A2A User Guideline - IfA V1

8/20/2019 A2A User Guideline - IfA V1

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Assessments to Action (A2A)

Toolkit for the IFA:Guidelines for Users


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Guidelines for Users


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Contents

1 Purpose of Guideline ............................................................................................. 1

2

Introduction ............................................................................................................ 2

2.1

Context and Scope of IIP A2A Toolkit ............................................................ 2

2.2

Assessment Methodology .............................................................................. 4

2.3 Description of Toolkit Modules ....................................................................... 4

2.3.1 Energy Use and Technical Best Practice Assessment (Excel File: A2ATA) 4

2.3.2

Generic Measure Library (Excel File: A2A Generic) and AmmoniaMeasure Library (Excel File: A2A Ammonia) ......................................................... 5

2.3.3 Energy Management System Assessment (Excel File: A2A MA) ............. 5

2.3.4 Productivity Improvement Assessment (Excel File: A2A PIA) ................... 5

2.3.5 Report Card and Opportunity Identification (Excel File: A2A RCOI) ......... 5

2.3.6

EE&M Plan Checklist (Excel File: A2A Checklist and Action Plan) ........... 6

2.3.7

EE&M Action Plan Template (Excel File: A2A Checklist and Action Plan) 6


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3.4 Ammonia Sub-Sector Specific Assessment ................................................. 22

4 Technical Measure Library .................................................................................. 24

4.1 Description ................................................................................................... 24

4.1.1 Objective .................................................................................................. 24

4.1.2

Variables Collected .................................................................................. 24

4.1.3

Layout of Tool .......................................................................................... 25

4.1.4 Flow of information Between the Tools ................................................... 27

4.1.5 Using the Tool ......................................................................................... 28

5

Management Best Practices Assessment ........................................................... 29

5.1 Description ................................................................................................... 29

5.1.1 Objective .................................................................................................. 29

5.1.2

Variables collected .................................................................................. 29

5.1.3 Layout ...................................................................................................... 29

5.1.4

Flow of Information Between Tools ......................................................... 31

5.1.5

Using the Tool ......................................................................................... 31

5 2 Accuracy Detail and Making Assumptions 32


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Exhibit 27: Productivity Improvement Assessment index table .................................. 33

Exhibit 28: Example of Productivity Improvement Assessment multiple optionselection ..................................................................................................................... 34

Exhibit 29: Tool 5 in the sequence.............................................................................. 35

Exhibit 30: Report and Opportunity Identification index table ..................................... 36

Exhibit 31: Report Card ―Edit Links‖ screen ................................................................ 39

Exhibit 32: Report card macro button on Tab RC 2 .................................................... 40

Exhibit 33: Report card opportunities table to be completed manually ....................... 40

Exhibit 34: Report card opportunities table to be completed manually ....................... 41

Exhibit 35: Report Card plant information to be checked ........................................... 42

Exhibit 36: Report Card product information and energy use per unit of production .. 42

Exhibit 37: Report Card pie charts .............................................................................. 42

Exhibit 38: Converting to PDF (step 2) ....................................................................... 43

Exhibit 39: Converting to PDF (steps 3 and 4) ........................................................... 43

Exhibit 40: Tool 6 in the sequence.............................................................................. 44

Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan indextable 45


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1 Purpose of Guideline

This guideline provides guidance for a user on how to use the Institute of IndustrialProductivity‘s ammonia sector Assessments to Action (A2A) toolkit. The user usingthe toolkit and this guideline needs to be:

Experienced in on-site energy efficiency auditing.

Familiar with industrial manufacturing processes, specifically ammonia

manufacturing.

Familiar with industrial technologies, energy management best practices, and

ISO 50001.

Proficient in using MS Excel.

This guideline does not provide guidance in how to conduct an audit, or explanations

of industrial processes, technologies, best practices and the use of MS Excel.

The outline of the toolkit is described in Sections 2.1 and 2.3, while the structure ofthe manual is described in 2.5.

Data obtained from plants are considered to be confidential and a confidentialityagreement can be signed with the company. An example confidentiality agreementtemplate is included in the toolkit and needs to be completed by the company and thecompany using the A2A toolkit to conduct an assessment.


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2 Introduction

2.1 Context and Scope of IIP A2A Toolkit

The Institute for Industrial Productivity (IIP) retained ICF Marbek, a Canadianconsulting firm, to develop an energy performance assessment and continuousimprovement toolkit. The toolkit provides a standardized methodology for industrial

energy performance assessments, and engaging companies to implement acontinuous improvement process to reduce energy use and improve energymanagement. The toolkit is to be used by trained users during on-site assessments ina consultative process to assist a company in implementing a continuous energyefficiency improvement plan.

This version of the toolkit was developed specifically for the ammonia manufacturingsector. The toolkit addresses the assessment, opportunity identification and planning

stages of the continuous improvement process, as illustrated in Exhibit 1.

Exhibit 1: Continuous improvement process.

Assess Energy

Performance &

Establish

Indicators

Identify

Opportunities

& Define

Implement

EE&M

Action Plan

Commitment

by Factory

A2A Toolkit


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Exhibit 2 illustrates the tools in the toolkit and how it correlates with the continuousimprovement process, and the results to be achieved. The tools and the use of thetools are described in detail in the guideline, and examples are provided throughoutthe guideline to illustrate the use of the toolkit.

Exhibit 2: Tools in the toolkit and results to be achieved

Obtain Commitment

Assess Performance

and Establish

Indicators

IdentifyOpportunitiesand

Define EE&M Plan

Scope

Technical Assessment

(Includes Energy Use Performance

and Technical Best Practices

Assessment)

Management Assessment

(Includes Technical Management Best

Practices Assessment)

Productivity Improvement

Assessment

Report Card and OpportunitiesIdentification

EE&M Plan Checklist

Company committed to energy

management

and allocating necessary resources

to energy management

Understand current energy use,

productivity and energy

performance.

Derive performanceindicators for

continuous improvement.

Definition and understanding of the

opportunities to improve energyperformance.

A defined scope for the EE&M Plan.

ContinuousImprovement

ProcessToolkit Results

MeasureLibrary(incl. Ammonia

Specific)


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2.2 Assessment Methodology

The toolkit is based on an assessment approach that includes:

Determining the overall plant energy intensity, or energy use per unit

production (for example, GJ/ton ammonia). In this version of the tool the

energy intensity is not calculated at a more detailed level, such as process

step, but determined by evaluating energy use in the plant against the mainproduct only.

Determining the implementation of technical best practices (TBP). Identifying

the technical best practices already implemented at a plant, reveals the

technical best practices not yet implemented at the plant. This provides an

opportunity to implement the applicable best practices that will reduce energy

use.

Determining the implementation of energy management best practices (MBP).Identifying the management best practices already implemented at a plant,

reveals the management best practices not yet implemented at the plant. This

provides an opportunity to implement the applicable best practices that will

assist in reducing energy use.

This comprehensive approach helps an assessor to understand and explain acompany‘s energy efficiency performance. For example, low implementation of MBPs

and TBPs identify reasons for low energy intensity values, and highlights opportunitiesand management areas for improvement to improve energy intensity values.

To assist companies in continuously improving their energy efficiency and energy


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best practices listed in this toolkit are commercialized, and exclude pilot-test ordemonstration technologies.

2.3.2 Generic Measure Library (Excel File: A2A Generic) and AmmoniaMeasure Library (Excel File: A2A Ammonia)

The measure library provides in format ion abou t each techn ical best pract ice . The

technical best practices are grouped in two broad categories:

Measures applicable to generic end uses. It refers to end uses that are not

sector specific, such as: boilers and steam systems, motors, process cooling

and refrigeration, and direct process heating in ovens, dryers, furnaces and

kilns. Energy efficiency technical best practices applicable to these end uses

are included in the Measure Library.

Measures only applicable to the ammonia manufacturing sector. Energy

efficiency technical best practices applicable to only the ammonia

manufacturing sector are included in the Measure Library – Ammonia Specific.

2.3.3 Energy Management System Assessment (Excel File: A2A MA)

The energy management assessment tool is used to obtain information to assess theimplementation of energy Management Best Practices (MPBs), illustrated by a highlevel of commitment, awareness, organization and acting in support of energy

management.

Numerous studies have shown that application of energy management practices is acritical success factor for sustained improvement in energy use performance in


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2.3.6 EE&M Plan Checklist (Excel File: A2A Checklist and Action Plan)

The energy efficiency and energy management (EE&M) plan checklist is used todetermine the status of energy management system implementation. Elements thatare not fully implemented are prioritized and then manually transferred to the actionplan template, which is described in the next point.

2.3.7 EE&M Action Plan Template (Excel File: A2A Checklist and Action Plan)

The energy efficiency and management (EE&M) action plan template is contained inthe same Excel workbook as the EE&M plan checklist. The action plan template isused to guide implementation of the opportunities and outstanding energymanagement system elements. The opportunities and elements are manuallycaptured as action items, responsibilities are assigned, scheduled dates forcompletion are assigned and the completion of the actions is tracked.

2.4 Managing and Updating Toolkit

The toolkit will be managed by IIP. IIP will regularly update the toolkit and releaserevisions of the toolkit. This guide is for the user who will not have to make changes tothe structure or methodology of the toolkit, and will only have to use the toolkit bypopulating it with data and information. IIP will provide training for users to use the A2A toolkit.

2.5 Structure of Guideline

Exhibit 3 illustrates the logical sequential flow of how the tools are used by a user.


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Tool 1: The technical best practices and energy use performance assessment

is completed though an on-site assessment, using the Technical Assessment

Excel workbook. The on-site assessment generally takes one to two days,

depending on the complexity of the plant. To optimize the time during the on-

site assessment a pre-site visit information request and site visit agenda are

send to the plant well in advance of the site visit. Examples of the information

request and agenda are included in the toolkit.Tool 2: The technical measure library (included in the Measure Library Excel

workbook) and the ammonia specific measure library (included in the Measure

Library – Ammonia Specific Excel workbook) are used as supporting

references for the technical best practices assessment conducted in Tool 1

above. The best practices are cross referenced in the Technical Assessment

workbook.

Tool 3: The energy management best practices assessment (which uses theManagement Assessment Excel workbook) is generally completed first in a

workshop setting with representatives from different levels in the organization

and who is using the energy management system of the plant.

Tool 4: Information is obtained regarding productivity improvement during the

on-site assessment using the Productivity Improvement Excel workbook.

Tool 5: Using the data, information and results from Tools 1, 2 and 3 the

report card is generated and opportunities are identified, using the Report Card

and OI (OI: Opportunity Identification) Excel workbook.

Tool 6: The results from all the tools are used to manually develop both an

energy efficiency and energy management plan and an action plan to ensure


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2.6 Common Elements in Tools

Each Excel workbook contains a similar structure and the first few pages in eachworkbook (see Exhibit 4) are:

Revisions: This page tracks the revisions that are made in the workbook and

is only to be managed by IIP.

Index: This page contains an outline of the pages in the Excel workbook andprovides descriptive names for each of the page tabs.

Instructions: A summary of the instruction to use the tool is provided on this

page.

Exhibit 4: Example of first few tabs in Excel tools


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3 Energy Use Performance and Technical Best Practices Assessment

Exhibit 5: Tool 1 in the sequence

3.1 Description

3.1.1 Objective

The purpose of the energy use performance assessment is to determine the profile of

Energy Use

Performance andTechnical Best

Practices

Assessment

Management

Best Practices

Assessment

ProductivityImprovement

Assessment

Report Card and

Opportunity

Identification

EE&M Plan

Checklist and

Action Plan

Template4

5

6

Technical

Measure Library

1

Management

Best Practices

Assessment

Technical

Measure Library

Management

Best Practices

Assessment

Technical

Measure Library

2

3


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questions pertaining to the overall energy use, production, characteristics of theequipment, and the presence of energy efficiency measures. The Excel workbookincludes the following sections:

Section A gathers general information regarding the facility production and

procurement of energy.

Section B is specifically related to generic equipment, such as cooling,

heating and motive power.Section C outlines types of heating, ventilation and air conditioning systems

specifically associated with occupancy comfort.

Section D is an overview of system practices, other major energy consuming

equipment, and the implementation of emerging technologies.

Section E collects data on ammonia production practices only.

3.1.3 Layout of the Tool

The following exhibit illustrates the layout of the Technical Best Practice Assessmenttool as shown in the index tab.

Exhibit 6: Technical best practice assessment index table


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The questionnaire is categorized according to the categories described above. Foreach Section B to E, the equipment number, type, operating hours and fuel-type used(where applicable) is requested. The energy efficiency features of the equipment arealso requested at the end of each section. Enter only operating equipment and do notinclude back-up equipment. The Excel workbook contains the following sheets:

Revisions

See section 2.6

Index

See section 2.6

Instructions

See section 2.6

TA 1

Plant information

Enter general information about the plant and its operation.

TA 2

Energy and Production Data

In Section A.1, statistics on the company purchases of energy is collected. It isimportant to ONLY list energy used as fuel, and EXCLUDE energy used as feedstock


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equipment that provides cooling and heating for occupancy comfort should NOT belisted in this section but in sections C.1 and C.2.

For each equipment type, it is possible to give up to four capacities. Each capacityrepresents a size range; however it is the average value of that size range which mustbe entered. See section 3.2 for more detail on average capacities.

The features questions should be left blank if the plant has no equipment in the givencategory.

TA 4

Compression Heating Equipment

All equipment related to compression is characterized in this section. This includescompressors for pneumatic equipment and compression systems for process gas orair systems.

For each equipment type, it is possible to give up to four capacities. Each capacityrepresents a size range; however it is the average value of that size range which mustbe entered. See section 3.2 for more detail on average capacities.

The features questions should be left blank if the plant has no equipment in the givencategory.

TA 5

Motor Related

The parameters of motive power equipment are summarized in this section including


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Exhibit 7: Tools in the toolkit and results to be achieved

Type StandardEnergyEfficient

Fluorescent T17, T12 T5, T8

CFL's All

Metal Halide Mercury Vapour All other

High PressureSodium All

Incandescent All

TA 8

Comfort-HVAC and Air System

Equipment providing heating and cooling for occupancy comfort, is entered in thissection with details on characteristics.

The ventilation data entered in the third table refers only to the motor power. If thereis heating of make-up air, the heating capacity should be entered in the second table(non-packaged HVAC equipment).

TA 9

Other & System Practice


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TA 12

Conversion

In this tab, conversions used in the calculations are provided for reference purposesonly.

3.1.4 Flow of Information Between ToolsThe responses from this questionnaire are used to:

Calculate the energy balance and portion of energy used by each end use and

energy source.

Calculate the technical best practice scores in the Report Card and

Opportunity Identification tool (see section 7), where a score for each TBP

category is determined.

Evaluate the opportunities available to a facility to implement improved TBP

practices (see section 7).

Develop an Energy Efficiency and Management Plan using the checklist and

template tools (see section 8.2).

3.1.5 Using the Tool

The equipment related tabs (TA 3 to TA 10) are divided into two groups of questions,followed by a table where additional opportunities can be entered.

Sect ion A : Fi rst Quest ion gro up: Purchased Energy


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Sect ion A: Link to water tables for steam enthalpy calculat ion

The energy content or enthalpy of steam can be calculated by linking the technicalassessment to the water97_V13 add-in. This is done as follows:

Copy the water97_V13.xla file to the appropriate directory

Add the water97_V13 file (provided) to Excel Add-in‘s

Select ―Edit links‖ in Excel and change the source link for the water97_V13 file

if necessary

Select ―Open source‖ from the ―Edit links‖ pop-up menu above.

Select ―Enable macros‖ in the technical assessment

Sect ion A: Second Quest ion grou p: Sold and sel f -generated Energy

The second part of this section is the documentation of sold fuel from the facility,

including self-generated electricity and steam generated on-site.Exhibit 9: Example of Technical Assessment Sold and self-generated fuel questions


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Exhibit 10: Example of Technical Assessment Sold and self-generated fuel questions

Sect ion A : Four th Quest ion grou p: Purchased Energy for Feedstock

This section is a summary of the fuel used as feedstock in the plant. The total quantityof feedstock and fuel for three main types of fuel are provided at the end of the tablefor verification.

Exhibit 11: Example of Technical Assessment feedstock questions


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Exhibit 12: Example of Technical Assessment equipment features questions (first question group)

This section of the questionnaire is completed by:

Filling in the blank white cells where a response is required.

Selecting from the drop down menu where available as shown below:

Exhibit 13: Example of Technical Assessment drop down menu


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If there is no equipment meeting criteria requested for the featured equipment

in the plant, enter ―0‖ in these cells (e.g. If there are 15 fluorescent lamps, and

none are high efficient, enter ―15‖ for ―number of (fluorescent) lamps, and enter

―0‖ for ―number of efficient lamps‖).

The number of high efficiency equipment must not exceed the number of

equipment for each capacity range. For example: in Exhibit 12, there are ten

2kW pumps. The sum of ―high efficiency motors‖ and ―premium efficiencymotors‖ must be ten or less in this capacity r ange.

If there is an option for ―high efficiency‖ as well as ―premium efficiency‖ as is

the case in Exhibit 12 for pumps, you can consider a piece of equipment as

high or premium efficiency, but not both.

Recording equipment as ―high‖ or ―premium‖ efficiency is left to the discretion

of the user. In some cases, guidelines are given in the manual for the given

measure. In general, it is unlikely that old equipment (greater than 10 to 15

years, depending on the type of equipment) can be considered ―high

efficiency‖

NTF (Not Technically Feasible) should be entered if the measure is not

applicable for the given piece of equipment.

For large counts of equipment, where it is difficult to provide and exact number

of equipment (eg number of motors or light fixtures), a best estimate can be

provided. The following can be used to provide this estimate:

Review of line drawings and determine capacity.

Equipment count lists available from maintenance staff / operators.

Name plate capacity of equipment with multiple motors can be grouped into


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Exhibit 15: Example of Technical Assessment general questions (second question group)

Drop-down menu selections for equipment features have responses with thefollowing implications:

―No Implementation‖ implies that the measure is applicable but not

implemented.

―Partially Adopted‖ implies that the measure has been considered and

introduced but is not fully adopted.

―Fully Adopted‖ implies that the measure has been fully adopted in the plant,with controls and verification in place where applicable.

―Not Technically Feasible‖ implies that the measure is not an option due to


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these can be omitted by indicating inapplicable sections in the boxes provided at thebeginning of each section.

It is anticipated that completing the questionnaire during an on-site assessmentrequires one to two days, depending on the complexity of the plant, the availability ofthe data, and verification of the energy balance (see section 3.2).

3.2 Accuracy, Detail and Making Assumptions

This questionnaire requires that ALL applicable sections to be filled in using one of theresponses available in the menus with all fuels purchased accounted for by theequipment using it.

3.2.1 Average equipment capacities and operating hours

There may be numerous pieces of equipment under each type, and it isrecommended to categorize this by size. Up to six ranges of equipment sizes can beentered, by providing weighted average equipment capacity values and averagehours of operation for each range.

For example, if there are 25 motors ranging in size from 0.3 to 0.5 kW, operatingbetween 500 to 6000 hours per year, the average range of equipment capacity wouldbe:

Average range [kw] = ∑ (motor power [kw]) x (motor hours of operation [h])∑ hours of operation [h]])

The hours of operation entry would be the average hours for all the motors in that


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Exhibit 17: Portion of the energy balance tables


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The adjustment factor is the ratio of net imported fuel to utilized fuel for each

fuel, and should always be less than one because of the following

assumptions:

Equipment is assumed to be 100% efficient.

The hours of operation are applied directly to operating time without

adjustment for load factors applied to equipment.

Equipment capacity is assumed to be the rated capacity.If the adjustment factor is much greater than one, the following should be

reviewed to address this:

Review quantity of purchased energy (may be too high).

Review the hours of operation of equipment using the fuel with the discrepant

adjustment factor.

Review the capacity rating of equipment using the fuel with the discrepant

adjustment factor.

Review the quantity of equipment using the fuel with the discrepant adjustment

factor.

Review the firing time and efficiency of equipment where this is reported, such

as for boilers and ovens.

Investigate whether all equipment using this fuel have been accounted for.

When the adjustment factor is close to one, then all purchased energy is being

accounted for by all reported equipment.

If the adjustment factor for steam as a fuel is much greater or less than one,

review the following:


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tabs of the questionnaire. Up to five such types of equipment can be detailed, in orderof energy use. It is expected that most equipment will be captured in tabs B.1 to C.2.

The ammonia specific table is shown in the exhibit below.

Exhibit 18: Ammonia sub-sector specific data table


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4 Technical Measure Library


4.1 Description

4.1.1 Objective

The purpose of the Technical Measure Library is to catalogue energy efficient

Energy Use

Performance andTechnical Best

Practices

Assessment

Management

Best Practices

Assessment

Productivity

Improvement

Assessment

Report Card and

Opportunity

Identification

EE&M Plan

Checklist and

Action Plan

Template4

5

6

Technical

Measure Library

1

Management

Best Practices

Assessment

Technical

Measure Library

Management

Best Practices

Assessment

Technical

Measure Library

2

3


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4.1.3 Layout of Tool

There are two types of tabs in the Excel spreadsheet of this toolkit module:

Index

This is a summary of all the energy efficient measures in the library. It lists thefollowing for each measure: Tab number, Measure Description, a breakdown of

applicable plant level to which this measure is applied (Plant Region, Plant Area,System, End Use, Other grouping), the applicable Industry (typically all for thisgeneric library), percent savings for each fuel type (natural gas, electricity, refinedpetroleum products, other fuel), and finally, the measure life. For more information onnavigating through the Measure Library using the Index tab see section 4.1.5.

Tabs 1 to 144

Each tab in this library has the same format. It is a repository of the details of eachenergy efficiency measure.


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Exhibit 20: Example of Measure Library tab


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Low – little or no capital cost would be required. Often involves behavioural

changes and only a rudimentary economic assessment may be needed.

Relat ive imp lementat ion di f f icul ty : each measure is rated as high, medium

or low to indicate the relative difficulty of implementation:

High – the implementation of the measure involves complex change to the

plant. The measure may involve redesign, and a detailed engineering

feasibility assessment would be required.Medium – may involve small equipment replacement or simple retrofits. A less

extensive technical feasibility assessment is usually required.

Low – relatively easy to implement the opportunities and most often involves

maintenance related opportunities and/or behavioural changes. Technical

feasibility studies are generally not required.

Lev el (1 to 5): further describe each measure based on which part of the plant

and which category of equipment the measure is relevant to. This allows the

user to filter the measure list on the Index tab by a variety of criteria.

Energy type: five energy types are listed: natural gas, electricity, refined

petroleum products, and other. Measure savings are shown for each fuel type.

As illustrated in Exhibit 20 (boiler economizer), some measures show savings

for more than one energy type. This indicates that there are multiple energy

source options for the given end-use; the savings will be calculated for the

energy source selected in the Technical Assessment, not all of the energy

sources listed in the library. For the measures which may save other types of

energy than those listed, the fuel type is entered in the ―Other fuel‖ line.

Savings percentage: the amount of energy that would be saved for that


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This toolkit module can be used to cross reference the energy efficiency measures inthe technical assessment or the opportunities listed in the report card. Each measurelisted in the technical best practice assessment has a number in column L, whichcorresponds to the measure number in the Measure Library. Note: do not changethe Measure Number or the tab numbers, as these are used to link to othertoolkit modules.

The Index tab can be used to easily navigate the library. The first column containsthe Tab Numbers (measure number) which can be clicked to view that particular tab.Filters are set up to show the measures by groups, or to sort measures as desired:click the down-arrow on any of the column headings to view the filter options. Forexample, as shown in Exhibit 20, to view only the measures related to pumps, clickthe filter arrow in the ―Level 4 – Enduse‖ column, un-check ―Select All‖ then check thebox beside ―Pumps‖ and click Ok.

Exhibit 21: Measure Library Index Tab


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Exhibit 23: Management Best Practice Assessment index table

There are seven tabs in the Excel spreadsheet of this toolkit module:

Revisions

See section 2.6

Index

See section 2.6

Instructions

See section 2.6

MA 1

Contact information


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5.1.4 Flow of Information Between Tools

The responses from this questionnaire are used to:

Calculate the management best practice scores in the Report Card and

Opportunity Identification tool (see section 7), where a score for each MBP

category is determined.

Evaluate the opportunities available to a facility to implement improved MBPpractices (see section 7).

Develop an Energy Efficiency and Management Plan and Action Plan using

the checklist and template tool (see section 8.2).


This section of the questionnaire is completed by:

Filling in the blank white cells where a response is required.

Selecting from the drop down menu where available as shown in Exhibit 24.

Exhibit 24: Example of Management Assessment drop down menu


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Al l sect ions are required to be filled out for this questionnaire. It is anticipated thatcompleting the questionnaire takes 45-60 minutes.


This questionnaire requires that ALL sections to be filled in using one of theresponses available in the menus.

No assumptions need to be made for this toolkit element.


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6 Productivity Improvement Assessment


6.1 Description

6.1.1 Objective

The purpose of the Productivity Improvement Assessment questionnaire is toevaluate the implementation and awareness of continuous improvement practices in

i ti Thi t th t t f t ki t t i d ti it ith th

Energy Use

Performance and

Technical BestPractices

Assessment

Management

Best Practices

Assessment

Productivity

Improvement

Assessment

Report Card and

Opportunity

Identification

EE&M Plan

Checklist and

Action Plan

Template4

5

6

Technical

Measure Library

1

Management

Best Practices

Assessment

Technical

Measure Library

Management

Best Practices

Assessment

Technical

Measure Library

2

3


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There are four tabs in the Excel spreadsheet of this toolkit module:

Revisions

See section 2.6

Index

See section 2.6

PI 1

Plant information

Enter general information about the plant.

PI 2

Productivity improvement

Enter more detailed information about the company and plant. This section includescompany presence within the country or worldwide, production quantities, andquestions related to productivity and profitability.

6.1.4 Flow of information Between Tools

The responses from this questionnaire are used to:

Define an Energy Efficiency and Management Plan and Action Plan using the

h kli t d t l t t l ( ti 8 2)


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7 Report Card and Opportunity Identification


7.1 Description

7.1.1 Objective

The Report Card and Opportunity Identification tool imports data from the assessmenttools, performs calculations to analyse and summarize the data, and presents theresults by means of graphs, charts and tables. The result is a report card which

Energy Use

Performance and

Technical Best

Practices

Assessment

Management

Best PracticesAssessment

Productivity

Improvement

Assessment

Report Card andOpportunity

Identification

EE&M Plan

Checklist and

Action Plan

Template4

5

6

Technical

Measure Library

1

Management


Technical

Measure Library

Management


Technical

Measure Library

2

3


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Exhibit 30: Report and Opportunity Identification index table

There are five tabs in the Report Card and Opportunity Identification tool:

Revisions

See section 2.6

Index

See section 2.6

RC 1

Report card


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RC 3

Energy Management (EM) Opportunities

The opportunities are listed in order, grouped by categories. Categories are shown incolumns, starting (on the left) with the highest priority. The priority is determinedbased on the best practice score for each category (the category with the lowestscore is given the highest priority).

RC 4

Technical Energy Management Calculation Summary

This tab is a summary of the calculations from the subsequent tabs, as well as animported summary of energy use from the Technical Assessment tool (EnergyBalance tab).

RC 5

Reference Data

A summary is provided of greenhouse gas emissions factors for the various energytypes and the reference source of the factor.

RC 6

Best Practice Calcs (Management)

This is where calculations are performed to determine the Management BestP ti Th d t i d i th f ll i


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Maximum score = 1 if the measure is technically feasible or 0 if the measure is

not

Achieved score = 0 if the question is answered ―no implementation‖, 0.5 if the

question is answered ―partial adopted‖ or 1 if the question is answered ―fully

adopted‖

A combined score is calculated by dividing the sum of the achieved scores by the sum

of the maximum scores.

7.1.4 Flow of information Between Tools

This toolkit imports data and finally summarizes the data in a concise and coherentplant report card.

The answers from the Technical Assessment and Management Assessments

tools are imported into ―RC 6‖ and ―RC 7‖ tabs where the scores arecalculated.

The energy use for each end-use is imported from the Technical Assessment.

The tool calculates best practices scores and uses them together with energy

use by end use to determine energy savings potential for each end-use, and to

prioritize the opportunities.

The report card (―RC 1‖) displays these results in the form of charts and tables.


The Report Card module functions automatically, however a series of steps must be


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Exhibit 31: Report Card “Edit Links” screen

I. Data Edit LinksII. Select ―A2A MA‖ from the list of sources

III. Click the ―Change Source …‖ button

IV. Select the Management Assessment file and press OkV. Click the ―Open Source‖, then go back to the Report Card Screen VI. Select ―A2A TA‖ from the list of sources VII. Click the ―Change Source …‖ button VIII Select the Technical Assessment file and press Ok


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Exhibit 32: Report card macro button on Tab RC 2

After running the macro, the report card is created. However, there are someadditional steps and/or checks to ensure the report is complete and presentable.These steps are outlined in detail below. In addition, a more concise checklist isprovided in Appendix A.

Tab ―RC 2‖

The technical opportunities are grouped by end-use. The end-uses are listedin order from highest potential opportunity to the lowest. The following exhibitshows the first end-use group after running the macro. There are two things todo/check on this tab after running the macro:

I. The column with maximum savings is left blank, and mu st be f i l led inmanual ly for each opportunity (in the example below, the first threesavings have been entered, and three more remain to be entered). Notethat the savings is given in the description. Sometimes this savings isgiven as a range; in that case, enter the maximum savings in the range.

NOTE: for the ammonia savings, the entry must be in energy units perton of ammonia production (eg. 0.4 GJ/t_NH3). Where savings areprovided in percent of energy use convert this to energy units per ton of


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Tab ―RC 3‖

The management opportunities are shown in tables in tab ―RC 3‖ as shown inthe following exhibit. The opportunities are grouped into categories andordered by those categories starting with the highest potential opportunity forimprovement in the left column, and decreasing to the right. There is noadditional data to enter on this tab, but it should be checked to ensure that notext is cut off by the grid (increase row height if necessary).

Exhibit 34: Report card opportunities table to be completed manually


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Exhibit 35: Report Card plant information to be checked

Below the pie charts, product should be shown, followed by energyuse per (main) unit of production. If div#/0! is shown, the productquantity was not entered in table A.3 of the Technical BestPractices Assessment tool.

Exhibit 36: Report Card product information and energy use per unit of production

Check the energy intensity number and ensure that the units are

suitable (GJ/t_NH3), and that only one decimal or no decimals areshown.

ii. Check the leader lines on the pie charts; they may need adjusting ifth l ll i h t ti l t h th


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converted to PDF format; these PDFs can then be included in summary reports forthe participating company. To make the PDFs using MS Excel 2007, ensure thatthe add-in for this version of Excel is installed and follow the steps below. Forolder versions of Excel, ensure you have the appropriate printer drivers installed tosave the file as a PDF.

I. Select tab ―RC 1‖.

II. From the ―Save as‖ menu, select ―PDF or XPS‖

Exhibit 38: Converting to PDF (step 2)

III. Under ―Save as type‖, select ―PDF‖

Exhibit 39: Converting to PDF (steps 3 and 4)


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8 Energy Efficiency and Management (EE&M) Plan and Action Plan


8.1 Description

8.1.1 Objective

The purpose of the Energy Efficiency and Management plan checklist and Action Plant l t i t i t i ti i d l i E M t Pl d

Energy Use

Performance and

Technical BestPractices

Assessment

Management

Best Practices

Assessment

Productivity

Improvement

Assessment

Report Card and

Opportunity

Identification

EE&M Plan

Checklist and

Action Plan

Template4

5

6

Technical

Measure Library

1

Management

Best Practices

Assessment

Technical

Measure Library

Management

Best Practices

Assessment

Technical

Measure Library

2

3


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Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan index table

There are three tabs in the Excel spreadsheet of this toolkit module:

AP 1

Plant Information

Enter general information about the plant and its operation.

AP 2

Outline of EE&M Plan

An outline of the elements of the Energy Efficiency and Management Plan.

AP 3


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48

Exhibit 43: Example EE&M Action Plan template.

EE&M

Element

Responsibility

Assigned to

Scheduled

Date

Status or

Date

Completed

Actions/

Comments

Do Do Check Act

5

9

Relative

Implementation

Difficulty1

Relative

Implementation Cost2

Maximum

Potential Energy

Savings3,4

[TCE]

Maximum

Potential

Energy Cost

Savings4

Responsibility

Assigned to:

Scheduled

Date

Status or

Date Completed

Actions/

Comments

Ammonia

Production

High emissivity coating of

radiant section refractory: 2 -

5% reformer heating energysavings Low Medium 451 465,988

Modify steam turbine drivers

to improve efficiency: 0 - 9.5

GH/t_NH3 energy savings Medium Medium 10,654 11,012,533

Energy Efficiency and Management (EE&M) Action Plan Template

The following Energy Efficiency and Management (EE&M) Action Plan template is to assist your enterprise in developing actions to implement the EE&M Plan. The EE&M

Action Plan includes a timeframe, responsibilities, and budget for each action. Actions are developed from the actions identified in the EE&M Plan checklist.

Implementation of Identified Opportunities

(Including Technical Best Practices and

Productivity Improvement)

Time Frame

Action Item (from EE&M Plan Checklist)

Plan

Project Management

Parameters to be considered in identifying Energy management project opportunities can include fuel substitution

and use of renewable energy.

Library

Reference #Library Description

AM-54

High emissivity coating of the refractory surfaces in the radiant section of the primary reformer reduces the radiant heat

reabsorbed by the combustion flame and flue gases. This increases the radiant section efficiency and reduces the reformer

bridgewall temperature. Less fuel is thus required to achieve a given reformer process outlet temperature. Fuel savings of 2-

5% have been demonstrated.

AM-34

Steam turbine drivers can be modified with updated designs for rotors and stationary parts to increase horsepower rating

while reducing the water rate and saving energy.


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This questionnaire requires that ALL sections to be filled in using one of theresponses available in the menus.

No assumptions need to be made for this toolkit element.


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9 Glossary

5S

A program of 'industrial housekeeping', the 5S's are 5 Japanese words which help toguide organizations to increased levels of cleanliness, organization, & efficiency.

Category (plant informat ion)

Grouping category provided when the enterprise was registered to obtain theirbusiness license from the government

Code of region

Regional code provided by the National Bureau of Statistics

End use

The final application or final use to which energy is applied, such as motors, boilers,and air compressors.

Energy intensi ty

The energy use per unit of product produced is referred to as the energy intensity. Inthis assessment energy intensity is determined by evaluating energy use against the

main product only.

Energy management system


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High Ef f ic iency Equipm ent

Equipment that by design and function consumes less energy than conventionalequipment for the same function. This equipment can be specified by its design forefficient use of energy and in some cases, identified by a national efficiency rating orlabel.

JIT

Just in Time: a strategy that exposes waste, makes continuous improvement a reality,and relies on total employee involvement. It concentrates on delivering what thecustomer wants, when they want it, tin the quantity they want. The key elements ofJIT are flow, pull, standard work (with standard in-process inventories), and takt time(takt time is a calculated value: available production time / customer demand).

Kaizan Bl i tz

Kaizan in lean terminology means 'continuous, incremental improvement' implyingeveryone applying small (low impact & low cost) improvements each and every day. Applied in this manner, kaizen can have the same effect as large, costly, infrequentchanges. A Kaizan Blitz refers to ―improvement workshops‖.

Kanban

Designates a pull production means of communicating need or service. Originally

developed as a means to communicate between operations in different locations, itwas intended to communicate a change in demand or supply. In application, it isgenerally used to trigger the movement of material to or through a process.


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Retrof i t measure/technology

An energy efficiency measure/technology that can be used to upgrade an existingpiece of equipment, as opposed to replacing it. Retrofit measures are applied on a fullcost basis and may be implemented immediately.

Six sigma

Refers to six standard deviations from mean. Six sigma methodology provides thetechniques and tools to improve the capability and reduce the defects in any process.

Standardized wo rk inst ruct ions

Specific instructions that allow processes to be completed in a consistent, timely, andrepeatable manner. By implementing SWI‘s employees will increase production,improve quality, and enjoy a safer, predictable working environment.

Technical best p ract ice

A set of energy efficiency measures that represent the most advanced technologyavailable.

TPM

Total Productive Maintenance: preventative maintenance carried out by all

employees. It is equipment maintenance performed on a company wide basis.

Value st ream mapping


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10 Abbreviations

A2A: Assessments to action

A2A MA: Energy management assessment tool of the A2A Toolkit

A2A PIA: Productivity improvement assessment tool of the A2A Toolkit

A2A RCOI: Report card and opportunity identification tool of the A2A Toolkit

A2A TA: Technical assessment tool of the A2A Toolkit

EE&M: Energy efficiency and management

EM: Energy management

h: hours

HVAC: Heating, ventilation and air conditioning

kW: kilowatts

IIP: Institute for Industrial Productivity

ISO 50001: Energy Management of the International Organization for Standardization

LHV: Lower heating value

MBP: Management best practices


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11 Appendices

Appendix A Report Card checklist and Completed Report Card

Linking and running macro

Review the Technical and Management Assessments to ensure that the data

contained is valid for analysis.For the Technical Assessment, verify that for all applicable sections B to E, theequipment feature questions at the end of each section are ALL be answeredincluding all features questions in Section D (TA 9); input either the level ofimplementation or NTF (not technically feasible).

Verify that the Technical and Management Assessments are saved with thecorrect name (following an established naming convention). If not, change thefile name.

Close the Technical and Management Assessments, and open the ReportCard template file (A2A RCOI).

If the Excel default is to disable macros, a security warning will appear,followed by an ―options‖ button. Click the button and enable the macros.

Save the file with the appropriate name (following an established namingconvention).

Link the Report Card to the appropriate Technical and Management Assessments, and open the files. The following exhibit shows the ―Edit Links‖screen where the subsequent steps are performed.

i. Data Edit Linksii. Select ―A2A MA‖ from the list of sources iii. Click the ―Change Source …‖ button iv Select the Management Assessment file and press Ok


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Checklist after running macro

Tab ―RC 2‖ All savings are filled in (manually)

Text is not cut off by grid

Tab ―RC 3‖ Text is not cut off by grid

Tab ―RC 1‖ No missing information (blank cells where there should be information

provided)

Energy use per unit of production: not div#/0!, has suitable units, set to one

decimal or no decimal places

Pie chart labels are legible and appropriately situated (i.e. not overlapping with

other labels)

Pie chart leader lines are appropriately situated (i.e. do not cover labels, are asuitable length, etc)

Graph axes and axis titles are not cut off

Creating a PDF (using Excel 2007 or higher)

1. Select tab ―RC 1‖. 2. From the ―Save as‖ menu, select ―PDF or XPS‖ 3. Under ―Save as type‖, select ―PDF‖

4. Click the options button. Under ―Publish what‖, choose ―Active sheets‖ andpress ―ok‖

5. Click the ―Publish‖ button to create the PDF. 6 Repeat these steps for tabs ―RC 2‖ and ―RC 3‖ Alternatively select ―RC 1‖


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A2A Toolkit

Energy and Technical Best Practice Assessment


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Location Industry

Organization Name Category

Registration Date Registrated Capital

Name of Legal Person Contact Phone Number

Address

Code of Region Post Code

Phone number Fax Number

Energy conservation Manager (primary)Energy conservation Manager

(secondary)

Phone number Phone number

E-mail address E-mail address

Name of Auditor Direct Telephone Number

Auditor's Organization /

Company NameFax Number

Title of Auditor E-mail address

Date of AuditEvaluation year (for purchased &

utilized energy)2009

The survey questionnaire is the ownership of IIP and ICF Marbek. Any use of the survey by another party requires to be granted permission by IIP or ICF Marbek prior to

use.

Confidential Plant Information

Auditor Information

Industrial Energy Use and Technical Best Practice Assessment

STEP 1 - Please complete the contact information requested on this page.STEP 2 - Review instruction sheet and complete the questions on the next pages.

TO DO:

IIP / ICF Marbek TA 1 Page 1 of 28

A2A Toolkit



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A.1. PURCHASED ENERGY (exclude energy purchased for use as raw material feedstock in ammonia production)What sources of purchased energy do you presently use at your facility?

Please indicate all types of purchased energy sources, quantities used and purchase totals (including taxes).

2009 2008 2009 2008 $ per

Electricity - kWh

Natural Gas 0.03897 m3

Gasoline 0.04311 ton (metric)

Diesel Oil (transport) 0.04269 ton (metric)

LPG 0.05023 ton (metric)

Fuel Oil type (select) - ton (metric)

Fuel Oil type (select) - ton (metric)

Gas type (select) - m3



Biomass type (select) - ton (metric)

Biomass type (select) - ton (metric)

Other Fuel (select) - ton (metric)

Other Fuel (select) - ton (metric)

Steam quantity 0.00090 ton (metric)

Steam Temp [k] 483 K

Steam Pressure[bar] 22 bar

*LHV's can be overwritten for coal or other fuels which may vary in energy content

This section includes energy used at your facility:- the purchased, self generated and sold energy products.

Fuel Type Units

LHV*

GJ per

[kg or m3]

Quantity Cost ($)Cost/unit (current year)



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A2A Toolkit



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A.3. PRODUCTION and PLANT DATA

2009 2008 2009 2008 2009 2008

Actual

Equivalent

Actual

Equivalent

A.4 FEEDSTOCK FUEL

2009 2008 2009 2008

Natural Gas 0.03897 m3 0 0

*LHV's can be overwritten for coal or other fuels which may vary in energy content

What type and quantity of feedstock do you presently use at your facility?

Fuel Type

LHV*

GJ per

[kg or m3]

Quantity

Units

Total fuel and feedstock

What are the main products produced at your facility, and what is the annual volume? Please list the most important products first and the reported annual energy consumption

in GJ.

Quantity

Annual Energy Consumption (all fuel

and feedstock)

[GJ]

Energy Consumption (all fuel and

feedstock) [GJ per unit of product]

Industrial Output ($)

Sales Revenue ($)

2009 2008

Share of energy consumption cost (%)

Specific industrial output energy

consumption (GJ/$)

% Change

Units

[please provide]

Energy Consumption cost ($)

Comprehensive energy consumption

(GJ)

Product Description


A2A Toolkit



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B.1 COOLING and HEATING SYSTEMS

I do not have this equipment--------> Go to Section B-2

Total: 0.0E+00

-

-

-

-

Total: 0.0E+00

-

-

-

-

Total: 0.0E+00

-

-

-

-

* NTF = Not technically Feasible

Annual Energy

Use

[GJ]

Average Age of

Equipment

[years]

Total number

of equipment

in each

Capacity

Range

COOLING / REFRIGERATION COMPRESSORS

BOILERS

What are the energy sources and features of your equipment? Exclude HVAC related equipment Please indicate the features that are not technically feasible.

Energy Source

[nat.gas / elec. /

etc]

This section includes Cooling and Heating equipment (excluding HVAC) at your facility.

This includes refrigeration compressors, ovens/dryers/kilns/furnaces and boilers.

Equipment

Nameplate Capacity

enter average value

of up to four ranges

Units

[ kW / MW]

OVENS / DRYERS / KILNS / FURNACES

Annual

Operating

Time

[hrs]

Number of high

efficiency

equipment

[enter number

or NTF*]



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Appendix E A2A Checklist and Action Plan Template

A2A Toolkit



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Are the following features included in your respective systems?

B.1.12

B.1.13

B.1.14

B.1.15

B.1.16

B.1.17

B.1.18

B.1.19

B.1.20

B.1.21

B.1.22

B.1.23

B.1.24

B.1.25

B.1.26

B.1.27

B.1.28

B.1.29


BOILERS

Features

Air curtains or other methods are used at the inlet/outlet of the oven/dryer to minimise

loss of hot air.

Equipment is included in regularly scheduled preventative maintenance program and

includes combustion efficiency testing.

Advanced/Automated boiler controls (e.g. linkage less control)

Boiler water treatment to remove impurities

Deaerator vent losses are minimized through regular inspection or automation

Condensate is returned to the boiler where it is technically feasible

Steam trap surveys completed within past 2 years and faulty traps were repaired

Boilers are included in regularly scheduled preventative maintenance program

At least 90% of insulation is in good condition

Systems have advanced heating/process controls

Adjust air-fuel ratio to optimize combustion efficiency

Automated blowdown control

Makeup water is preheated with heat recovered from other heat sources

Boiler load assessment was conducted when boiler was installed to ensure it is optimumsize.

For multiple boilers load management study was conducted to define optimum load

management strategy.

At least 90% of insulation is in good condition

Infrared or radiant heating is used instead of convection heating

Heat from the flue gas is recovered and used

Rating

Rating


A2A Toolkit



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Additional Opportunities Identified (Describe)

BOILERS

COOLING / REFRIGERATION COMPRESSORS


A2A Toolkit



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B.2 COMPRESSION SYSTEMS

I do not have this equipment--------> Go to Section B-3

Total: 0.0E+00

-

-

-

-

Total: 0.0E+00

-

-

-

-


This section includes Compression Systems at your facility.

This includes air compressors used for pneumatic equipment and air/gas compressors used for process.

What are the energy sources and features of your equipment?

Please indicate the features that are not technically feasible.

Equipment

Nameplate Capacity

[enter average value of

up to four ranges]

Units

[ kW / MW]

Total number

of equipment

in each

Capacity

Range

Energy Source

[nat.gas / elec. /

etc]

Number of high

efficiency

equipment

[enter number or

NTF*]

Average Age of

Equipment

[years]

Annual

Operating

Time

[hrs]

Annual Energy

Use

[GJ]

AIR COMPRESSORS FOR PNEUMATIC EQUIPMENT

AIR OR GAS COMPRESSORS FOR PROCESS



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A2A Toolkit



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AIR OR GAS COMPRESSORS FOR PROCESS

Additional Opportunities Identified (Describe)

AIR COMPRESSORS FOR PNEUMATIC EQUIPMENT


A2A Toolkit



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B.3 MOTORS, PUMPS, FANS and CONVEYORS

Please indicate the inventory of Motors, Conveyors, Pumps and Fans and their features?

If you do not have a list of this inventory, please provide your best estimate. Exclude equipment related to HVAC.

Average Rated

Capacity Range

[kW]

(enter average

value of up to six

ranges)

Total number of

equipment ineach Capacity

Range

Number with VFDs

/ ASDs[enter number or

NTF]

Number of Class

2 Motors[enter number

or NTF*]

Average Ageof Equipment

[years]

Number of

Motors with

Synchronous

Belts

[enter number or

NTF*]

Number of Class

1 Motors[enter number

or NTF*]

Annual

OperatingTime

[hrs]

AnnualEnergy Use

[GJ]

Total: 0.0E+00

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0


This section includes motors and motor-related equipment (fans, pumps, conveyors) at your facility.

PUMPS

FANS

OTHER MOTORS (including those for conveyors)



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A2A Toolkit


B 4 ONSITE TRANSPORT EQUIPMENT


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B.4 ONSITE TRANSPORT EQUIPMENT

I do not have this equipment--------> Go to Section C-1

Please list the onsite transport equipment used at your facility. Please indicate the features that are not technically feasible.

Annual Energy

Use [GJ]

Rated CapacityUnits

[kW / MW]Total: 0.0E+00

-

-

-

-

-* NTF = Not technically Feasible

Are the following features included in your onsite transport equipment systems?

B.4.1

B.4.2

B.4.3

B.4.4

Transport Equipment Opportunities Identified (Describe)

Alternative fuelled vehicles or hybrid technology adopted to reduce energy

consumption

Minimal idling

Preventative vehicle maintenance program

Category or Type of

vehicle

[eg. excavator,

truck, forklift]

Energy Source

[nat.gas / diesel /etc]

Number of

vehicles ofthis type

Average Equipment Rating (incl.

auxiliary equipment)

High Efficiency Battery Chargers for forklift type vehicles

Features

This section includes onsite transport vehicles used at your facility.

Number of high

efficiency

equipment[enter number or

NTF*]

Annual

Operating

Time

[hrs]

Rating


A2A Toolkit



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C.1 LIGHTING

This section includes lighting system features in the entire facility

What lighting is present at the facility?

Annual Energy Use

[GJ]Total: 0.0E+00

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Does your lighting system include the following?

RatingLocation

[interior / exterior /

both

Latest system design

change

MM YYC.1.1

C.1.2

C.1.3

C.1.4

C.1.5 Lighting (auditing) survey completed

Average Rated Capacity

[Watts]

Number of Lamps

that are EnergyEfficient

Fluorescent and

CFL's

Metal Halide

High Pressure

Sodium

Incandescent and

Other

Occupancy sensors

On/off timer settings

Annual Operating

Time[hrs]

Features

High-efficiency ballasts for lighting

Control of lighting system according to zones

or production areas

Total Number of

LampsType of Lighting


A2A Toolkit



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Other:

Equipment / Technology:

Control:

Lighting System Energy Efficiency Opportunities Identified (Describe)


A2A Toolkit


C 2 HEATING VENTILATION and AIR CONDITIONING (HVAC)


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C.2 HEATING, VENTILATION and AIR CONDITIONING (HVAC)

Please list any HVAC equipment (equipment with the highest energy-use).

I do not have this equipment

Rated

Capacity

Units

[ kW /

MW]

Rated

Capacity

Units

[cooling ton

/ kW / HP]

-

-

-

-

- * NTF = Not technically Feasible Total: 0.0E+00

Does your plant contain any /all equipment below for ventilation?

I do not have this equipment

Rated

Capacity

Units

[ kW /

MW]

-

-Total: 0.0E+00

Average

Equipment

Age

[years]

Average

Equipment

Age

[years]

Air exhaust system(s)

Total Motor Power

Energy Source

[nat.gas / elec / etc]Process equipment description

Annual

Operating

Time

[hrs]

Air make-up system(s)

Annual

Energy Use

[GJ]

Avg Unit Cooling

Capacity

Number of

high efficiencyequipment

[enter number

or NTF*]

Annual

Energy Use

[GJ]

Annual

Operating

Time

[hrs]

This section includes all HVAC equipment in the facility, including that used in offices and the plant.

Energy Source

[nat.gas / elec /

etc]

Avg Unit Heating

CapacityNumber of

equipment

in of this

type

Categories / Typesof Equipment

[eg. radiant heaters/

convection heaters /

chillers / window air

conditioning]


A2A Toolkit


Does your HVAC system include the following?


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Does your HVAC system include the following?

C.2.1

C.2.2

C.2.3

C.2.4

C.2.5

C.2.6

C.2.7

C.2.8

C.2.9

C.2.10

C.2.11

C.2.12

C.2.13

C.2.14

C.2.15

C.2.16

Radiant heaters are used in areas close to loading dock doors and where

convection heating is not required

Loading docks are well insulated, sealed and managed to minimise loss of

heated/cooled air

Within last 3 years an assessment was conducted to determine ventilation

requirements and ventilation system was optimised.

Recover heat from process or exhaust gas to heat make-up air

Premium efficiency motors on fans

System uses free cooling

System uses variable speed fans

Destratification fans are used to reduce air stratification in large areas.

System uses demand-controlled ventilation

The HVAC system is included in scheduled preventative maintenance

program.

An assessment was made to install solar walls to heat ventilation air

Features Rating

Heat pumps for cooling/heating

Different heating and cooling set points for seasonal and daily fluctuations

Set back temperatures when facility is not occupied, e.g. during weekends

Recover heat from exhaust flow

Automated plant HVAC control system


A2A Toolkit


HVAC Opportunities Identified (Describe)


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HVAC

Other Heating Equipment

Air Make-up and Exhaust

Other

HVAC Opportunities Identified (Describe)



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A2A Toolkit



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D.2 GENERAL FACILITY PRACTICESPlease indicate if your facility practices include any of the following?

D.2.1

D.2.2

D.2.3

D.2.4

D.2.5

D.2.6 Heat exchanger maintenance and repair is

D.2.7 Heat exchanger optimization completed periodically

D.2.8D.2.9

D.3 EMERGING TECHNOLOGY Are there any other emerging technologies you are considering or you have implemented in your facility?

Features

What is the power factor for your facility? (enter value


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A2A Toolkit



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E.2 AMMONIA PROCESS PRACTICES - GeneralPlease indicate if your facility practices include any of the following?

E.2.1

E.2.2

E.2.3

E.2.4

E.2.5

E.2.6

E.2.7

E.2.8

E.2.9

E.2.10

E.2.11

E.2.12

E.2.13E.2.14

E.2.15

E.2.16

E.2.17

E.2.18

E.2.19

E.2.20

E.2.21

E.2.22

E.2.23E.2.24

E.2.25

E.2.26

E.2.27

E.2.28

Optimized Refrigeration Levels

Retrofit of Gas Turbine for improved Efficiency

Supplemental reboiler to heat CO2 removal condensate

2 Stage Stripping for CO2 Removal Solvent in the process

CO2 Removal Condensate Reboiler installed

Synthesis Gas Molecular Sieve Dryer and Direct Synthesis Converter Feed in process

Optimized Control of Refrigeration Inerts

Warm Ammonia Delivery to Consumers

Compressor Seal Gas Leakoff Recovery

Low-Pressure difference synthesis reactor

Waste Heat Recovery from Lean Solvent

Optimized Loop Recycle Flow

Recovery and Recycle of Flashed gases

Improved steam turbine design to improve efficiency

Axial-radial flow converter to improve conversion efficiency and reduce pressure drop

High Efficiency Packings and Internals for CO2 Removal Columns

Pressure Swing Adsorption for product purification

Improved catalysts in Shift Process

Hydrogen separation and recovery from synthesis gases

RatingFeatures

Installation of Gas Turbine to drive process air compression, using hot exhaust gases

Improved Ammonia synthesis catalysts

Improved Design for Shift Converter Gas Distributor and Collector

Flash of CO2 Solvent with Ejectors or Mechanical Recompression

Isothermal CO converter with built in heat exchanger

Enhanced CO2 removal solvents

High Conversion Synthesis Reactor (indirect cooling) to remove reaction heat

Waste heat recovery from compressor synthesis gas

Advanced Process Control to optimize Ammonia synthesis process


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E.3 AMMONIA PROCESS PRACTICES - Natural Gas

This type of fuel is NOT used --> This is the last page of the survey

Please indicate if your facility practices include any of the following?

E.3.1

E.3.2E.3.3

E.3.4

E.3.5

E.3.6

E.3.7

E.3.8

E.3.9

E.3.10

E.3.11

E.3.12

E.3.13

E.3.14

E.3.15

E.3.16

E.3.17

E.3.18

E.3.19

E.3.20

Reformer tubes are made of micro alloys with minimum permitted wall thickness

Improved catalysts in reforming process

Saturation of feed gas with recycle process condensate to allow export of steam

Radian section of primary reformer refractory has high emissivity coating

Increase mixed feed preheat temperature, convection modifications to optimize process energy use in process

Improved secondary reformer burner design to optimize reform reaction equilibrium at exit.

Optimize (reduce) secondary reformer catalyst volume/ redesigned collector

Recycle of hydrogen to primary reformer improves catalyst performance

Improved arch seals at primary reformer that reduce leakage while permitting thermal movement of tubes

Rating

Modified reformer operating Pressure

High Pressure water power recovery turbine to drive absorbent liquid pump

Lower reformer steam-carbon ratio to reduce primary reformer heat demand

Waste Heat to preheat fuel gas

Adiabatic pre-reformer to reduce primary reformer duty

Waste heat recovery from reformer using heat exchanger reactorWaste Heat Recovery from reformer flue Gas

Improved insulation of reformer furnace

Expansion of fuel gas for power recovery

Features

Optimized shift reformer duty balance between primary and secondary reformer

Other Notes or Remarks

This is the last page of this survey. Thank you very much for your time and assistance.

Isobaric ammonia manufacturing


A2A Toolkit


Energy Balance


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Equipment energy-reported GJ/yr1 2 3 4 5 6 8 7

Electricity Natural Gas Diesel Fuel Oil Gasoline PropaneBiomass /

Other fuelSteam

Cooling / Refrigeration - - - - - - -

Boilers - - - - - - - -

Ovens / Dryers / Kilns / Furnaces - - - - - - - -

Pneumatic Compressors - - - - - - - Air or Gas Compressors - - - - - - - -

Fans, Motors, Pumps -

Heavy Transport - - - - - -

HVAC and Air System - - - - - - - -

System & Other Process - - - - - - - -

Ammonia production - - - - - - - -

Lighting -

Total energy/year - - - - - - - -

Energy Balance

Electricity Natural Gas Diesel Fuel Oil Gasoline Propane Other fuels Steam

Purchased Energy (GJ/yr) - - - - - - - - Sold Energy* (GJ/yr) - - - - - - - -

Net Purchased Energy (GJ/yr) - - - - - - - -

Self Generated Energy (GJ/yr) - -

Net Imported Energy (GJ/yr) - - - - - - - -

Adjustment Factor - - - - - - - -

Equipment / Purchased ratio - - - - - - - - * Energy content of sold steam is converted back to the fuel used to generate steam with an adjustment factor for efficiency of conversion (see TA2)

Equipment energy-adjusted GJ/yr

Electricity Natural Gas Diesel Fuel Oil Gasoline Propane Other fuels Steam

Cooling / Refrigeration - - - - - - - -

Boilers - - - - - - - -

Ovens / Dryers / Kilns / Furnaces - - - - - - - -

Pneumatic Compressors - - - - - - - -

Air or Gas Compressors - - - - - - - -

Fans, Motors, Pumps - - - - - - - -

Heavy Transport - - - - - - - -

HVAC and Air System - - - - - - - -

System & Other Process - - - - - - - -

Ammonia production - - - - - - - -

Lighting - - - - - - - -

Total energy/year - - - - - - - -


A2A Toolkit


Year of Evaluation 2009


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Energy Share By End Use Steam energy by end useAll Energy GJ/year % of Total GJ/year % of Total

Cooling / Refrigeration #N/A #N/A #N/A #N/A

Boilers #N/A #N/A #N/A #N/A

Ovens / Dryers / Kilns / Furnaces #N/A #N/A #N/A #N/A

Pneumatic Compressors #N/A #N/A #N/A #N/A

Air or Gas Compressors #N/A #N/A #N/A #N/A

Fans, Motors, Pumps #N/A #N/A #N/A #N/AHeavy Transport #N/A #N/A #N/A #N/A

HVAC and Air System #N/A #N/A #N/A #N/A

System & Other Process #N/A #N/A #N/A #N/A

Ammonia production #N/A #N/A #N/A #N/A

Lighting #N/A #N/A #N/A #N/A

Total - -

Purchased Energy By Fuel Typennua et

Purchased

Energy [GJ]

Annual Purchased

Energy Cost [$]

GJ Cost ($)

Electricity #N/A -

Natural Gas #N/A -

Diesel #N/A -

Fuel Oil #N/A -

Gasoline #N/A -

Propane #N/A -

Other fuels #N/A -

Steam #N/A -

Total - -

Energy Share By End Use

Electricity

0%

Natural Gas

0%

Diesel

0%

Fuel Oil

0%

Gasoline

0%

Propane

0%

Other fuels

0%

Steam

0%

Annual Purchased Energy Cost

[$]


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Energy1,2

GJ Weight1

kg Volume1

L Power Units1

kW Energy1,2

TCE

GJ 1 ton (metric) 1000 gallon 3.785 BHP 0.746 GJ 0.034129693

kWh 0.0036 ton [short] 907 ft3 28.317 HP 0.7355 kWh 0.000122867

kVA 0.0036 ton [long] 1,016 L 1 BTU/hr 0.000293 kVA 0.000122867

TCE 29.3 kg 1 m3 1000 MMBTU/hr 293.0711 TCE 1

kgCE 0.0293 lbs 0.454 Cooling Ton 3.517 kgCE 0.001BTU 1.05506E-06 lb 0.454 Boiler HP 9.8095 BTU 3.60087E-08

kCal 4.19E-06 kW 1 kCal 1.42867E-07

MMBTU 1.05506 MW 1000 MMBTU 0.036008874

References

1. www.engineeringtoolbox.com

2. LBNL BEST tool

Conversion Tables (Multiplication Factors)


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Appendix C A2A Energy Management System Assessment

A2A Toolkit

Energy Management System Assessment


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Plant Name

Company Name

Sub-sector (choose from menu)

Plant Address:

Street and number

City

Province

Postal codePlant Telephone Number

Name

Title (Position)

E-mail Address

Telephone Number

Name of Auditor

Title of Auditor

Auditor's Organization / Company Name

Direct Telephone Number

E-mail address

Date of Audit

Confidential Plant Information

Auditor Information

Plant Contact Info

Institute for Industrial Productivity


TO DO:

STEP 1 - Please complete the contact information requested on this page.

STEP 2 - Review instructions sheet and complete the questions on the next pages.

The survey questionnaire is the ownership of IIP and ICF Marbek. Any use of the survey by another party requires to be granted permission by IIP or ICF Marbek

prior to use.

IIP / ICF Marbek Page 1 of 10 MA 1

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1.1

1.2

1.3

1.4

1.5

%

1.6

1.7

1.8

1.9

1.10

1.11

If no, does the company intend to develop a carbon management plan?

Has the company calculated the GHG footprint of the plant, company or both?

What is the plant’s current annual operating cost reduction target? [%/year]

What percentage of the plant’s total operating costs in the latest fiscal year was represented by purchased energy

costs?

1.0 Corporate Information

Does the company have a plan to phase out old equipment over a specific period of time?

What is the company’s desired return on investment on a capital project designed to improve energy use

performance and reduce energy operating costs? (Can be expressed in terms of simple payback, NPV or IRR)

Has the plant adopted any elements of a nationally recognised Energy Management standard?

What is the company’s current annual operating cost reducti

Documents

A2A User Guideline - IfA V1