Energy Management. LIEN Workshop - Energy Savings in the work and drink sector. Thursday April 6th 2006 Ramada Hotel Alan Ryan Project Manager

Transcription

1 Energy Management LIEN Workshop - Energy Savings in the work and drink sector Thursday April 6th 2006 Ramada Hotel Alan Ryan Project Manager

2 Contents Policy and other drivers Solutions Energy Management Practical Tips SEI Assistance

3 Why are we here? Regulations IPPC EU ETS Financial Electricity + 50% in last 5 years Fuels?% + Environmental Suppliers Corporate Cost of Carbon And on, and on

4 Whats the main objective? AIM To achieve business objectives at minimum energy cost Energy Supply Energy Usage Pay less per unit of energy Reduce energy consumed

5 Solutions Available Energy Supply EEI / EPI s Tender Supplies CHP Housekeeping Green Electricity Biofuels Energy Usage Energy Teams Training IS393 Energy Management M & T Planning Benchmarking Audits Checklists EnergyMAP Copyright SEI 2005

6 Ad hoc approach 0 Costs +5% Costs high = Audit Waste cutting, some investment Costs high again: Where s that last audit? Here we go again! -5% -10% Under control. -15% -20% -25% 0 Years 5

7 Energy Management Approach Senior management commit to programme Costs +5% Initial savings sustained 0-5% -10% -15% -20% -25% Investment Housekeeping first then investment Becomes company culture 0 Years 3

8 3 key elements of successful energy management? Organizational Management Commitment Balance all 3 for a successful programme Technical Understanding your energy usage and how to control it People Developing an energy efficient culture

9 5 Step Approach Implement Monitor & Review Plan Identify Commit

10 5 step strategy Energy Policy properly communicated Appoint Senior manager sponsor Appoint energy coordinator Commit

11 Making the Business Case Financial Indicators Previous Year Current Year % change Annual Op. Costs (AOC) 3,150,000 4,005, % Total Energy Cost 105, , % Energy as % of AOC 3.36% 3.85% +12.8% Annual Profits 289, , % Energy as % of Profits 36.61% 51.07% +28.3% % increase in Profits by a 10% decrease in energy costs 3.66% 5.11% +28.3%

12 5 step strategy Detail and trend past & present energy consumption Identify the main energy users Identify the main influences on energy consumption Identify saving opportunities Identify Energy Review

13 Energy Review - Energy and emissions mapping Steam CIP 10% 21% HVAC 8% Electricity Bills Production Equipment 22% Line A 7% Line B 3% Compressed Air Line A 5% 22% AHU s 8% Fuel Bills Factory X HVAC AHU s 9% 35% Chill B 20%

14 Energy Review - Step into the process - Do we need to use energy? - Can we use a cheaper form? - What are its minimum operating conditions? - Are we operating it to this operating conditions? - Then and only then - Are we distributing it efficiently? - Are we generating it efficiently? Process Steam Electricity Chilling Other

15 Identifying opportunities Audits IPPC Audit Guidelines Good Practise Guide 316 Undertaking an energy audit You know best! Energy Team Energy Wardens SEI best practice website (EnergyMAP May 06) (GPG316)

16 Pay less per Unit of Energy Negotiate Lowest Price Cost Avoidance Measures Generate Own Power Select Best Tariff Change of Fuel SEI Biofuels Programme

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18 Renewable Energy - Indicative Funding Levels Demonstration projects: up to 25% Shared cost R&D projects: up to 45% Public good R&D projects: up to 100% Indicative Upper Level of Funding is 1mEuro of Eligible Costs

19 Relevant areas of support available from RE RDD Prog Biomass boilers - 25% of installed cost Liquid biofuels projects (transport or heat) Anaerobic Digesters small to medium scale biogas plants Large scale >10MW wood biomass CHP plant Wind or Hydro auto production example

20 Register of Opportunites Sample Energy Opportunities Register for XXXXXX Ltd Last Updated xx/xx/xxxx Assumptions Average Elec Day Unit Price /kwh CO2 per kwh elec x gco2/kwh Average Elec Night Unit Price /Kwh CO2 per kwh gas x gco2/kwh Average Gas Cost /kwh Feasibility Analysis Energy Opportunity PersonEst YearlyEstimatedEst. Yearly Simple Comment ResponWh savingc02 saving savings Payback Housekeeping Housekeeping Actions Thermal Turn off boiler 1 at weekends Tech 1 Ongoing turn off boiler 2 at weekends Tech 2 Electrical Air Handling Turn off AHU 1 at weekends Tech 1 Procedures & methods Turn off AHU 2 3rd Saturday off the mtech 2 Bills management Tender gas and electricity supply Completed Enter the WPDRS Technology & investment Totals Capital Actions Install Economiser Eng 1 1-Jun Replace bucket trap on machine 7 Replace process 1 with process 2 Eng 2 1-Oct Items worth investigating Replace bucket traps with thermody Eng 1 1-Jun Replacing machine No.7 Prod Eng CHP plant Eng 2 1-Oct Totals Copyright SEI 2005

21 5 step strategy Establish a programme plan Plan Set objectives and targets Identify & allocate resources

22 Energy Plan XXXX Ltd Programme Plan 2005 No Objective and target Saving CO2 SavingBudget Manager Responsible General 1 To train 40 key people in basic energy awareness Training MGr 2 To continuously identify wastage and turn off Production and facilities manager 3 To invest 100,00 euro on energy and Facilities manager complete at least 20 energy saving projects 4 To identify opportunities for saving every 6 months Facilities manager instead of every year Significant users 1 To reduce compressed air consumption by 5% by Facilities supervisor a. installing a sequence controller b. installing heat recovery on compressor 1 c. agressively tackling leaks on machines 2 To reduce air handling units consumption by 5% by HVAC supervisor a. reviewing production monthly and turn off if NIU b. installing energy efficient motors on 5 AHU's 3 To reduce production consumption by 2% by Production manager a. replacing machine 7 with new process 4 To reduce gas consumption by 7% by HVAC supervisor a. turning off AHU's (see 2a) b. installing air fuel ratio controller Totals Signed Managing Director Signed EMAP Senior Manager Copyright SEI 2005

23 5 step strategy Implement Promote energy-efficient practices and awareness amongst employees Train key personnel in energy efficient practices Establish an energy savings register Ensure the efficient operation and maintenance, design and purchase of significant energy users

24 The bane of energy managers!

25 Operation and maintenance, design and purchasing Operate what you have correctly Learn from mistakes design and purchase correctly Proj. Project Description Estimated Est Yearly Est. Yearly Act Yearly No. Cost kwh savings savings Savings Jan Feb Mar A Utility Bills - Joe, Utilities Engineer Zero Cost Savings 2 Savings over PES tariff with supplier B 0 - Housekeeping #REF! 133,620 16,834 3 ESB MD Incentive scheme 0? 8,000 15,318 16,519 1 Winter rebate - items off 5pm-7pm N/A B. Air Handling/Motive power - John, A/C Tech No cost 1 Turn off AHU 11 ev/we 0 60,000 Procedures 3,600 2,400& methods Low/Medium cost 1 Replace AHU 12 motors with Class , An energy efficient purchasing policy TBC C. Compressed Air - Bill, Tech Technology & investment Zero Cost 1 Reduce generation pressure from 7.5 to 7 b 0 230,000 13,800 3,450 1,150 1,150 1,150 Low/Med costs 2 Shutoff production line 1 CDA auto ,000 1, Sequence and control compressors ,000 6,900 D. General Services (Lights, PC's, office equipment) - Adam, Security Supervisor Zero Cost 1 Turn off lights from 7pm to 8am - B ,632 6,353 1, Turn off PC's from7pm to8am- B

26 5 step strategy Monitor & Review Develop and monitor Energy Performance Indicators (EPI) Establish a measuring and monitoring system Report performance with management regularly Management Review annually

27 Practical Energy Management Reality suggests: Management commitment is not a given Staff time is in short supply Staff is technically, not management-oriented Limited energy management infrastructure How to manage energy, with no time, no resources and no management support!

28 SEI Supports LIEN Training programmes Technology Promotion RD&D support Energy Awards

29 SEI Energy Management Supports Energy Agrements IS393 Energy Management System Energy Bill > 2m In development EnergyMAP (Energy Management Action Programme)

30 In conclusion Ad hoc approach not sustainable Structured approach key to maintaining savings Senior management commitment pre requisite What are my next steps? Energy review Ongoing energy management programme Formal energy management system An appropriate level for every company The business case for action is clear

31 Alan Ryansei.i

32 Kyot o Target f or Ireland Waste Agriculture Mt CO Solvent and Other Product Use Industrial Processes Energy 10 0 Land Use Change & Forestry p