Better Tools for Better Plants - EERE - U.S. Department of Energy

Highlighting Industrial Leadershipin the Better Buildings ChallengeBetter Buildings, BetterPlants ChallengeDOE’s BetterBuildings, BetterPlants Program10-year, 25% savings target (or equivalent)or moreAdopt “market innovations”Transparency in market innovations andresultsQuarterly reporting on innovationsAnnual reporting on resultsRecognized as premier market leaders10-year, 25% savings targetAnnual reportingProgram requirements track Save EnergyNowU.S. Industrial Companies6 | Advanced Manufacturing Office eere.energy.gov

Success to Date• Save Energy Now LEADER (SENL) was officially launched in Decemberof 2009• 108 companies signed the DOE Pledge to reduce energy intensity by 25% ormore in 10 years• As of November 1, 2011, SENL companies representing over 1,300 facilitieshave submitted annual reports documenting their energy intensityimprovements, energy use data, and achievements– Total energy use (most updated baseline source energy consumption) representedby these companies is over 1 quadrillion Btu– The share of total U.S. manufacturing energy use represented by these companiesis 4.8% (MECS 2006)• Over two-thirds of reporting companies are on track to meet their 25%improvement goal– Six companies have met their 10-year targets– Several firms are making multi-million dollar EE investment commitments– Many SENL companies are pursuing Superior Energy Performance certification7 | Advanced Manufacturing Office eere.energy.gov

Better Buildings, Better PlantsProgram• DOE will continue partnering with SENL companies through theBetter Buildings, Better Plants Program. Key program requirementswill stay the same. Companies:– Keep their 10-year, 25% energy intensity improvement target– Maintain their baseline year and any progress made toward the target– Report annually on their progress– Receive national recognition for their achievements• Official name change occurs December 1, 2011DOE will transition all SENL companies to the Better Buildings,Better Plants Program, although any company may opt-out8 | Advanced Manufacturing Office eere.energy.gov

Better Buildings ChallengeThe Better Buildings Challenge: The Better Buildings Challenge is aPresidential leadership initiative which calls on Chief Executive Officers,University Presidents, and State and local leaders to create American jobsthrough energy efficiency. These leaders make public commitments to actionand share their successful strategies with other organizations and arerecognized for their leadership.Different kinds of organizations can be part of this vanguard:PARTNERS:• Commercial• Industrial• Universities• CommunitiesALLIES• Financial9 | Advanced Manufacturing Office eere.energy.gov

Challenge Milestones• President Obama announced the Better Buildings Initiative, includingthe Better Buildings Challenge, in February• DOE Secretary Chu highlighted the Better Buildings Challenge at theClinton Global Initiative in June; DOE and White House profiledinaugural partners• Official launch of the program in Fall 2011, including industrialpartners10 | Advanced Manufacturing Office eere.energy.gov

Better Buildings, Better PlantsChallengeCommit• Assign Senior Executive• Set public energy goal for next 2-5 years; can retain 25%, 10-year goal alreadyestablished• Announce market innovations, e.g., energy efficiency capital set aside programs,scalable models for Superior Energy Performance certification, supply chainengagement, emerging technology deployment, etc.Take Action• Showcase project within 9 months. Can include:― Whole building improvement― Project over $1 million― Project to reduce energy intensity by 10% or more within a single facility• Organization-wide energy management plan within 9 monthsReport Results• Share information and marketplace blueprints• Share portfolio-wide, facility-level energy performance; flexibility provided forproprietary information• Quarterly updates on progress11 | Advanced Manufacturing Office eere.energy.gov

Recognizing LeadershipBetterBuildings,BetterPlantsChallengeCompany MilestoneTaking the ChallengeAnnouncing market innovationsand showcase projectsQuarterly and AnnualAchievementsSuccessfully completing marketinnovations and showcaseprojectsAchieving goalsJoining programAchieving >2.5% energy intensityimprovement in a single yearAchieving 10-year, 25% targetType of DOE RecognitionLetter from DOE Secretary to CEO,detailed on-line profile on web site,participation in Challenge launch (forfounding partners); press releaseExposure through web profile, DOEinitiatedmedia outreachLeadership press releasesDOE-initiated media outreach; webprofile; DOE press releasesPublic event, DOE-initiated mediaoutreach, letter from DOE SecretaryLetter signed by AMO ProgramManager (PM), basic on-line profile onAMO web siteLetter signed by AMO PM; pressreleaseLetter and plaque signed by DOESecretary; press releaseBetterBuildings,BetterPlantsProgram12 | Advanced Manufacturing Office eere.energy.gov

Next Steps• Better Buildings Challenge Launch in Fall of 2011• SENL officially transitions to Better Buildings, Better Plants ProgramDec. 1, 2011• Recruitment ongoing for both program tiers (contactBetterPlants@ee.doe.gov)• Revised tools ready by end of year13 | Advanced Manufacturing Office eere.energy.gov

New Resources• To help all partners meet their goals, AMO is revamping its suite ofon-line tools and resources and organizing them through a moredynamic, user-friendly portal to:– Support continuous improvement in energy management through ISO50001 and SEP– Enable Program Partners to more easily track energy intensityimprovement and report annually– Accommodate plants and companies at different levels of maturity inenergy management14 | Advanced Manufacturing Office eere.energy.gov

Technology Deployment ResourcesAMO supports manufacturers in rapidly adopting energy efficienttechnologies, practices, and management approaches by providing:Software Tools• Process heating, steam,motors and pumps, fans• Plant Energy Profiler• Energy and carbonbaselining• Energy managementInformation• Technical knowledge• Fact and tip sheets• Case studies• Sourcebooks• Design and retrofitguidelinesTraining• Introductory coursesvia webinars• Advanced/QualifiedSpecialist• Certified PractitionersAudience• ISO 50001• SEP plantcertification• Better Plants• Other PlantSavings Assessments• In-plant, peer-to-peer• Industrial AssessmentCenters (IACs)http://www1.eere.energy.gov/industry/saveenergynow/resources.html15 | Advanced Manufacturing Office eere.energy.gov

Self-Paced Module• Based on the International Energy Management Standard ISO 50001• 7 step process for developing an Energy Management System (EnMS) andimproving energy performance• Guides the user through the entire process- from the decision to implementan EnMS to successful implementation and beyond• Focuses on continual improvement• Designed to help the organization realize the benefits of implementing anenergy management system:– Improved operational efficiencies– Decreased energy intensity– Energy data for fact based decisions– Support for organizational and cultural change– Drivers for organizational integration– Reduced environmental impacts– Competitive advantages over firms that neglect resources management– Visible demonstration of corporate social responsibility– Positioning for carbon accounting17 | Advanced Manufacturing Office eere.energy.gov

Supply Chain EnergyManagement ToolAMO is developing tools that industry partners can distribute to suppliers• Supply chain energy management tool is designed to help companies new tothe issue develop basic energy management systems• Describes simple steps companies can take to improve energy managementand links to additional templates, worksheets, and guidance to help companieswork through the steps18 | Advanced Manufacturing Office eere.energy.gov

Energy ManagementToolkit StructureTrack, Prioritize andFollow-up on EnergySaving OpportunitiesCorporate AnalysisToolsEnergy ManagementSystem ImplementationSelf-Paced Module(Based on ISO 50001)Step 1- Getting StartedTechnical System Area Tools, Calculatorsand ScorecardsEach system area will include software tools andsimple calculators/scorecards.Corporate Baseline CreationAnnual Report GeneratorStep 2- Profile Your EnergySituationIndustrial Buildings andFacilitiesCompressed AirFacility Analysis ToolsFacility Baseline(subset of corporate baseline)Recommendations PortfolioStep 3- DevelopOpportunities, Objectives andResourcesStep 4- Reality Check: Stop!Look! Can I Go?Data CentersMotorsFansPlant Energy ProfilerProject Prioritization Tool(roll-up from projects)Project Tracker Tool(roll-up from projects)Step 5- Manage Current Stateand ImprovementsStep 6- Check the SystemProcess HeatingPumpsProject Analysis ToolsProject Prioritization ToolProject Tracker ToolStep 7- Sustain and Improvethe SystemSteamSupplierSelf-PacedModule“Lite” Version19 | Advanced Manufacturing Office eere.energy.gov3

Software Tools: Plant ProfilerINPUTSPlant Energy Profiler (PEP)• Plant description• Utility supply data• Energy useinformation• Overview of plant energy• Energy cost distributions• Preliminary assessment• Areas for improvement• Energy reduction potentialOUTPUTShttp://www1.eere.energy.gov/industry/quickpep_ml20 | Advanced Manufacturing Office eere.energy.gov

Small Tools CurrentlyBeing Developed• Upgraded Industrial FacilitiesScorecard• Daylighting tool• Fans VSD Calculator• Pumps VSD Calculator• Boiler Excess Air Tune-up• Solar Photovoltaic Array• Outside Air Intake Calculator• Waste Heat Recovery Calculator• Vortex Nozzles for Cleaning• Energy Savings for Low DemandPeriods• Solar Thermal Heating (Flat-Plate)• Solar Thermal Heating (Parabolic-Trough)• Notched V-Belt• Air Pressure Reduction Calculator• Air Leak Loss Calculator• Synthetic Lubricant Savings21 | Advanced Manufacturing Office eere.energy.gov

Motor Decisions Are MadeEasier with MotorMaster+Decide correctly with a motor systems management plan.22 | Advanced Manufacturing Office eere.energy.gov

Pumping System Assessment Tool(PSAT)Energy Flow for Pumping SystemsElectric utilityfeederTransformerMotor breaker/starterAdjustablespeed drive(electrical)At each interface, there are inefficiencies.The goal is to maximize overall costeffectiveness of the pumping, or how muchflow is delivered per unit of input energy.MotorCouplingPumpFluidsystemUltimategoal23 | Advanced Manufacturing Office eere.energy.gov

PSAT Tool: Identify SignificantPotential Energy SavingsUsing the requiredhead estimateinstead of the actualoperating head couldyield much greatersavings: ~$53K24 | Advanced Manufacturing Office eere.energy.gov

AirMaster PlusAirMaster+ can be used tobaseline a compressed air systemand then evaluate the energysavings from seven energyefficiency measures:• Reduce Plant Air Leaks• Adjust Manual Staging• Use Unloading Controls• Reduce System Pressure• Sequence CompressorsAIRMaster+ provides a systematic approach to assessingthe supply-side performance of compressed air systems.• Reduce Run Time• Add Primary Storagehttp://www1.eere.energy.gov/industry/bestpractices/software_airmaster.html25 | Advanced Manufacturing Office eere.energy.gov

Steam System Assessment Tool (SSAT)26 | Advanced Manufacturing Office eere.energy.gov

Application of SSATFacilities can use SSAT to evaluate these key areas forenergy performance improvements:• Real cost of steam• Steam quality• Boiler efficiency• Alternative fuels• Cogeneration opportunities• Steam turbines vs. PRVs• Boiler blowdown• Condensate recovery• Steam trap operatingefficiency• Heat recovery• Vent steam• Steam leaks• Insulation efficiency• Emissions calculations27 | Advanced Manufacturing Office eere.energy.gov

PROCESS HEATING ASSESSMENTSOFTWARE Tool (PHAST)Plant Energy Use and CostDistribution Report*The report shows:• Estimated annual energy use andestimate annual cost of energy forheating equipment (furnaces, ovensetc.)• List of heating equipment and % oftotal energy cost used for eachequipment in order of annual costof energy used.* for the Surveyed Process Heating Equipment28 | Advanced Manufacturing Office eere.energy.gov

PHASTFurnace Heat BalanceEnergy Use—LossesDistributionThe report shows analysis ofenergy used in various partsof a furnace under a givenoperating condition.29 | Advanced Manufacturing Office eere.energy.gov

Energy ManagementToolkit StructureTrack, Prioritize andFollow-up on EnergySaving OpportunitiesCorporate AnalysisToolsEnergy ManagementSystem ImplementationSelf-Paced Module(Based on ISO 50001)Step 1- Getting StartedTechnical System Area Tools, Calculatorsand ScorecardsEach system area will include software tools andsimple calculators/scorecards.Corporate Baseline CreationAnnual Report GeneratorStep 2- Profile Your EnergySituationIndustrial Buildings andFacilitiesCompressed AirFacility Analysis ToolsFacility Baseline(subset of corporate baseline)Recommendations PortfolioStep 3- DevelopOpportunities, Objectives andResourcesStep 4- Reality Check: Stop!Look! Can I Go?Data CentersMotorsFansPlant Energy ProfilerProject Prioritization Tool(roll-up from projects)Project Tracker Tool(roll-up from projects)Step 5- Manage Current Stateand ImprovementsStep 6- Check the SystemProcess HeatingPumpsProject Analysis ToolsProject Prioritization ToolProject Tracker ToolStep 7- Sustain and Improvethe SystemSteamSupplierSelf-PacedModule“Lite” Version30 | Advanced Manufacturing Office eere.energy.gov3

Portfolio Tool• Provide Portal users a central location for viewing, comparing and prioritizingenergy saving opportunities and projects• Planning tool, not a tracking tool– Designed to provide data to tools that support verification for DOE’spledge programs– Will not include verification and validation components– Designed to support the export of projects into management software fortracking purposes• Currently in development- release date is December 31, 201131 | Advanced Manufacturing Office eere.energy.gov

Software Tool-Related TrainingTraining at several levels for:• Awareness webcasts (1-2 hours)– Four-part energy management series– Tool specific• Online, self-paced end-user training• Qualified Specialist training andcertification(2 days)• Certified Practitioner training andcredentialing (2-3 days)– Energy Management– Systems• Data Center Energy Practitioner trainingand certification (1-3 days)See www.eere.energy.gov/industry for details32 | Advanced Manufacturing Office eere.energy.gov

ITP’s Publication and Product CatalogAllows Searching or Browsing by Topichttp://www1.eere.energy.gov/library/browsebytopic.aspx?Page=633 | Advanced Manufacturing Office eere.energy.gov

How Can I Contact AMO?• Bill Orthwein, Tool Development(202) 586-3807• Paul Scheihing, Tech Deployment team lead and Superior EnergyPerformance(202) 586-7234• Andre de Fontaine, Save Energy Now LEADER (Better Plants) and SupplyChain(202) 586-6585• John Smegal, Workforce Development: Certified Practitioner and IACprograms(202) 287-6225• Scott Hutchins, National Partnership Development(202) 586-0670• Sandy Glatt, States and Utilities(303) 275-4857http://www1.eere.energy.gov/industry/34 | Advanced Manufacturing Office eere.energy.gov