Program Name or Ancillary Texteere.energy.gov DOEs Industrial
Assessment Centers Michael R. Muller USA Rutgers University, Center
for Advanced Energy Systems U.S.- Brazil Industrial Energy
Efficiency Workshop Rio de Janeiro, Brazil August, 2011
Slide 2
2 | Industrial Energy Efficiencyeere.energy.gov Introduction
Program Participants Stakeholder Benefits Program Management The
Assessment Protocol Results and Databases Workforce Development
Outine
Slide 3
At Rutgers since 1979 Ran IAC from 86-92 IAC Field Manager
since then Director, Center of Advanced Energy Systems at Rutgers
since 2002 Meu nome Michael Muller Universidade de Rutgers Current
passions: Organic Rankine Cycles Cooling tower operation Industrial
Gasifiers Uses of Smart Grids
Slide 4
4 | Industrial Energy Efficiencyeere.energy.gov Research:
Outreach Programs: http://caes.rutgers.edu
Slide 5
5 | Industrial Energy Efficiencyeere.energy.gov University
based technical assistance program Funded by US DOE (no cost to
clients) Primarily directed toward small and medium sized
manufacturers IACs perform industrial assessments at nearby
manufacturing centers. Performed by teams made up of faculty and
students This is NOT a student project Normally consists of a 1 day
site visit at an industrial plant Each center serves factories
within 150 miles of the campus Yearly number of assessments depends
on funding levels Max = 40, Min = 12 IAC Industrial Assessment
Centers
Slide 6
6 | Industrial Energy Efficiencyeere.energy.gov A brief, but
thorough evaluation of a manufacturing plant by an external team of
technical experts Fundamentally a multiple-system assessment When
resources are limited teams can focus on a subset of important
systems Industrial Triage Must be integrated to include waste and
productivity (dangerous, otherwise) An energy audit grown up What
is an Industrial Assessment?
Slide 7
7 | Industrial Energy Efficiencyeere.energy.gov History of IAC
Program IAC program was formed in 1976, as the Energy Analysis and
Diagnostic Program (EADC) Result of Oil Embargo Originally 4
Universities Students were always involved Goal was to fill gap in
education Energy Conservation was not taught in Engineering
Database was added in 1981 In 1992 the database was put online In
1995, waste minimization and productivity capabilities were added
and the program became the IAC
Slide 8
8 | Industrial Energy Efficiencyeere.energy.gov Costs including
management are about $10k per assessment All participants are paid
Faculty normally paid only 9 months/year as professors Students are
employees helps with insurance issues and oversite Industry
contributes through providing engineers and managers as hosts in
kind contributions Equipment and travel are other normal costs
Sometimes overnight stays are needed For long trips, often the
industry pays for lodging IAC Industrial Assessment Centers
Slide 9
9 | Industrial Energy Efficiencyeere.energy.gov This program
assumes that good energy efficiency projects exist Will be
implemented because they save money Based on what drives
manufacturer Even with waste, green does not get it done We are an
idea service, Not an engineering design service! We do not compete
with consultants Actually we create business Not a financing
vehicle Program Rationale
Slide 10
10 | Industrial Energy Efficiencyeere.energy.gov Currently 26
IACs Over last 25 years: 14,000+ Assessments Conducted 98,000+
Recommendations Recommended: $9.2 Billion Implemented: $2.8 Billion
IAC Industrial Assessment Centers
Slide 11
11 | Industrial Energy Efficiencyeere.energy.gov
Slide 12
12 | Industrial Energy Efficiencyeere.energy.gov IACs are
selected by a competitive bidding process every five years Most
recent solicitation just closed on August 2, 2011 Bidding Centers
are asked to respond to a number of prescribed criteria about their
qualifications, experience, etc. Centers must be at accredited
engineering departments only (ABET) Center Director must be tenured
faculty Doing this work is not conducive to acquiring tenure
Program Participants Selection of Centers
Slide 13
13 | Industrial Energy Efficiencyeere.energy.gov A selection
committee composed of DoE staff, Field Manager, industry
professionals and other knowledgeable people is created, to review
proposals and make recommendations to ITP Centers can be removed
for cause, under the terms of their agreement with DOE Field
Mangers are also competitively bid on a different five year term
Program Participants Selection of Centers
Slide 14
14 | Industrial Energy Efficiencyeere.energy.gov Normally the
center is championed by a particular professor has the necessary
skill sets Without the motivated professor, centers struggle
Workload is reduced by having an active assistant director It is
also common to have one or two full time engineers During good
funding times Many centers have additional programs which help
support staff Program Participants The Center Professional
Staff
Slide 15
15 | Industrial Energy Efficiencyeere.energy.gov A major focus
of the program Can include both undergraduate and graduate students
(typical numbers range from 6 20) Hopefully, a range of experience
the newer students learning from those more experienced Students
MUST be making satisfactory progress toward their degree Students
can love IAC work so much that their grades suffer Successful
students like hands-on problem solving Would have grown up working
on cars a generation ago Program Participants The Center Student
Assistants
Slide 16
16 | Industrial Energy Efficiencyeere.energy.gov Program
Participants Student Participants Over 2,900 students trained On
average, 50% - 60% pursue energy-related careers upon graduation
100 160 students departing each year Engineering fields:
Mechanical, Industrial, Electrical Student status: Undergraduates
70%, Graduates 30% Average time spent in IAC: 18 months
Slide 17
17 | Industrial Energy Efficiencyeere.energy.gov Very low
turnover of schools Several directors have 25+ years Center
Experience
Slide 18
18 | Industrial Energy Efficiencyeere.energy.gov Who Wins?
Success, Job Growth, Higher Revenues
Slide 19
19 | Industrial Energy Efficiencyeere.energy.gov How does it
benefit the government? (taxpayers) Workforce development energy
engineers Environmental impacts energy, CO 2, pollution reduction
Helps improve the economy of the manufacturing base Government
agencies with common goals work together Environmental Protection
Agency Energy Star Stakeholders
Slide 20
20 | Industrial Energy Efficiencyeere.energy.gov How does it
benefit the Industrial Client? They get unbiased advice on energy
efficiency and management, waste minimization and productivity We
dont sell anything or represent vendors faculty are prohibited from
consulting with any clients Many clients hire our students Clients
get access to workshops and/or training offered by ITP
Benefits
Slide 21
21 | Industrial Energy Efficiencyeere.energy.gov How does it
benefit the Universities? Adds practical component to activities
Increases demand for students Adds an educational component to
their curriculum, which reaches students beyond those in the center
Provides networking with local industry The assessment is just the
start of a long term relationship Establishes the university as a
hub for energy expertise Universities see it as a regional outreach
effort Outreach is a required activity at most US universities
Benefits
Slide 22
22 | Industrial Energy Efficiencyeere.energy.gov Rapid changes
are taking place at universities The IAC's continue to impact their
home universities with improvements to the student experience and
curricula. Recent new examples include: Master's degree program in
Energy Conversion and Thermosciences at Colorado State University
Master's program in Clean and Renewable Energy just begun by the
University of Dayton. Undergraduate Certificate programs in Energy
Systems at Rutgers and other schools An accredited major in energy
engineering is being discussed nationally Curriculum
Development
Slide 23
23 | Industrial Energy Efficiencyeere.energy.gov How does it
benefit the Faculty? Provides steady funding and income Great
opportunity to work closely with students Often problems discovered
at a plant leads to research Benefits Its in the factories where I
get my ideas! Arvind Atreya, Director of the IAC, University of
Michigan
Slide 24
24 | Industrial Energy Efficiencyeere.energy.gov Vendors
(including banks) Energy service companies Engineering firms Users
of the database Students and alumni Other beneficiaries
Slide 25
25 | Industrial Energy Efficiencyeere.energy.gov Benefits
Hands-on training in diagnostics, data collection, and analysis of
energy savings opportunities Opportunities to conduct research and
author publications related to technical needs and challenges of
industry clients Exposure to a wide range of industries, energy
systems and solutions Interactions with plant staff, utility
representatives and equipment vendors OSU students team at Bama
biscuit manufacturing plant for McDonalds UD students team in
action The IAC Difference for Students
Slide 26
26 | Industrial Energy Efficiencyeere.energy.gov Benefits
Exposure to U.S. energy policy, DOE technical resources for energy
management Part-time experience in a consulting-office
structure/environment, while completing undergraduate and graduate
engineering degrees Expedited ability to obtain professional
licensure and certification Experience high-demand by industry,
consulting organizations, utilities, ESCOs University of Michigan
IAC student team conducting an IAC assessment University of
Louisiana IAC student team on an oil platform in the Gulf The IAC
Difference for Students
Slide 27
27 | Industrial Energy Efficiencyeere.energy.gov Benefits "We
get a real world perspective of a variety of industries. We learn
about conservation, and things companies need to do to save energy
and money. Former IAC Student An IAC student engineer uses an
infrared gun at a manufacturing plant IAC student engineers looking
at HVAC equipment at a manufacturing plant
Slide 28
28 | Industrial Energy Efficiencyeere.energy.gov Management of
the Program Three levels of Management US Government Department of
Energy Industrial Technologies Program (ITP) establishes policy and
budget DOE Golden Field Office manages contracts with the
universities Oak Ridge National Laboratory links the IAC to other
ITP activities such as Save Energy Now and International, manages
IAC student activities Field Management Rutgers University provides
technical oversight, center performance reviews, manages the
database Helps to publicize the program Insures continuous
improvement Information transfer between DOE and the centers Center
Management University 26 Universities do the work! -- Lots of
management needed
Slide 29
29 | Industrial Energy Efficiencyeere.energy.gov Department of
Energys Industrial Technology Program Program Areas Energy-
Intensive Industries Crosscutting Technologies Save Energy Now
LEADERS Industrial Assessment Centers Superior Energy Performance
US Department of Energy Research and Development Energy
Management
Slide 30
30 | Industrial Energy Efficiencyeere.energy.gov IAC Team
Member Set IAC Policy & Budget Implement Policy Center
Selection Activities University Contracting and Funding Technical
Oversight, Performance Reviews Program Metrics and Reporting
Student and Alumni Crosscutting Activities Operate Centers DOE-ITP
DOE-Golden Field Office ORNL Rutgers University Centers IAC
Organizational Roles
Slide 31
31 | Industrial Energy Efficiencyeere.energy.gov Client
Solicitation Pre-visit preparation Pre-assessment data collection
Intake interview Plant Tour Recommendation brainstorming Onsite
Data Collection Exit Interview Post Assessment Report Workup Review
of assessment impact Implementation callback (about 1 year after
plant visit) Assessment Components
Slide 32
32 | Industrial Energy Efficiencyeere.energy.gov Results in a
formal report being sent to the client firm Each report has several
recommendations which provide: Sufficient engineering design to
explain the recommendation Anticipated savings Implementation costs
Simple payback Students Fully Involved Pre-Assessment prep Onsite
data and measurement Post-assessment analysis Report writing
Presentation of results The IAC Industrial Assessment (cont.)
Slide 33
33 | Industrial Energy Efficiencyeere.energy.gov Self
determined through direct contacts (primarily phone calls) Normally
6-12 months after delivering report Seeks reasons if recommendation
not implemented Other DOE/Field Manager reviews of implementation
rates Periodically but normally much later Shows good agreement
with self determined rates Some measures no longer in place But,
about 12% of measures originally not implemented eventually are
installed Scales as expected with very inexpensive measures having
the highest implementation rates Implementation of
Recommendations
Slide 34
34 | Industrial Energy Efficiencyeere.energy.gov Program has
historically had high implementation rates typically on the order
of 50% of recommendations Reasons : Level of ignorance in the small
manufacturer. High technical quality of senior personnel at IACs.
Focus of the assessment on short to medium term payback period ARs.
Close work of the assessment team with plant management No "hidden
agendas" by the assessment team. Implementation of Recommendations
(cont.)
Slide 35
35 | Industrial Energy Efficiencyeere.energy.gov Publicly
Available Contains: Facility data Recommendation data
Implementation data Searchable by Size (in energy usage, employees,
etc) Industry Type (NAICS or SIC) Location Recommendation Type
Updated in Real-Time as the assessments are completed The IAC
DATABASE
Slide 36
36 | Industrial Energy Efficiencyeere.energy.gov Primary uses:
Generating ideas for energy efficiency projects Supporting the
design of energy efficiency programs Training and teaching Enduser
distribution: The IAC DATABASE
Slide 37
37 | Industrial Energy Efficiencyeere.energy.gov Clients served
Program strictly for industrial operations Standard industrial
classification codes (SIC) 20 through 39 Plant normally located
within a 150 miles (242 kilometers) of an IAC Directed at small and
medium sized manufacturers primary customer is: Have gross annual
sales of
