Industrial Energy Efficiency and

Sustainable Energy Curriculum

A training program for industrial workers

TECHNICAL ASSISTANCE PROGRAM

Industrial Energy Efficiency

GOALS:

Train workers throughout the region in Energy Efficiency Practices

Develop a curriculum for industrial energy efficiency

Identify $1,000,000 in Energy Savings for industries within the region

4 New Curricula DevelopedOver 20 companies Engaged

14 Companies implemented projects115 Workers Trained137 Workers Received Certification

101 Participation certificates 36 Implementation certificates

Energy Efficiency-to date:

Left: At the Process Heating Assessment & Scoping (PHAST) workshop in Kokomo, Indiana, instructor John Clarke demonstrates how to use the software tool to determine potential natural gas savings by properly controlling the mixture of fuel and air in a furnace.

Value Stream Mapping (VSM) is to “walk the line” collecting data on the Current State of a

process.

The Infrared Imager camera can see both visible and infrared light, overlay them in a single image, and identify an overloaded

‘hot’ circuit.

Developed and Piloted ‘Energy Use Mapping’ tool

Return on Investment from Energy cost savings expected

to exceed $2.3M per year.

• Over $5 million in potential energy cost reduction identified

• Purdue Technical Assistance Program is pursuing additional US Department of Energy, Department of Labor, and State of Indiana funding to leverage the materials developed under this project to provide additional training throughout the State of Indiana

• Energy Efficiency Practitioner and Energy Efficiency Survey Boot camp programs were both developed under this project and will be provided on an ongoing basis by Purdue TAP’s Energy Efficiency Services program

• NOTE: Detailed documents for the following overviews are provided in a separate pdf document.

Sustainability:

For more information: Randy Hountz

Associate Director -- Technical Assistance Program

Purdue University

Phone:  (765) 494-0766

Fax: (765) 494-9187

Email: rhountz@purdue.edu

“This product was funded by a grant awarded under the Workforce Innovation in Regional Economic Development (WIRED) Initiative as implemented by the U.S. Department of Labor’s Employment & Training Administration.  The information contained in this product was created by a grantee organization and does not necessarily reflect the official position of the U.S. Department of Labor. All references to non-governmental companies or organizations, their services, products, or resources are offered for informational purposes and should not be construed as an endorsement by the Department of Labor.  This product is copyrighted by the institution that created it and is intended for individual organizational, non-commercial use only.”

WIRED Industrial Energy Efficiency Practitioner worker certificate program

1.0 Energy Efficiency Practitioner worker certificate program

1.1 WIRED IEEP Program Agenda

1.2 WIRED IEEP Workbook

1.3 WIRED IEEP QuickPEP Worksheet

1.4 WIRED IEEP Wrap-Up Meeting Agenda

1.5 WIRED IEEP RFP Brochures

1.6 WIRED IEEP Certificate

2.0 Energy Boot camp

2.1 Energy Boot Camp Program Agenda

2.2 Energy Boot Camp PPT

2.3 General Improvement Plan spreadsheet

2.4 Waste Stream Mapping map

3.0 Heat Recovery

3.1 Heat Recovery PPT part 1

3.2 Heat Recovery PPT part 2

3.3 Heat Recovery Analysis

3.4 Heat Recovery Analysis Manual

Step 1:Program Overview and Plant Energy Profile Discuss client expectations and team responsibilities. Collect data and perform a data gap analysis. Site tour. Perform a Quick Plant Energy Profiler analysis Teach use of the tool. Identify opportunities and prioritize

Step 2: Systems workshops Set up a matrix of team members and workshops. Identify goals for attending each workshop. Identify information necessary to bring to workshops Perform a cost benefit analysis Implement a project Measure energy savings and calculate cost savings Report

Program Agenda

Step 3: Management System for Energy / General Energy Education General education of macro and micro energy issues Electricity and natural gas purchasing and risk management Measurement & Validation protocols for energy savings contracts Cost benefit analysis

Step 4: Energy Use Mapping Day 1: Educate team on the VSM tool

Develop a map of the “current state” of an energy intensive process Identify opportunities to save energy

Day 2: Develop a “future state” map Quantify the energy cost savings potential of projects Qualify possible solutions Prioritize

Program Agenda continued

Step 5: Implementation Identify a project for the team to work on Identify a solution Perform a cost benefit analysis Implement a project Measure energy savings and calculate cost savings Report

Program Agenda continued

Go Back

WIRED IEEP Wrap-Up Meeting Agenda

1. Review the program purpose and events – what workshops attended, work done on-site, etc.

2. Document any projects using the Project Implementation Report. (Have some on hand.)

a. Who: which team membersb. What: problem and solutionc. When: started and finishedd. How much: energy (e- or g+) saved and how much $ savede. As for success story

3. Talk about goals identified in application and which were achieved. 4. Present certificates if not already mailed5. How would they improve the program?6. Discuss future IEEP events and workshops7. Discuss Green program, ask if they would like to participate

Go Back

WIRED IEEP Certificate

Go Back

Energy Boot Camp Program AgendaDay 1

8:00 am Program launch: Managing energy for cost reduction• Who should attend:

all energy team members, Optional: plant manager, financial officer, HR manager

• Program overview Map out plan of action for four days

• Establish expectations Your expectations and our capabilities Review past projects & discuss planned projects Agree how the program can provide value

• Energy overview Overview of energy terms and measurements Review of utility bills (Optional: perform Quick Plant Energy Profiler analysis)

• Life Cycle Cost Discuss life cycle costs Preventive & predictive maintenance Review case studies or client examples

• Prioritizing projects Scoring projects Combining projects vs. cherry picking

3:30-4 pm Wrap-up

Energy Boot Camp Program Agenda

Day 2 Day 3 & 48:00 am Energy Survey

•Survey planningSafety reviewIdentify systems of interestIdentify information to collect

•Initial Plant tourLook at energy intensive systemsFocus on systems already prioritized for improvement

•Tour reviewList all possible projectsFilter & sortPreliminary energy calculationsData gap analysis

•Score & prioritizeScore projects for potentialAssign future actions

3:30-4 pm Wrap-up

8:00 am Waste Stream Mapping•Establish a current state

Select waste streamIdentify processesDevelop process flow mapsIdentify inputs and outputsQuantify(Optional) re-tour plant to collect additional information

•Establish future stateIdentify opportunities from process flow mapsMatch projects from surveyCalculate impactsIdentify resources neededScore & prioritize projects

•Create a preliminary report3:30-4 pm Wrap-up

Go Back

2.3 General Improvement Plan spreadsheetPlant: Andersons Team: Logansport Date: 7/28/2009

Action Items Impact(H, M, L)

Cost/Effort(H, M, L)

Owner Target Date Note

1 Consider RO to replace DI -on demand water H H Zac $150k

2 On-Site Water Storage-Tower or Tank H H Zac

3 Use De-icer heat to heat Urea 50/50 H L Zac

4 Optimize cleaning process-mixers H L Zac

5 Consider new tank to consolidate cleaning water H L Zac

6 Reuse Cleaning water from totes (in process) H L Zac

7 Comprehensive plan to eliminate totes in waste water H M Zac

8 Error-proof/Train to deter false Regens on DI L L Zac

9 Look at Reject Pump on DI L L Zac

10 Paint Urea Tank Top Black L L Zac

11 Trench in Packaging Room L L Zac

12 Programmable Thermostats L L Zac

13 Formalize Recycling Plan L L Zac

14 Recycle Plastic Containers L L Zac

15 Investigate Waste Exchange for Totes L L Zac

16 ? Bailer or compactor to reduce number of pulls- Solid waste L L Zac

17 Seal Dike in Packaging L L Zac

18 Automated Doors to minimize heat loss L L Zac

19 Solar Thermal Hose on Pre-heat DI before heat L M Zac

20 Use Daylight or EE Fluorescent to reduce energy costs L M Zac

21 Minimize Leakage in Mixer Area L M Zac

22 Investigate Economizer on Boiler M L Zac

23 Investigate Dedicate Totes work w/Suppliers M L Zac

24 Request Iron sulfate(FeSO4) in Super Sack M L ZacGo Back