APPLIED INDUSTRIAL ENERGY AND ENVIRONMENTAL MANAGEMENT · PDF fileAPPLIED INDUSTRIAL ENERGY AND ENVIRONMENTAL MANAGEMENT ... Applied Industrial Energy and Environmental Management

APPLIED INDUSTRIAL ENERGY AND ENVIRONMENTAL MANAGEMENT Z. K. Morvay, D. D. Gvozdenac

Part III:

FUNDAMENTALS FOR ANALYSIS AND CALCULATION OF ENERGY AND

ENVIRONMENTAL PERFORMANCE

1

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 2

1. Awareness and Motivation for Energy Performance

Improvements 2

Checklist 2

2. Analysis of Energy Management Practice 2

Questionnaire for Energy Management Audit 2

Checklist for Metering And Control 5

Checklist for Housekeeping Needs for Industrial Plants 6

Questionnaires for Training Needs Assessment 7

Questionnaire for Line Managers 7

Questionnaire for Technical Personnel 8

Questionnaire for Maintenance Staff 10

Training Recommendations 11

Part B: Environmental Management 12

1. Motivation for Environmental Management 12

2. Company Commitment 13

3. Key Environmental Issues Associated with Company

Operations 14

4. Water and Wastewater Management 15

5. Air Emissions 15

6. Solid Waste Management 16

7. Effective Spill Prevention and Response Program 17

8. Hazardous Materials Management 18

9. Package 18

10. Measuring Environmental Performance 18

11. Environmental Risk Prevention Program 19

Part III – Toolbox 1:

AUDITING OF ENERGY AND ENVIRONMENTAL MANAGEMENT PRACTICE 2

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 organization’s 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 don’t?

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

2. 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:



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

4. If periodically, when was last review?

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).

6. Does the analysis identify the relationship between consumption of energy and

level of activity?

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



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?



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 M’s

If we can’t Measure, then we can’t 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


Any load > 50 kW

Refrigeration


(buildings)

Any load >50 kW



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 10–100 meters

Steam 3–20 meters

Compressed air 3–10 meters

Refrigeration 3–10 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)



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

the organization. 1 2 3 4 5

T&D

needs

A2: Identifying and evaluating opportunities to improve

energy performance. 1 2 3 4 5

T&D

needs

A3: Advising on ways to formulate and implement

effective energy performance improvement measures

throughout the organization. 1 2 3 4 5

T&D

needs

Section B: Performance and Control

Staff names:

B1: Developing awareness of energy efficiency 1 2 3 4 5 T&D

needs

B2: Advising and supporting individuals and teams

with regard to measuring energy performance 1 2 3 4 5

T&D

needs

B3: Reviewing the energy performance of the

organization 1 2 3 4 5

T&D

needs

B4: Supporting continuous improvement in the use of

energy 1 2 3 4 5

T&D

needs



Section C: Financial aspects

Staff names:

C1: Selecting suppliers for specified supplies on a life

cycle cost basis 1 2 3 4 5

T&D

needs

C2: Contracting for supply 1 2 3 4 5 T&D

needs

C3: Recommending, monitoring and controlling the use

of resources 1 2 3 4 5

T&D

needs

2.4.2 Questionnaire for Technical Personnel




Section A: Energy Management Techniques

1. Measurement and metering 1 2 3 4 5

T&D

need

s

2. Monitoring and targeting 1 2 3 4 5

T&D

need

s

3. Marketing energy efficiency 1 2 3 4 5

T&D

need

s

4. Motivating people 1 2 3 4 5

T&D

need

s

5. Reporting and informing on energy management

results 1 2 3 4 5

T&D

need

s

6. Preparing proposals for energy efficiency projects to

the management board 1 2 3 4 5

T&D

need

s

7. Cost evaluation of energy efficient equipment 1 2 3 4 5

T&D

need

s



Section B: Best Operational Practices

1. Boilers 1 2 3 4 5

T&D

need

s

2. Steam management 1 2 3 4 5

T&D

need

s

3. Condensate system 1 2 3 4 5

T&D

need

s

4. Refrigeration systems 1 2 3 4 5

T&D

need

s

5. Compressed air systems 1 2 3 4 5

T&D

need

s

6. Air conditioning 1 2 3 4 5

T&D

need

s

7. Electric motors 1 2 3 4 5

T&D

need

s

8. Peak load control 1 2 3 4 5

T&D

need

s

9. Reactive power compensation 1 2 3 4 5

T&D

need

s

10. Lighting 1 2 3 4 5

T&D

need

s

11. Water system 1 2 3 4 5

T&D

need

s

12. Preventive maintenance system 1 2 3 4 5

T&D

need

s



Section C: Technologies

1. Variable speed drives 1 2 3 4 5

T&D

need

s

2. Computerized energy management systems 1 2 3 4 5

T&D

need

s

3. Efficient electric motors 1 2 3 4 5

T&D

need

s

4. Low temperature waste heat recovery 1 2 3 4 5

T&D

need

s

5. High temperature waste heat recovery 1 2 3 4 5

T&D

need

s

6. Combined heat and power generation 1 2 3 4 5

T&D

need

s

7. Process integration techniques 1 2 3 4 5

T&D

need

s

8. Advanced control systems 1 2 3 4 5

T&D

need

s

9. Absorption chillers 1 2 3 4 5

T&D

need

s

10. Optimal insulation thickness 1 2 3 4 5

T&D

need

s

11. Efficient lighting systems 1 2 3 4 5

T&D

need

s



2.4.3 Questionnaire for Maintenance Staff




Section A: Housekeeping

1. Importance of leak prevention and elimination

(steam, compressed air, chilled water, water ) 1 2 3 4 5

T&D

need

s

2. Piping, valves and flanges insulation 1 2 3 4 5

T&D

need

s

3. Cleaning of fixtures and luminaries of lighting

systems 1 2 3 4 5

T&D

need

s

4. Lubrication 1 2 3 4 5

T&D

need

s

5. Adequate cooling of electric motors 1 2 3 4 5

T&D

need

s

6. Checking steam traps and maintenance 1 2 3 4 5

T&D

need

s

7. Condensate return and insulation of condensate

system 1 2 3 4 5

T&D

need

s



Section B: Preventive Maintenance Practice

1. Boilers 1 2 3 4 5

T&D

need

s

2. Steam distribution 1 2 3 4 5

T&D

need

s

3. Condensate system 1 2 3 4 5

T&D

need

s

4. Chillers 1 2 3 4 5

T&D

need

s

5. Air compressors 1 2 3 4 5

T&D

need

s

6. Air conditioners 1 2 3 4 5

T&D

need

s

7. Electric motors for pumps and fans 1 2 3 4 5

T&D

need

s

8. Peak load control 1 2 3 4 5

T&D

need

s

9. Reactive power compensation 1 2 3 4 5

T&D

need

s

10. Lighting 1 2 3 4 5

T&D

need

s

11. Water treatment 1 2 3 4 5

T&D

need

s

12. Filters 1 2 3 4 5

T&D

need

s

13. Cooling towers 1 2 3 4 5

T&D

need

s

14. Condensers 1 2 3 4 5

T&D

need

s

15. Evaporators 1 2 3 4 5

T&D

need

s

16. Metering and control 1 2 3 4 5

T&D

need

s



2.5 Training Recommendations

The recommended training topics for

three target groups, listed in order of

priority :

Recommended

training provider(s),

Comments

Managers

1.

2.

3.

4.

5.

Persons responsible for energy

1.

2.

3.

4.

5.

Staff

1.

2.

3.

4.

5.



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?



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)



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 company’s 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



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?



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



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



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?



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



11. Environmental Risk Prevention Program

Describe the environmental risk prevention program that has been developed and

implemented?

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APPLIED INDUSTRIAL ENERGY AND ENVIRONMENTAL MANAGEMENT · PDF fileAPPLIED INDUSTRIAL ENERGY AND ENVIRONMENTAL MANAGEMENT ... Applied Industrial Energy and Environmental Management