Energy Management System ISO 50001 Training Course ENG.pdf · Energy Management System ISO 50001 Training Course Dipl.-Ing. Thomas Frank ... Management Review Correction and Preventive

© 2011 by Envidatec 1

Energy Management System

ISO 50001

Training Course

Dipl.-Ing. Thomas FrankEnvidatec GmbH

Hamburg


Trainings Agenda, 8 Blocks in 2 days

Day 1:

1) Introduction to energy management in generalshort break

1) Introduction to ISO 50001 / DIN EN 16001lunch break

1) Differences / Integration ISO 14000 vs. ISO 50001short break

1) Presentation of the individual topics of ISO 50001

Day 2:

1) Details measuring techniqueshort break

1) Details energy controllinglunch break

1) Practical examples of energy efficiency measuresshort break

1) Further topics / concluding discussion


Corporate Development

● 2001 Foundation of the central office in Hamburgfor expertise on the efficient use of energy

● 2004 Starting a branch office in Vienna as a scientific centre for research and development

● 2007 Foundation of the omtec Energiemanagement GmbH, Vienna● 2009 Establishment of: Energy-efficient into the Future! –

DIN EN 16001● 2010 Starting branch office Envidatec-Ost in Yekaterinburg, Russia

● Company Envidatec founded out of E.ON as an independent business to be a centre of expertise on energy management systems.

● Central area of expertise is energy efficiency analysis, individual tailoring of solutions to reduce costs, and the implementation of said solutions.

● Service provision, hardware and software for efficient energy use.


Company Structure

HeadquartersHamburg

● Executive Management● Sales and Marketing● Product Management● Project Implementation● Development● Support und Training

Hamburg

Representation in Austria

● Sales and Consulting Services● Project Implementation

Eastern Branch Office

Envidatec OstYekaterinburg, Russia

● Sales and Consulting Services● Project Implementation

Omtec Energiemanagement GmbHVienna


Introduction toEnergy Management in general


Energy Management System Envidatec GmbH

Analysis & Conceptualisation:

Energy Efficiency Analysis,Implementation Concepts,

Energy ManagementSystems

Project Implementation& Supervision:

Project Leadership,Installation,

Training

Systematic Solutions:Energy and Operations,

Data Management,My-JEVis

System ControlData Logging

BusinessSegments


Energy Management System Legal Framework (Selection)

● Energieeinsparungsgesetz EnEG, Energy Savings Law● Energieeinsparverordnung EnEV, Energy Savings Ordinance● Erneuerbare-Energien-Gesetz EEG, Renewable Energy Law● Erneuerbare-Energien-Wärmegesetz EEWärmeG, Law on

Renewable Energy in Heating● Bundes-Immissionsschutzgesetz BimSchG, Federal Emissions

Control Law● Energieeffizienzgesetz EnEfG (Entwurf), Energy Efficiency Law

(Draft)


Energy Management System Introduction of Regulatory System in Germany

Stage 4(begins 2013)

Updates to Energy Management Systems(Mandatory for Companies;

will be a condition for Energy Tax Rebates)


Introduction of Management Processes; aimed at bringing about continuous improvement

Advocacy for the Introduction of Energy Management Systems (EnMS)

Energy Data Recording and Systematisation;Development of Energy Management Structures

(Conditions for an Energy Tax Rebate - Transitional Phase)

Stage 1(2008)



Energy EfficiencyAnalysis

Optimisation

ISO 50001

Monitor andMeasure

EnMS according to

Continuous Controlof Improvement

Energy Management System ISO 50001A Process of Continuous Improvement


Energy Management System ISO 50001Central Ideas

Goals

● To offer support in the development of systems and processes which improve energy efficiency

● Systematic energy management leads to:● Reduction of costs● Reduction of greenhouse gas emissions

● Develop a corporate energy policy● Define aims and processes● Take into account necessary measures to improve output

Success is only attainable with the support of all departments, at all levels, including top-level management


Mehr Energieeffizienz für More

Energy Efficiencyfor

Industry and

Manufacturing

PowerProducers

Property Management/Building Serv.

Engineers

Hospitals,Banks, Schools,

Universities, Recreation Centres...

Target Groups for Energy Management

ChainStores


Client

Put newRegulations /

Guidelines in place

ImageCultivation

(GreenCompany)

Oversightof

Energy UseReductionof

Energy Costs

Implemen-tation of

Sustainable,Effective

Processes

Implement anOptimised

Mix of Energy

Secure Tax Rebates

Energy Management Customer's Benefits


Monitor and Measure

Planning

Implementation and Operation

Energy Policy

Internal Audit Checking andCorrective Action

ManagementReview

Correction andPreventive Action

Energy Management System ISO 50001


Coffee Break


Introduction toISO 50001 / DIN EN 16001


Energy Management System The origin of ISO 50001 / DIN EN 16001

• DIN EN 16001 adopted in July 2009 in Europe

• Based on PDCA-cycle• Nearly identical to ISO 50001• Same Structure as ISO 14001• Related to VDI 4602 (German

engineering norm about energy management)


Definition of Energy Management System

From VDI 4602:

“Energy management is the forward-looking, organised and systematic co-ordination of the procurement, conversion, distribution and utilisation of energy in order to cover requirements and which takes ecological and economic objectives into consideration.”

“The term “energy management system” covers not only the organisational and information structures required for implementing the energy management system but also the technical resources needed for this (software and hardware, for example).”


Monitor and Measure

Planning


Energy Policy


ManagementReview




ISO 50001 – Terms and DefinitionsAction Plan (3.1)

Activities with defined responsibilities and a beginning and end.

Boundaries (3.2)

Physical or site limits and/or organisational limits as defined by the organisation.

Continual Improvement (3.11)

Recurrent activity to enhance energy performance and the energy management system.

NOTE 1: The process of establishing objectives and finding opportunities for improvement is a continual process. Continual improvement can achieve improvements in overall energy performance, consistent with the organisation's energy policy.

NOTE 2: Adapted from ISO 9000


ISO 50001 – Terms and DefinitionsEnergy Management System (EnMS or EMS) (3.3)

Set of interrelated or interacting elements of an organization to establish energy policy and objectives and to achieve those objectives.

Energy Policy (3.4)

Overall intentions and direction of an organization related to its energy performance as formally expressed by top management that provides a framework for action.

Energy (3.5)

Electricity, fuel, steam, heat, compressed air, renewables and other like media.

NOTE: For the purpose of this standard, energy refers to the various forms of primary or secondary energy which can be purchased, stored, treated or used in equipment or in a process.


ISO 50001 – Terms and DefinitionsEnergy use (3.6)

Manner or kind of application of energy.

NOTE 1: Examples are ventilation, heating, processes, production lines.NOTE 2: The quantity of the energy applied is expressed as energy

consumption.

Energy baseline (3.7)

Quantitative reference providing a basis for comparison of energy performance

Energy efficiency (3.8)

Engineering accepted use of the term by the organisation.

NOTE: Examples are conversion efficiency, energy required/energy used, output/input, theoretical energy used to operate/energy used to operate.


ISO 50001 – Terms and DefinitionsEnergy profile (3.10)

Status of the organisation's energy performance.

Energy performance (3.9)

Measurable results related to energy.

Examples: energy efficiency, energy intensity (the inverse of energy efficiency), specific energy use, energy consumption (energy use divided by product or other appropriate variable etc.).

Energy performance indicator (EnPI) (3.12)

Quantitative index of energy performance as defined by the organisation.

NOTE: Quantifying the amount of energy used or saved per normalised unit of appropriate variable.


ISO 50001 – Terms and Definitions

Energy Efficiency

Energy Consumption

Energy Intensity

Energy Performance

Specific Energy Use


ISO 50001 – Terms and DefinitionsNonconformity (3.13)

Non-fulfillment of a requirement.

Objective (3.14)

Desired outcome or achievement set to meet the organisation's policy related to energy.

Organisation (3.15)

Company, corporation, firm, enterprise, authority or institution, or part or combination thereof, whether incorporated or not, public or private, that has its own functions and administration and that has the authority to control its energy use and consumption.

Team (3.24)

person or person(s) responsible for effective implementation of the energy management system activities and delivering energy performance improvements


ISO 50001 – Terms and DefinitionsProcedure (3.16)

Specified way to carry out an activity or a process.

NOTE 1: Procedures can be documented or not.

NOTE 2: When a procedure is documented, the term “written procedure” or “documented procedure is frequently used. The document that contains a procedure can be called a "procedure document.”

Significant energy use (3.17)

Energy use accounting for substantial energy consumption and/or offering considerable potential for energy performance improvement.

Target (3.18)

Measurable performance requirement to be set and met to achieve part or all of an objective.


ISO 50001 – Terms and DefinitionsDocument (3.19)

Information and its support medium

NOTE 1: The medium can be paper, magnetic, electronic or optical computer disc, photograph or master sample or a combination thereof.

NOTE 2: A set of documents, for example specifications and records, is frequently called "documentation."

NOTE 3: Some requirements (e.g. the requirements to be readable) relate to all types of documents, however, there can be different requirements for specifications (e.g. the requirements to be revision controlled) and records (e.g. the requirement to be retrievable).


ISO 50001 – Terms and DefinitionsRecord (3.20)

Document stating results achieved or providing evidence of activities performed.

NOTE: Records can be used, for example, to document traceability and to provide evidence of verification, preventive action and corrective action.

Top management (3.21)

Person or group of people who directs or controls an organisation at the highest level.

NOTE: Top management controls the organization defined within the scope of the management system for energy.


ISO 50001 – Terms and DefinitionsCorrective action (3.22)

Action to eliminate the cause of a detected nonconformity or other undesirable situation.

NOTE: There can be more than one cause for a nonconformity.

Preventive action (3.23)

Action to eliminate the cause of a potential nonconformity or other undesirable potential situation.

NOTE 1: There can be more than one cause for a potential nonconformity.

NOTE 2: Preventive action is taken to prevent occurrence whereas corrective action is taken to prevent recurrence.


Special Requirements of ISO 50001

Important conditions in the organisation for the functioning of an energy management system:● Energy Team

● authorised by the top management● acting as “management representative”

● Documentation● collection of documents concerning energy use,

processes, installations and work flows as well as reports and reviews

● has to be maintained (“up to date”) and be accessible to the personnel



The Energy Team should:

● identify the facilities, equipment, processes and personnel working for or on behalf of the organisation that significantly affect energy consumption and demand, significant energy uses and cost;

● identify other relevant variables affecting energy consumption;

● establish energy performance indicators;● record the method(s) for identifying these significant energy

uses;● review the identified significant energy uses on a regular

basis;● modify the list of significant energy uses as operational and

facility changes occur; and● identify and prioritise opportunities for improving energy

performance.



The members of the Energy Team should have:

● the skill through appropriate experience of more than one year;

● appropriate training or qualification related to energy management;

● knowledge of theories for improving energy management system; and

● a central role in promoting energy efficiency in the field.



Documentation requirementsThe level of detail within the system documentation should be sufficient to describe the energy management system and the interaction between its processes, systems and activities. This documentation should be better to integrate with existing management systems implemented by the organisation.

The extent of energy management system documentation may differ from one organisation and another,depending on:● the size and type of organisation and its energy uses;● the complexity of process and their interactions;● the competence of personnel; and● the maturity of organisation’s management system.



Important energy terms for the report and review process:

● Energy Profile

● Energy Baseline

● Energy Performance Indicators (EnPIs)



Energy Profile (1)The purpose of developing an energy profile of the organization is to understand the areas of significant energy consumption

I.e. the buildings, equipment and processes which account for the greatest energy use or which offer the most potential for energy savings

The identification of the energy profile is critical in understanding where energy is used within the organization and forms the basis for prioritizing the efforts to reduce energy consumption.

The organization that intends to implement an energy management system should start by establishing its current position.



Energy Profile (2)a) Analyse energy use based on measurement and other data1. How much energy the organization is consuming and its trends, changes, anomalies, etc.2. Estimate how much energy will be consumed in the coming period, typically the next financial budget period.3. Examine where energy is currently being sourced which will typically be a local utility company and examine other potential sources including e.g. internal waste heat.

b) Based on energy use analysis, identify the areas of significant energy use1. Where the energy is being used, i.e. what are the significant consumers?2. What is driving the energy use? This is often difficult to determine but is very important.3. Which people have significant impact on energy use and identifies their relevant training needs.



Energy Profile (3)c) Identify and prioritize opportunities for improving energy performance, including use of renewable or alternative energy sources, where applicable.1. Identify energy reduction opportunities by a variety of means, e.g. analysis of the data from (a) and (b), energy audits and studies, examination of EnPIs, etc. 2. Prioritize the known opportunities based on the organizations normal work and investment prioritization criteria.3. It may be relevant to examine the technical and financial costs and benefits of renewable or alternative energy sources such as biomass, solar, wind, co-generation, etc.

The organisation's energy use will change on an ongoing basis due to plant changes such as new buildings or equipment, energy performance changes, changes of personnel, etc. Organizations will typically update the energy profile on a regular basis, e.g. annually or when a significant change occurs.



Energy BaselineThe energy baseline shall be established using the information in the initial energy profile considering a minimum of 12 months of data (cause of seasonal variations)Significant organizational changes that affect the validity of the EnPIs may be reasons to adjust the baseline. These may include changes in:● product mix● production levels● operating schedule● facility infrastructure● equipment and systems● new energy resources● legal or regulatory requirements

The EnPIs and baseline should be generated using as long period of relevant data as possible



Energy Performance Indicators (EnPIs)EnPIs are a quantitative index of energy performance as defined by the organization. The concept of an EnPI can be used to compare organizational performance at different points in time.

● The organization shall identify EnPIs to be used to determine energy performance and to subsequently evaluate progress towards objectives and targets.

● The method(s) used for definition and update of the EnPIs shall be recorded.

● EnPIs shall be reviewed and compared to the energy baseline on a regular basis.

Methods for defining EnPI will vary depending on the organization’s operations and complexity. EnPI should be easy to understand which will aid its usefulness for sharing information and improving motivation to make improvements.



Energy Performance Indicators (EnPIs)

Examples and Notes:● Comparison of annual energy use with targeted use.● Energy consumption divided by production● Comparison of normalized energy consumption with production

amount, actual seasonal temperature, number of customers, length of service time, and so on (Benchmarking). Methods for normalization may vary such as linear compensation, or a theoretical calculation.

● When the organization chooses EnPIs whose variables are not being measured, a measurement plan should be developed and implemented.

● EnPIs can be made relevant for different functions and levels in the organization. E.g. for top management, EnPIs are typically translated to relate cost impacts and to support strategic goals.

● Trends in the EnPI should demonstrate continual improvement of the energy performance of the organization.


Lunch Break


Differences / IntegrationISO 14001 vs. ISO 50001


Integration of ISO 50001 in other Standards

● EMAS III● ISO 14001● DIN EN 16001


Similarities ISO 14001 / ISO 50001

● Same structure / outline (PDCA-cycle)

● Same items / denominations of elements of standard

● Same “philosophy” (continuous improvement, creation of a system, individual “Energy Manager”)


Differences ISO 14001 / ISO 50001 (1)

● Additional – energy specific – terms and definitions● Provide resources for obtaining information and for

achievement of objectives● Itemisation of possibilities for energy savings,

energy performance indicators● Nomination of an energy manager – reporting to the

top-management● Requirements in the operational controls (energetic

considerations for the purchasing department, criteria for the operation and maintenance)


Differences ISO 14001 / ISO 50001 (2)

● Estimation of the potentials for more efficient energy “as soon as possible”

● Management Review: decisions and actions to improve the energy performance

● Regular, detailed energy reviews (not only once, as in the environmental assessment)

● Check-list


Integration of ISO 50001 into ISO 14001 (1)

Energy Policy:

● includes the term Energy Efficiency● Energy objectives have to be measurable,

documented, and labelled with a time-frame● includes a commitment to ensure the availability of

information and of all necessary resources to achieve objectives and targets



Planning

To add to ISO 14001:● Energetic aspects● Energy indicators● Prominent areas of energy consumptions: summary of

changes in retrospective and estimation of future energy consumptions




To add to ISO 14001:● Qualification and competence of management

representative concerning energy efficiency● Additional topic for training: energy● Energetic consideration in procurement, energy

efficiency as a criterion● Rate the energy consumption in the interpretation,

modification or repair of any assets, including buildings, with substantial impact on energy consumption



Monitor and Measure

To add to ISO 14001:● Set the relationship between energy consumption and

associated factors for every practicable case and assess the actual energy consumption compared to the expected at fixed time intervals.

● Hold records of all significant unplanned deviations from the expected energy consumption, including the reasons and remedies.

● The relationships between energy consumption and energy factors must be reviewed at set intervals and revised as necessary.

● Whenever possible, the organisation has to compare the indicators for their energetic performance with similar internal or external organisations or constellations.


Integration of ISO 50001 into ISO 14001 (5) – The special Role of the Energy Team

Top-Management(Energy Manager)

Energy Representativeother leader boards

Finance / Controlling Production Marketing Personnel

Energy Officer

...Energy Officer

...

...

Energy Officer

...

Energy Officer

...

...

...

...

= Energy Team


Coffee Break


Presentation of the individual topicsof ISO 50001


Monitor and Measure

Planning


Energy Policy


ManagementReview


Energy Management System ISO 50001 Topics


Energy Policy

● Determine energy policy objectives with those responsible (Top Management)

● Cover all aspects of energy implementation● Define areas affected● Determine which parties are responsible● Commit to continuous improvement● Specify resources needed to achieve objectives● Supply adequate information



Energy Policy

Top Management shall ensure that the energy policy:● defines and documents the scope and boundaries of

the energy management system● is appropriate to the nature and scale of, and impact

on, the organisation's energy use● provides the framework for setting and reviewing

energy objectives and targets● supports the purchase of energy efficient products

and services● is documented, communicated, and understood

within the organisation, and● is regularly reviewed and updated



Planning

● Investigation and testing of existing energy implementation● Analysis of energy usage● Estimation of expected energy usage ● Identification of areas for potential improvement● Identification of all persons and their activities, which affect

total energy usage● Accounting for compliance with legal requirements● Determination of responsibilities● Goals have to be measurable, documented, and developed

with a time frame in which they are to be accomplished



Implementationand Operation

● Top Management must make the necessary resources available (personnel, technical and financial capital, know-how)

● Personnel must be provided with adequate knowledge (energy policies, requirements of the EnMS, influence of their work on total energy usage, etc.) → Provision of Training

● Internal and external communication● Documentation describing the organisation's EnMS ● Communicate work flows and plans of action that guarantee

compliance with the firm's energy policy



Checking andCorrective Action


The organisation shall ensure that:● the key characteristics of its operations that determine energy

performance are monitored, measured and analysed● the equipment used in monitoring and measuring of key

characteristics provides data which is accurate and repeatable

Key characteristics shall include at a minimum:● the energy profile,● significant energy uses and● effectiveness of the action plans in achieving objectives and

targets.


Local System Solutions

Limit Value Monitoring Reporting

Internet Portal

JEChart JEBench

JEAlarm JEReport

Graphical curve display Benchmarking Tool

Checking andCorrective Action



Monitor andMeasure

● Evaluation and description of the requirements of the organisation's energy program

● Periodic measurement, oversight and recording of central energy uses, as well as the factors affecting them



Web client

InternetInternet

LAN / WLANLAN / WLAN

Data Server

Industrial PC

VIDA350

LON Device

Web client

Web client

FTPServer

Monitor andMeasure



Corrective andPreventive Action

● Detect and investigate nonconformities● Resolve them in a suitable manner within a defined time frame● Initiate corrective and preventive actions● Reviewing the effectiveness of the action taken

Corrective and preventive actions shall be appropriate to the magnitude of the actual or potential problems and the energy consequences encountered.



Internal Audit


Examples of subjects for consideration by internal auditing include:● proper implementation of energy management programmes,

processes and systems;● opportunities for continual improvement;● capability of processes and systems;● use of information technology.

Internal audits may be performed by employees of the organisation and/or by external parties appointed by the organisation. In both cases the person or persons performing the audits are qualified, experienced, objective, impartial and independent of the area of the organisation to be audited.


INITIAL ENERGY EFFICIENCY ANALYSIS

ThermalRegul-ation

HeatingCooling

Com-pressed

Air

Thermo-graphy Electric Water

EnergyPurch-asing

Compl.Energy

Concept

ENERGY EFFICIENCY – SPECIAL ANALYSIS

Internal Audit

Energy Management System DIN EN 16001Requirements


ManagementReview

● The top Management shall review the EnMS at predetermined intervals

● The management review is to be documented and presented● Input parameters:

● Follow-up actions from previous management reviews● Review of the energy policy● Review of energy performance (and EnPI)● The extent to which the energy objectives and targets have been met● Evaluation of its conformity with legal requirements and changes within● Status of corrective and preventive actions● Energy management system audit results



End for Today!!


Details Measuring Technique



Monitor and Measure

Planning


Energy Policy

Internal Audits Checking andCorrective Action

ManagementReview




Monitor and Measure

Planning


Energy Policy


ManagementReview



Production I

Production II

Administration

Distribution of Energy in the Corporation

Power [kWh]

Gas [Nm]3

Water [m]3

Heat [kWh]



Organisation● Requirements for measurements and monitoring of your EnMS ● Regularly measuring, updating and storing the important energy

consumptions● Accuracy and reproducibility of the measurement setup

Measurements will be used for the Definition of Goals of Energy Reduction


Typical Measurements for different Branches

Chemical Industry

FoodIndustry

PaperIndustry

OfficeBuildings

PublicTranspor-tation

Hospital Supermarkets

Heating

Cooling

Compressed air

Steam

Electricity

Ventilation

Water

Gas


● Energy-review has to contain:● Historical and actual energy consumption on the basis of

measurements and other data

● Goals of energy reduction = relative measurement of energy use● Energy use per piece, per kg, per sqm or sth. comparable● Goal of energy independent of change in production

Energy Management System ISO 50001Monitor and Measure



● Define operative goals● Analysis of energy consumptions (e. g. of processes,

compressed-air, heating, illumination,...) is facilitated● Intermittent estimation and validation of energy consumptions● Introduction of performance indicators for energetic power

● e. g. kWh per production unit● e. g. kWh per sqm building area● Use key values for ongoing control, to assure intervention in the

case of deviations



Examples for Monitor and Measure:● Ongoing monitoring and recording● Summary in the form of key values● Analysis of key values for validation● Intervention in case of deviations● Examination of power and adaptation of goals



● Calibration of measurement setup and storage of data recordings● Requirement: identification of improvements● Measurements as well as measurement techniques have to be

comprehensible at every status● The reproducibility is leading, not the accuracy of the

measurements



● Introduction of procedures● Procedures should describe the following:

● How are energy consumptions measured, recorded and monitored

● The comprehension of monitoring, including the measuring intervals

● Calibration and maintenance of the measurement setup● Tasks and responsibilities of the relevant personnel● How energy consumption is presented against the

performance indicators for energetic power


Energy Management System ISO 50001System Setup (distributed Solution)

JEVis Service Center

JEVis Network

Data logger VIDA350

DB


LON

!200

!200

EVU

Synchr.

0 0 0 0 0 1 8

User Panel

Ethernet-TCP/IP

FullClient

Database

GPRS / Ethernet-TCP/IP / GSM

MY JEVis Portal

Printer Database

WebClient

Internet

Software

WebClient

Energy Management System ISO 50001System Setup (internal Solution)


Energy Management System ISO 50001Measuring Technique

● Converter measurements● Direct measurements● Switching operations

● Bellow-, rotary piston-, turbine gas meter

Electric Meter

● Vortex-, ultrasonic flow meter


Energy Management System ISO 50001Measuring Technique

● Fan-, volume meter / Woltmann meter● Ultrasonic flow meter

● Flow meter ● Thermometer

● Pressure-, partial pressure transmitter


Services of the Envidatec GmbHMeasuring Technique

● Conceptual design of measuring points● Determination of important consumers● Determination of suited measuring technique● Creation of a system solutions

● Monitoring the installation● Commissioning● Operation of the monitoring network● Temporary measurements● Turnkey installation


Coffee Break


Details Energy Controlling



Monitor and Measure

Planning


Energy Policy


ManagementReview



Register

Optimise

● Energy report ● Benchmarking

● Measuring and recording of relevant operational data

● Reduction of costs

● Implement Measures (organisational and investment)

● Control of success

Analyse

Energy and Operating Data Controlling


Energy and Operating Data Portal


● User-specific access privilege

● Access with standard-browser

● User-specific system design

● Automatic data acquisition

● Cyclic data delivery

● Data exports (CSV, MSCONS)

● Windows-compliant interface

● Representation in tree structures

● High data security

My-JEVis Portal


● Graphical representations of user-definable data channels

● Display of comparison and reference curves

● Possibility of multiple choice and combination of different curves

● Automatic scaling

● Comprehensive zoom

● Free choice of the time range

● Show the switching operations for load management

Graph-Tool JEChart


● Comparison of consumption and costs based on defined indicators

● Creating rankings for real estate, offices or facilities

● Representation of the percentage errors

● Convenient graphical processing

Benchmarking-Tool JEBench


● Automatic monitoring of energy and operating data

● Reporting and alerting on threshold violation

● Alarming via SMS, email or fax● Storage of all relevant records in

the database● Comprehensive alarm

management with feedback

Alarm-Tool JEAlarm


● Customer-specific● Automatic generation of concise

energy reports

● Accounting of monthly or weekly periods

● Representation of consumer ratings with specific key figures

Energy Reporting


● Allocate energy consumption and costs● Create and evaluate statistics● Comparisons of key figures● Energy reports● Multi-vendor solutions, and propose

measures to be implemented jointly with the user

● Control of success of the measures● Continuous monitoring

Services of the Envidatec GmbHEnergy and Operating Data Portal


Standard week Mon. - Sun.Savings: 10,500 m3 / year, or approximately 33,000 € / year

Water leakage

Water use after optimisation

Optimisation Example 1: Detecting Water Leakage


Savings: 193,000 kWh / year, or approximately 22,000 € / year

Power consumption before optimisation

Power consumption after optimisation

Optimisation Example 2: Renewal of the cooling



Power consumption before optimisation

Power consumption after optimisation

Standard week Mon. - Sun.

Optimisation Example 3: Changing Ventilation Control


Optimisation Example 4: Detecting Defective Lighting Control



Lunch Break


Practical Examples ofEnergy Efficiency Measures


Practical Examples of Energy Efficiency Measures

Identification Processes● Energy Efficiency Analysis● Energy Monitoring● Internal Audit / Management Review

Energy Saving Measures● Optimal settings for regulation controls ● Closing of “Energy Leaks”● Investment measures for more energy efficient installations


Case Studies


Example LSG Sky Chefs

Renewal of the Cooling Installation


Brief Introduction LSG Sky Chefs Deutschland GmbH

LSG Sky Chefs is the world's largest provider of integrated in-flight solutions, including catering, procurement, equipment, aircraft sales to in-flight management.

LSG Sky Chefs serves more than300 airlines in some 200 establishmentsin 49 countries and produces 418 million airline mealsper year.


Energy costs at the location in Hamburg = 305.000 € in the year 2004Objective: reduction of costs by 15 %CO

2 - Reduction

Starting Situation

192Anrichte38.00 qm

EQ KIT EQ KIT

SM HRL

Band

WS 2 WS 2

WS 1WS 3

WS 4

WS 1

VERPACKUNG

COS/CIS NB

Trolley Puffer

WS 1

WS 2

WS 5

WS 6WS 4

WS 3Trolley Puffer

Sandwich Produktion

Anrichten

EQ KITS

Maschine 3

Maschine 2

Maschine1


2004: Installation of energy data monitoring with My-JEVis

1. Step: Identification of potential savings


2004: Carrying out energy efficiency analysis

Commission of the organisation to host the actual situation List of potential savings Quantification of the cost reduction in consumption Quantify the investment requirements Drawing up a rough schedule



Results of the data monitoring / energy efficiency analysis

Main energy consumers are:

Commercial refrigeration = 60% of electric power

Ventilation, Production (kitchen), Lighting = 40% of electric power




● Ventilation:

Frequency regulation of ventilation 40 % reduction Runtime optimisation of ventilation 15 % reduction

● Energy data monitoring:

Transparency of energy consumptions 5-15 % reduction




● Previous cooling:

cooling machines as one-circuit-setup Timed defrosting of the cooler Refrigerator control with high hysteresis Heat recovery without function Ages between 15-27 years 2 additional TK rentable containers in use



the old installation



Preferred areas for saving measures / expected savings

Cooling installationCooling through a frequency-integrated facility

Cooling adapted to be expected load spectrum / 20-25%

Heat adsorption and defrosting of refrigerator in the cooling roomsIntelligent control with defrosting on demand / 8-12%

Renewal of heat recoveryUse heat for hot water generation and ventilation / at least 20%

Heat incursion into the cooling facilitiesWarm air curtain / 2-5%



2005: Start of project

Services / project schedule:

Planning phase Call for tenders Assessment of tenders Contract negotiations Construction assistance / supervision

2. Step: Designing of the new refrigeration composite plant


3. Step: Completion of the new refrigeration composite plant


Savings achieved:

Saving electric power = 234 MWh / year36 % Reduction of electric power consumption

Saving heat = 1,788 MWh / year65 % Reduction of heat usage

Reduction CO2-Emission = approx. 500 t / year56 % Reduction CO

2-Emission

Results: Total Reduction of Consumptions


Results: Reduction of electric power consumption

Electric power consumption old installation (single compressors)

Electric power consumption new installation (composite plant)


Investment = 425.000 EuroFunding = 70.000 EuroSaving = 152.000 Euro / year

Technical amortisation period = 2 years, 4 months(including funding)

Results: Cost effectiveness of the installation


Example Bode Chemie GmbH

Renewal of the Compressed Air Installation


Brief Introduction Bode Chemie

Bode Chemie is one of the leading producers for disinfection and antisepsis products in Europe. Brands like Sterillium® or Cutasept® are used everyday in over 40 countries worldwide.


Starting Situation: Energy Costs and Consumptions

Complete energy consumption in 2009:● Electric power 2,479,480 kWh ● Gas 4,500,000 kWh● Water 27,414 m3

Load peak in 2009 was 507.8 kW

Energy Costs in 2009:● Electric power 246,237 € ● Gas 182,349 €● Water 113,494 €

CO2-Emission in 2009:● 2,622,237 kg


Starting Situation: Compressed Air installation

Compressor Model Motor Power

max. Pressure

Delivery Quantity

max. electric

power incl. fan

Switch-Point On

Switch-Point Off

electric consump-tion in idle

time

Compressor 1 KAESER

BS 61 37 kW 10 bar 5.3 m3/min 41.7 kW 9.4 bar 9.7 bar 25.0 kW

Compressor 2 KAESER

BS 61 37 kW 10 bar 5.3 m3/min 41.7 kW 9.6 bar 10.0 bar 24.4 kW

Compressor 3 KAESER

ASD 31 18.5 kW 10 bar 2.7 m3/min 18.9 kW 8.7 bar 9.6 bar 8.3 kW

Compressor 3 KAESER

ASD 37 22.0 kW 10 bar 3.1 m3/min 28.7 kW 8.7 bar 9.6 bar 7.4 kW

Compressor 3 ASD 31 was exchanged with a new KAESER ASD 37


Additional Components

● Adsorption dehumidifier DELTECH, Model ZW 450, year of manufacture 1999

● Holding tank 2.000 l, year of manufacture 1999● Adsorption dehumidifier DELTECH, Model Eurodry 2085● Holding tank 750 l, year of manufacture 1992


Requirements for the setup

● Demand for larger compressed air capacity● Increase of energy efficiency● Exchange of old components as well as acquisition of new ones

➔ Conceptualisation of a system combining old and new components and satisfying new capacity demand


Acquired Data

The installation was monitored over a period of one week. From 18.11.2009 to 25.11.2010 the profiles of the compressors were taken.During the 168 hours of the measured period the 3 compressors have consumed 9.404 kWh of electric power. From this 5.935 kWh were used during load operation and 3.469 kWh in idle time. Therefore, 37 % of the electric power were consumed in the idle time.During the measured period, the 3 compressors have done 31.341 alternations of load. Taking the mean value per compressor results in one alternation of load every 53 s.

Electric power consumption total 1 week: 9.404 kWh 983 €Electric power consumption total 1 year: 489.008 kWh 52.129 €Electric power consumption idle time 1 week: 3.469 kWh 344 €Electric power consumption idle time 1 year: 180.388 kWh 17.914 €


Load Profile of Compressed air

Load time

Idle time


Dimensioning of the new Compressed Air Installation

● For increase of energy efficiency renewal of some parts of the compressed air installation

● Special focus on regulation and control● New frequency controlled compressors:

➔ Higher reliability and durability➔ Use 35 % less energy compared to ones in use➔ Switch off when no demand for compressed air

● Soft start function to avoid high swicht-on currents● New control has to be compatible with idle-runtime compressors

to implement old compressors in the new setup● connection to waste heat recovery


Adsorption Dehumidifier

Expected potential energy saving when exchanging old cold regenerated adsorption dehumidifier against warm regenerated one: 10 – 12 %

Potential saving:electric current saving 1 week: 1,188 kWh 118 €electric current saving 1 year: 61,800 kWh 6,137 €CO2-reduction 1 year: 38 t/a

Investment costs for adsorption dehumidifier: 37,605 €Additional costs: 2,000 €Technical amortisation period: 6.5 years


Compressor

Expected potential energy saving when exchanging old compressor against frequency controlled VSD (variable speed drive) compressor: 36 %


Investment costs for compressor: 21,610 €Additional costs: 3,500 €Technical amortisation period: 1.4 years


Master Control with increased Consumption in the Compressed Air Network

When using a master control unit, a small energy saving can be achieved, even with an increased demand of compressed air capacity.


Investment costs for compressor: 18,500 €Additional costs: 13,500 €Technical amortisation period: 3.8 years


Waste Heat Potential

In compressed air systems lies a huge waste heat potential. About 75% of the electrical energy supplied is converted to heat and often goes to waste. Possible potentials can be the storage heating or hot water.

electric power consumption per year: 343,720 kWhWaste heat potential: 75 %Efficiency heat exchanger: 72 %Potential saving per year: 232,000 kWhCO2-reduction per year: 55 t/a

Investment costs: 42,000 €Technical amortisation period: 4.5 years


Additional Measures

Lowering the operating pressure

Reducing the operating pressure only by 1 bar provides a non-negligible saving potential.

Potential saving:Electric power consumption per year: 489,008 kWh/aSaving potential by reducing pressure: 7 % 34,231 kWh/aPotential saving per year: 3,529 €/aCO2-reduction per year: 21 t/a


Additional Measures

Repairing of the leaks

There is no compressed air network without leaks. Even for new networks the leakage rate is approx. 10 %. It is estimated that only 90% of the leaks are possible to fix.

Potential saving:Electric power consumption per year: 489,008 kWh/aSaving potential by closing leaks: 10 % 48,901 kWh/aPotential saving per year: 5,042 €/aCO2-reduction per year: 30 t/a


Summary of Realisation Concept and Saving Potentials

The 3 existing compressed air compressors will be implemented into the new control installation. Additionally, a new 45 kW frequency controlled compressor is designated.The existing cold regenerated adsorption dehumidifier is used as redundancy. A new warm regenerated one will be integrated.Additional components are a new after cooler, superfine filter and a activated carbon filter.


Summary of Realisation Concept and Saving Potentials

Electric power savings per year (25% more): 267,540 kWh 26,569 €CO2-reduction per year: 166 t/a

Investment costs for compressor: 21,610 €Investment costs adsorption dehumidifier 37,605 €Investment costs after cooler 05,290 €Investment costs filter 01,830 €Investment costs storage 03,560 €Additional costs: 12,500 €Investment costs total 82,395 €

Technical amortisation period: 3.1 years


Increasing Energy Efficiency in a networkThe LEEN principle


● On September 22th, 2010 the first energy efficiency network Hamburg und Mecklenburg-Vorpommern was founded in the castle of Schwerin.

● 10 energy intensive companies from Hamburg and Mecklenburg-Vorpommern have formed a cross-industry network

● At the moment 11 companies participating

● 1/3 of the costs will be funded by the BMU

● Includes moderated energy efficiency tables, initial consultings, …

● Accompanied the implementation of an energy management system to DIN EN 16001

● Running time (funding time): 3 years

Energy Efficiency Network Hamburg and M-V


The 30 LEEN networks project

• LEEN = Local Energy Efficiency Network

• 30 networks will be funded by the BMU

• Each network with 10-15 participants

• 2 networks per federal state

• Potential of 500-800 networks in Germany

• Energy costs of participants must be higher than 150,000 and lower than 50 Mio. €

• Training and certification of network hosts and advisory Engineers


Production specific energy consumption and CO2 emissions,weather and area adjusted, for the period 2001 – 2006 :

An increase of the energy efficiency of 16.7 %A CO2 migitation of 6.6 % (lower value caused by higher energy consumption and

its higher CO2 emissions)

At an increase in sales of 67 %and an increase in area of 45 %

The annually savings of 486,000 €correponds to a

increase in sales of 16,200,000 €/a at 3% profit margin

Example (Mulfingen and Niederstetten)


Initial situation in small/medium enterprises • The priority of the management are primarily on labor productivity, increase in sales and

product quality ⇒ Energy costs = overhead costs• There are many other tasks to do for the person responsible for energy

Not enough time for analysing the energy situation in the enterpriseSlightly metering data / no energy consumption linked to the products

Not enough time for a market overview about energy efficiency actions and techniques

High costs for internal searching and decision

Why do companies often realize just a part of profitable investments?

Orientation of the investment only to the payback period also held at the internal rate of return at 80% of companies


What does a network change?Procedure of a LEEN network

Time span: 3-4 years

y

Phase 0(3 – 9 months)

)

Information eventon EEN concept Organisation Procedure Costs

Letter of Intent

Inaugural event ofthe EEN


)

Identification of economical energy saving potentials - Initial questionnaire- Site inspection- Initial report

target agreements- Energy migitation- CO2-migitation

Phase 2(3-4 years)

Define relevant topicsPeriodical meetings

(3 – 4 per year):- Site inspection- Lectures of expertsPresentation of the results realized actions- Know how exchange


)

Presentation and publication of the results where applicable

Monitoring of the results


What does a network change?

Benefits from the view of the enterprise

• Initial consulting through experts / independent benchmarking of planned actions

• Moederated know how exchange( ca. every 3 months)

• Learning from other and providing information to other = know how transfer at eye level – „No re-inventing of the wheel“

• Additional knowledge trough extern experts about the newest techniques

Decreasing the searching and decision costs

• Defining a common migitation target leads to a higher implementation

• Plan for actions, project list –implementation if time and bidget is available

• Greater willingness of to management to invest because actions will be watched scientifical and engineer technical / profitability calculation

• Continuous monitoring /Image improvement by trustworthy climate protection

• Continuous and sustained improvement in employee skills

Conclusion: On average, the energy efficiency progress doubled per year compared to the average for the industry


Results of the oldest network: Model Hohenlohe

Based on 9 enterprises

After 4 year, at 10 enterprises: • 100,000 €/ a Eenergy cost reduction• 10,000 t CO2/ a Migitation: 140 € gross revenue/ t CO2 • After deduction of all costs: 10 to 20 €/ t CO2 renevue

Energy cost reduction from 2007: ca. 120.000 €/ a CO2 migitation from 2007: ca. 17.000 t/ a

Revenue of each reduced tonne CO2: 10 – 20 €


Contact:Envidatec GmbHVeritaskai 221079 HamburgTel.: +49 (0) 40 / 300 857 – 0Fax: +49 (0) 40 / 300 857 – 70Email: [email protected]: www.envidatec.comInternet: www.iso50001.ru

Energy-efficient into the Future! Energy Management System ISO 50001

mailto:[email protected]

http://www.envidatec.com/

Documents

Energy Management System ISO 50001 Training Course ENG.pdf · Energy Management System ISO 50001 Training Course Dipl.-Ing. Thomas Frank ... Management Review Correction and Preventive