

How is energy consumption reviewed? From head office or on location Periodically according to a schedule or irregularly According to a plan or irregularly If periodically, when was last review?

4.

5.

How is energy consumption analyzed (check appropriate boxes): by department; by product; by source; by month or number of working days (shifts) per month; by cost; appliance categories (lighting, hot water, space air conditioning, power, refrigeration etc.); functional categories (office, factory, warehouse, transport etc). Does the analysis identify the relationship between consumption of energy and level of activity?

6.

7.

What units of measurement are used? (Convert consumption of different sorts of energy into one unit; also into money.)

8.

What are the metering control arrangements? (how frequently are readings taken; to what extent is there a sub metering; what records are kept, who analyzes the records, to whom are the reports sent?)

9.

Is there an energy consumption forecast? Yes No

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

10. Have performance indicators been set i.e. standard energy consumption for each process or building? Yes No

11. Are performance indicators compared with: previous periods; other locations; other companies; 12. Has the management set targets: for absolute levels of consumption; for levels of consumption based on activity; for levels of idle time; for percentage cuts in consumption?

13. Does management consider information on energy consumption to be an essential part of the management information system? Yes No If not, why not?

14. What steps have been taken by way of promoting the awareness or education of employees, to promote energy management?

15. What steps are being/have been taken in re-cycling energy e.g. sale of byproducts (having intrinsic energy content); reclamation of energy as heat from air, water, hot products, etc; using waste as a fuel?

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

16. To what extent is preventive maintenance in operation?

17. How often are different classes of plant inspected or tested e.g. for corrosion, cracking, fouling, leaks, malfunctioning steam traps, inaccurate or inoperative control devices?

2.2 Checklist for Metering And Control The rule of 2 Ms If we cant Measure, then we cant Manage!! Energy metering is critical to the long-range success of a plant energy management program. 1. What to meter? (a) Primary metering (purchased energy) Electricity Natural gas Steam Fuel oil _____________ (b) Sub-metering (distributed to plants) Electricity All low voltage feeders All individual loads > 50 kW Steam All major plant areas Any load > 1 t/hr Compressed air All major plant areas Any load > 50 kW Refrigeration All major plant areas (buildings) Any load >50 kW

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

2. How are we going to use meters? Accounting; cost distribution Accountability; area responsible (kWh/shift) Troubleshooting; maintenance Optimize performance; improve efficiency (kW/ton) Fuel only cost analysis Project audits Feedback for energy management program 3. How many meters and where? Use utility single-line diagrams Typical industrial facility requires: Electrical 10100 meters Steam 320 meters Compressed air 310 meters Refrigeration 310 meters Meter all critical loads Initially budget 5 % of annual utility cost for meters 4. Which type of meters to buy? An inaccurate meter is worse than no meter at all, but excessive accuracy is neither required, nor economically justified The application determines the type The best meters are electronic, solid state technology: Vortex Insertion turbine Electric meters with demand 5. Use and maintenance of meters Identify a single individual with primary responsibility for coordinating the use and maintenance of metering Assign meters to individuals, plant areas, individual processes, and/or products Provide adequate maintenance support for the energy metering systems Automate, centralize and computerize meter reading at the later stage of the program 2.3 Checklist for Housekeeping Needs for Industrial Plants Fuel, gas, or oil leaks Steam leaks Compressed air leaks Condensate leaks Water leaks Damaged or missing insulation Excessive heating or cooling Leaks of (or excess in) heating, ventilation, and air conditioning system Burners out of adjustment Faulty steam trap operation (each trap is to be tagged with date of inspection)

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

Dirty heating surfaces such as coolers, exchangers, etc. Hot spots on furnaces, indicating deteriorated lining Bad bearings, gear drives pumps, motors, etc. Dirty motors Worn belts Improper viscosity of lubricating oils for large electric drives and hydraulic pumps (proper viscosity minimizes pumps drive slippage) Dirty lamps Excess or accumulated additives in fuel Improper operating pressure and temperature 2.4 Questionnaires for Training Needs Assessment The following Questionnaires may be used in either of three ways listed bellow: (1) by interviewing the superiors of the personnel concerned; (2) by talking directly to the personnel concerned; (3) by observing the current operational practice related to energy efficiency, and then comparing it with best practice. If operational inefficiencies are observed, this is the indication of training needs in a particular area! 2.4.1 Questionnaire for Line Managers Training & Development (T&D) Needs Assessment Name Position Company To what degree is your staff responsible for or competent in (1 5): 1 = LOW degree of responsibility/competence; 5 = HIGH degree of responsibility/competence Section A: The Strategic Category Staff names: A1: Appraising the options for energy management for 1 2 the organization. A2: Identifying and evaluating opportunities to improve 1 2 energy performance. A3: Advising on ways to formulate and implement effective energy performance improvement measures 1 2 throughout the organization. Section B: Performance and Control Staff names: B1: Developing awareness of energy efficiency B2: Advising and supporting individuals and teams with regard to measuring energy performance B3: Reviewing the energy performance of the organization B4: Supporting continuous improvement in the use of energy 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 5 5 5 5 T&D needs T&D needs T&D needs T&D needs

3 3 3

4 4 4

5 5 5

T&D needs T&D needs T&D needs

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

Section C: Financial aspects Staff names: C1: Selecting suppliers for specified supplies on a life cycle cost basis C2: Contracting for supply C3: Recommending, monitoring and controlling the use of resources

1 1 1

2 2 2

3 3 3

4 4 4

5 5 5

T&D needs T&D needs T&D needs

2.4.2 Questionnaire for Technical Personnel To what degree is your staff responsible for or competent in (1 5): 1 = LOW degree of responsibility/competence; 5 = HIGH degree of responsibility/competence Section A: Energy Management Techniques 1. Measurement and metering 1 2 3 4 5 T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s

2. Monitoring and targeting

3. Marketing energy efficiency

4. Motivating people 5. Reporting and informing on energy management results 6. Preparing proposals for energy efficiency projects to the management board 7. Cost evaluation of energy efficient equipment

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

Section B: Best Operational Practices 1. Boilers 1 2 3 4 5 T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s

2.

Steam management

3.

Condensate system

4.

Refrigeration systems

5.

Compressed air systems

6.

Air conditioning

7.

Electric motors

8.

Peak load control

9.

Reactive power compensation

10. Lighting

11. Water system

12. Preventive maintenance system

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

10

Section C: Technologies 1. Variable speed drives 1 2 3 4 5 T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s

2.

Computerized energy management systems

3.

Efficient electric motors

4.

Low temperature waste heat recovery

5.

High temperature waste heat recovery

6.

Combined heat and power generation

7.

Process integration techniques

8.

Advanced control systems

9.

Absorption chillers

10. Optimal insulation thickness

11. Efficient lighting systems

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

11

2.4.3 Questionnaire for Maintenance Staff To what degree is your staff responsible for or competent in (1 5): 1 = LOW degree of responsibility/competence; 5 = HIGH degree of responsibility/competence Section A: Housekeeping 1. Importance of leak prevention and elimination (steam, compressed air, chilled water, water ) Piping, valves and flanges insulation Cleaning of fixtures and luminaries of lighting systems Lubrication 1 2 3 4 5 T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s

2. 3.

4.

5.

Adequate cooling of electric motors

6. 7.

Checking steam traps and maintenance Condensate return and insulation of condensate system

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

12

Section B: Preventive Maintenance Practice 1. Boilers 1 2 3 4 5 T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s T&D need s

2.

Steam distribution

3.

Condensate system

4.

Chillers

5.

Air compressors

6.

Air conditioners

7.

Electric motors for pumps and fans

8.

Peak load control

9.

Reactive power compensation

10. Lighting

11. Water treatment

12. Filters

13. Cooling towers

14. Condensers

15. Evaporators

16. Metering and control

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

13

2.5 Training Recommendations The recommended training topics for three target groups, listed in order of priority : Managers 1. 2. 3. 4. 5. Persons responsible for energy 1. 2. 3. 4. 5. Staff 1. 2. 3. 4. 5. Recommended training provider(s), Comments

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

14

Part B: Environmental Management 1. Motivation for Environmental Management Why is environmental management important to your business?

What are the external and internal pressures for environmentally responsible operation?

What are the ways in which environmental issues are impacting upon your company?

Is the workforce aware of applicable environmental laws and regulations?

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

15

2.

Company Commitment Is there an environmental policy in place?

Does the company possess an environmental mission statement?

Who is responsible for environmental affairs?

Does the company apply the concept of environmental accountability and conduct periodic audits of environmental performance and practices? (If Yes, please describe)

Does it share non-proprietary information about environmental performance with the public? (If Yes, please describe)

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

16

3.

Key Environmental Issues Associated With Company Operations Is there a register of significant environmental impacts? (If Yes, attach a copy)

What are the challenges facing the companys operations in each of the following topics: 3.1 Water and wastewater management

3.2 Solid and hazardous waste management

3.3 Hazardous materials management

3.4 Air quality

3.5 Raw material management

3.6 Packaging

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

17

4.

Water and Wastewater Management Is there a Wastewater Quality Policy?

What are the types and sources of wastewater generated at company plants? Types Sources

Is there a regular control of the quantity and quality of wastewater discharges?

5.

Air Emissions Is there an air emissions quality policy?

What are the types and sources of air emissions? Types Sources

Is there regular control of the quantity and quality of air emissions?

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

18

6.

Solid Waste Management What are the types and sources of solid waste generated at plants? Types Sources

Does the company minimize the discharge of waste materials into the environment and promote the efficient use of raw materials throughout processes? (If Yes, please describe)

Does the company understand and address the problems of solid waste generated in its own facilities and help local communities by implementing recycling and solid waste management systems? (If Yes, please describe)

Are disposal costs reduced through increasing the density of disposed material?

Are there specific handling/storage/disposal instructions and procedures for some special wastes (i.e. oils, solvents, cleaners, batteries, chemicals): Segregation from general trash Special storage areas Use of only authorized disposal facilities Record keeping Training Spill and emergency response procedures

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

19

7.

Effective Spill Prevention and Response Program Does the company evaluate the potential for spill at its facilities? (If Yes, please describe)

Does the company implement procedures aimed at reducing the potential for spill? (if Yes, please describe)

Does the company develop spill response and reporting plans? (if Yes, please describe)

Does the company conduct spill response training? (if Yes, please describe)

Is there a tank management procedure that assures: Developing and maintaining accurate tank information Conducting frequent inventories of tank contents and reconciling with dispensing records Periodic testing of tank integrity Establishing effective material transfer practices

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

20

8.

Hazardous Materials Management What hazardous materials are used in the company's operations?

Are there appropriate handling procedures in place for hazardous materials?

9.

Package What steps has the company taken to minimize the environmental impacts of packaging?

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

21

10. Measuring Environmental Performance Does anybody identify regularly the opportunities for reducing waste, minimizing water use and wastewater generation and reusing or even eliminating waste of raw materials?

Given the key environmental issues for company operations, what measurements are taken to track and to determine environmental performance? a. Water

b. Wastewater

c. Solid waste

d. Hazardous materials

e. Air quality

f. Raw materials

g. Packaging

Part III Toolbox 1: AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE

22

11. Environmental Risk Prevention Program Describe the environmental risk prevention program that has been developed and implemented?