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Assessments to Action (A2A) Toolkit for the IFA: Guidelines for Users (Version 1)

Assessments to Action (A2A) Toolkit for the IFA:

Assessments to Action (A2A) Toolkit for the IFA: Guidelines for Users (Version 1)

Guidelines for Users

(Version 1)

Assessments to Action (A2A) Toolkit for the IFA: Guidelines for Users (Version 1) Developed by:

Assessments to Action (A2A) Toolkit for the IFA:

Guidelines for Users

(Version 1)

Developed by:

Institute for Industrial Productivity, and ICF Marbek

16 June 2011

Contents 1 Purpose of Guideline 1 2 Introduction 2 2.1 Context and Scope of IIP

Contents

1 Purpose of Guideline

1

2 Introduction

2

2.1 Context and Scope of IIP A2A Toolkit

2

2.2 Assessment Methodology

4

2.3 Description of Toolkit Modules

4

2.3.1

Energy Use and Technical Best Practice Assessment (Excel File: A2A

TA)

4

2.3.2

Generic

Measure

Library

(Excel

File:

A2A

Generic)

and

Ammonia

Measure Library (Excel File: A2A Ammonia)

 

5

2.3.3 Energy Management System Assessment (Excel File: A2A MA)

5

2.3.4 Productivity Improvement Assessment (Excel File: A2A PIA)

 

5

2.3.5 Report Card and Opportunity Identification (Excel File: A2A RCOI)

5

2.3.6 EE&M Plan Checklist (Excel File: A2A Checklist and Action Plan)

6

2.3.7 EE&M Action Plan Template (Excel File: A2A Checklist and Action Plan) 6

2.4 Managing and Updating Toolkit

6

2.5 Structure of Guideline

6

2.6 Common Elements in Tools

8

3 Energy Use Performance and Technical Best Practices Assessment

9

3.1

Description

9

3.1.1 Objective

9

3.1.2 Variables Collected

9

3.1.3 Layout of the Tool

10

3.1.4 Flow of Information Between Tools

14

3.1.5 Using the Tool

14

3.2

Accuracy, Detail and Making Assumptions

20

3.2.1 Average equipment capacities and operating hours

20

3.2.2 Energy Balance

20

3.3

Technical Best Practices Assessment

22

3.4

Ammonia Sub-Sector Specific Assessment

22

3.4 Ammonia Sub-Sector Specific Assessment 22 4 Technical Measure Library 24 4.1 Description 24 4.1.1

4 Technical Measure Library

24

4.1

Description

24

4.1.1 Objective

24

4.1.2 Variables Collected

24

4.1.3 Layout of Tool

25

4.1.4 Flow of information Between the Tools

27

4.1.5 Using the Tool

28

5 Management Best Practices Assessment

29

5.1

Description

29

5.1.1 Objective

29

5.1.2 Variables collected

29

5.1.3 Layout

29

5.1.4 Flow of Information Between Tools

31

5.1.5 Using the Tool

31

5.2

Accuracy, Detail and Making Assumptions

32

6 Productivity Improvement Assessment

33

6.1

Description

33

6.1.1 Objective

33

6.1.2 Variables collected

33

6.1.3 Layout

33

6.1.4 Flow of information Between Tools

34

6.1.5 Using the Tool

34

7 Report Card and Opportunity Identification

35

7.1

Description

35

7.1.1 Objective

35

7.1.2 Variables collected

35

7.1.3 Layout

35

7.1.4 Flow of information Between Tools

38

7.1.5

Using the Tool

38

7.1.5 Using the Tool 38 8 Energy Efficiency and Management (EE&M) Plan and Action Plan 44

8 Energy Efficiency and Management (EE&M) Plan and Action Plan

44

8.1

Description

44

8.1.1

Objective

44

8.1.2

Variables collected

44

8.1.3

Layout

44

8.1.4

Flow of Information Between Tools

45

8.1.5

Using the toolkit module

46

8.2

Accuracy, Detail and Making Assumptions

49

9 Glossary

50

10 Abbreviations

53

11 Appendices

54

Appendix A

Report Card checklist and Completed Report Card

54

Appendix B

A2A Energy Use and Technical Best Practice Assessment

56

Appendix C

A2A Energy Management System Assessment

57

Appendix D

A2A Productivity Improvement Assessment Template

58

Appendix E

A2A Checklist and Action Plan Template

59

Table of Exhibits Exhibit 1: Continuous improvement 2 Exhibit 2: Tools in the toolkit and

Table of Exhibits

Exhibit 1: Continuous improvement

2

Exhibit 2: Tools in the toolkit and results to be achieved

3

Exhibit 3: Sequential use of tools

6

Exhibit 4: Example of first few tabs in Excel tools

8

Exhibit 5: Tool 1 in the sequence

9

Exhibit 6: Technical best practice assessment index table

10

Exhibit 7: Tools in the toolkit and results to be achieved

13

Exhibit 8: Example of Technical Assessment Purchased fuel questions

14

Exhibit 9: Example of Technical Assessment Sold and self-generated fuel questions15

Exhibit 10: Example of Technical Assessment Sold and self-generated fuel questions

 

16

Exhibit 11: Example of Technical Assessment feedstock questions

16

Exhibit 12: Example of Technical Assessment equipment features questions (first

question group)

17

Exhibit 13: Example of Technical Assessment drop down menu

17

Exhibit 14: Example of Technical Assessment ―section not applicable‖ box

17

Exhibit 15: Example of Technical Assessment general questions (second question

group)

19

Exhibit 16: Example of Additional Opportunities boxes

19

Exhibit 17: Portion of the energy balance tables

21

Exhibit 18: Ammonia sub-sector specific data table

23

Exhibit 19: Tool 2 in the sequence

24

Exhibit 20: Example of Measure Library tab

26

Exhibit 21: Measure Library Index Tab

28

Exhibit 22: Tool 3 in the sequence

29

Exhibit 23: Management Best Practice Assessment index table

30

Exhibit 24: Example of Management Assessment drop down menu

31

Exhibit 25: Example of Management Assessment button selection

31

Exhibit 26: Tool 4 in the sequence

33

Exhibit 27: Productivity Improvement Assessment index table

33

27: Productivity Improvement Assessment index table 33 Exhibit 28: Example of Productivity Improvement Assessment

Exhibit 28: Example of Productivity Improvement Assessment multiple option

selection

34

Exhibit 29: Tool 5 in the sequence

35

Exhibit 30: Report and Opportunity Identification index table

36

Exhibit 31: Report Card ―Edit Links‖ screen

39

Exhibit 32: Report card macro button on Tab RC 2

40

Exhibit 33: Report card opportunities table to be completed manually

40

Exhibit 34: Report card opportunities table to be completed manually

41

Exhibit 35: Report Card plant information to be checked

42

Exhibit 36: Report Card product information and energy use per unit of production

42

Exhibit 37: Report Card pie charts

42

Exhibit 38: Converting to PDF (step 2)

43

Exhibit 39: Converting to PDF (steps 3 and 4)

43

Exhibit 40: Tool 6 in the sequence

44

Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan index

table

45

Exhibit 42: Example of EE&M Plan Checklist

46

Exhibit 43: Example EE&M Action Plan template

48

1 Purpose of Guideline This guideline provides guidance for a user on how to use

1 Purpose of Guideline

This guideline provides guidance for a user on how to use the Institute of Industrial Productivity‘s ammonia sector Assessments to Action (A2A) toolkit. The user using the toolkit and this guideline needs to be:

Experienced in on-site energy efficiency auditing.The user using the toolkit and this guideline needs to be: Familiar with industrial manufacturing processes,

Familiar with industrial manufacturing processes, specifically ammonia manufacturing.to be: Experienced in on-site energy efficiency auditing. Familiar with industrial technologies, energy management

Familiar with industrial technologies, energy management best practices, and ISO 50001.manufacturing processes, specifically ammonia manufacturing. Proficient in using MS Excel. This guideline does not

Proficient in using MS Excel.energy management best practices, and ISO 50001. This guideline does not provide guidance in how to

This guideline does not provide guidance in how to conduct an audit, or explanations of industrial processes, technologies, best practices and the use of MS Excel.

The outline of the toolkit is described in Sections 2.1 and 2.3, while the structure of the manual is described in 2.5.

Data obtained from plants are considered to be confidential and a confidentiality agreement can be signed with the company. An example confidentiality agreement template is included in the toolkit and needs to be completed by the company and the company using the A2A toolkit to conduct an assessment.

2

Introduction

2 Introduction 2.1 Context and Scope of IIP A2A Toolkit The Institute for Industrial Productivity (IIP)

2.1 Context and Scope of IIP A2A Toolkit

The Institute for Industrial Productivity (IIP) retained ICF Marbek, a Canadian consulting firm, to develop an energy performance assessment and continuous improvement toolkit. The toolkit provides a standardized methodology for industrial energy performance assessments, and engaging companies to implement a continuous improvement process to reduce energy use and improve energy management. The toolkit is to be used by trained users during on-site assessments in a consultative process to assist a company in implementing a continuous energy efficiency improvement plan.

This version of the toolkit was developed specifically for the ammonia manufacturing sector. The toolkit addresses the assessment, opportunity identification and planning stages of the continuous improvement process, as illustrated in Exhibit 1.

Exhibit 1: Continuous improvement process.

A2A Toolkit Assess Energy Commitment Performance & by Factory Establish Indicators Identify Implement
A2A Toolkit
Assess Energy
Commitment
Performance &
by Factory
Establish
Indicators
Identify
Implement
Opportunities
EE&M
& Define
Action Plan
EE&M Plan
Develop
Additional
EE&M
Support
Action Plan

The actual implementation of both the energy efficiency and energy management (EE&M) plan and the action plan may require additional resources and support. This support may include, for example, financial support to implement opportunities, training and capacity building in energy management, and technical expertise to undertake detailed economic and feasibility studies. This support can be resourced either internally from within a company, or an external organizations, such as service providers or financial institutions.

The assessment tools included in the toolkit are appropriate as a first-order, high-level assessment to identify and prioritize energy efficiency opportunities. The results from the assessments will assist in short and long term strategic planning to implement the opportunities, and to identify follow-up actions. More detailed energy audits, and feasibility studies may be required for some of the opportunities that are identified with the toolkit.

Exhibit 2 illustrates the tools in the toolkit and how it correlates with the continuous

Exhibit 2 illustrates the tools in the toolkit and how it correlates with the continuous improvement process, and the results to be achieved. The tools and the use of the tools are described in detail in the guideline, and examples are provided throughout the guideline to illustrate the use of the toolkit.

Exhibit 2: Tools in the toolkit and results to be achieved

Continuous Results Improvement Toolkit Process Company committed to energy management Obtain Commitment and
Continuous
Results
Improvement
Toolkit
Process
Company committed to energy
management
Obtain Commitment
and allocating necessary resources
Technical Assessment
to energy management
(Includes Energy Use Performance
and Technical Best Practices
Assessment)
Understand current energy use,
productivity and energy
Measure Library (incl. Ammonia
Assess Performance
performance.
Specific)
and Establish
Management Assessment
Indicators
Derive performance indicators for
(Includes Technical Management Best
continuous improvement.
Practices Assessment)
Productivity Improvement
Assessment
Definition and understanding of the
Report Card and Opportunities
Identify
opportunities to improve energy
Identification
Opportunities and
performance.
Define EE&M Plan
EE&M Plan Checklist
Scope
A defined scope for the EE&M Plan.
Develop Action Plan
Action plan to guide developmen t
EE&M Action Plan Template
to Implement EE&M
and implementation of EE&M Plan.
Plan
Implement Action
Plan
of EE&M Plan. Plan Implement Action Plan Training and Capacity Building of Trainers and Auditors The

Training and Capacity Building of Trainers and Auditors

The development of the toolkit included a comprehensive review by international experts, and was pilot tested at Chinese factories to ensure ease of use and practical applicability. IIP will manage updating and maintaining the toolkit, and will most likely develop new versions tailored to other industrial sectors. IIP will retain intellectual property of the toolkit and licence it to users and companies without any cost to the users or company.

2.2

Assessment Methodology

2.2 Assessment Methodology The toolkit is based on an assessment approach that includes: Determining the overall

The toolkit is based on an assessment approach that includes:

Determining the overall plant energy intensity, or energy use per unit production (for example, GJ/ton ammonia). In this version of the tool the energy intensity is not calculated at a more detailed level, such as process step, but determined by evaluating energy use in the plant against the main product only.toolkit is based on an assessment approach that includes: Determining the implementation of technical best practices

Determining the implementation of technical best practices (TBP). Identifying the technical best practices already implemented at a plant, reveals the technical best practices not yet implemented at the plant. This provides an opportunity to implement the applicable best practices that will reduce energy use.energy use in the plant against the main product only. Determining the implementation of energy management

Determining the implementation of energy management best practices (MBP). Identifying the management best practices already implemented at a plant, reveals the management best practices not yet implemented at the plant. This provides an opportunity to implement the applicable best practices that will assist in reducing energy use.the applicable best practices that will reduce energy use. This comprehensive approach helps an assessor to

This comprehensive approach helps an assessor to understand and explain a company‘s energy efficiency performance. For example, low implementation of MBPs and TBPs identify reasons for low energy intensity values, and highlights opportunities and management areas for improvement to improve energy intensity values.

To assist companies in continuously improving their energy efficiency and energy management it is recommended to use the A2A Toolkit on a regulate basis, such as every second year, to track progress in improving energy efficiency and the implementation of best practices.

2.3 Description of Toolkit Modules

The seven modules in the toolkit are summarized in Exhibit 2 and described below.

2.3.1 Energy Use and Technical Best Practice Assessment (Excel File: A2A TA)

The technical assessment tool is used to collect data applicable to assess energy use performance and to determine the implementation of TBPs. Energy use performance includes generating an energy balance to determine energy use by each end use (such as, boilers, motors, and process cooling) and by energy source (such as electricity and natural gas). It also includes the calculation of the overall energy intensity of the plant in terms of energy use per unit production (for example GJ / ton ammonia).

Energy technical best practices are production system and efficiency measures that reduce energy use per unit of production. An example of a TBP is installing a heat recovery system on a process exhaust stream to preheat a feed stream, resulting in reduced process energy use per unit of output. The TBP performance indicator is the total number of applicable TBPs that are implemented at a plant. All Energy technical

best practices listed in this toolkit are commercialized, and exclude pilot-test or demonstration technologies. 2.3.2

best practices listed in this toolkit are commercialized, and exclude pilot-test or demonstration technologies.

2.3.2 Generic Measure Library (Excel File: A2A Generic) and Ammonia Measure Library (Excel File: A2A Ammonia)

The measure library provides information about each technical best practice. The technical best practices are grouped in two broad categories:

Measures applicable to generic end uses. It refers to end uses that are not sector specific, such as: boilers and steam systems, motors, process cooling and refrigeration, and direct process heating in ovens, dryers, furnaces and kilns. Energy efficiency technical best practices applicable to these end uses are included in the Measure Library.best practices are grouped in two broad categories: Measures only applicable to the ammonia manufacturing

Measures only applicable to the ammonia manufacturing sector. Energy efficiency technical best practices applicable to only the ammonia manufacturing sector are included in the Measure Library – Ammonia Specific. Ammonia Specific.

2.3.3 Energy Management System Assessment (Excel File: A2A MA)

The energy management assessment tool is used to obtain information to assess the implementation of energy Management Best Practices (MPBs), illustrated by a high level of commitment, awareness, organization and acting in support of energy management.

Numerous studies have shown that application of energy management practices is a critical success factor for sustained improvement in energy use performance in industrial facilities.

2.3.4 Productivity Improvement Assessment (Excel File: A2A PIA)

The productivity improvement assessment tool is used to obtain information to evaluate at a high-level the current awareness regarding productivity improvement.

Integrating energy use performance with productivity improvement systems and strategies exposes the importance of energy efficiency, and optimize the use of resources.

2.3.5 Report Card and Opportunity Identification (Excel File: A2A RCOI)

The report card and opportunity identification tool is used to ―read‖ the data from the assessment tools (described in the previous points above) and to generate the results and output exhibits.

The results and exhibits include the energy use profiles, TBPs and MBPs benchmarks, and prioritized opportunities. These opportunities include associated savings in terms of energy, cost and GHG emissions.

2.3.6

EE&M Plan Checklist (Excel File: A2A Checklist and Action Plan)

Plan Checklist (Excel File: A2A Checklist and Action Plan) The energy efficiency and energy management (EE&M)

The energy efficiency and energy management (EE&M) plan checklist is used to determine the status of energy management system implementation. Elements that are not fully implemented are prioritized and then manually transferred to the action plan template, which is described in the next point.

2.3.7 EE&M Action Plan Template (Excel File: A2A Checklist and Action Plan)

The energy efficiency and management (EE&M) action plan template is contained in the same Excel workbook as the EE&M plan checklist. The action plan template is used to guide implementation of the opportunities and outstanding energy management system elements. The opportunities and elements are manually captured as action items, responsibilities are assigned, scheduled dates for completion are assigned and the completion of the actions is tracked.

2.4 Managing and Updating Toolkit

The toolkit will be managed by IIP. IIP will regularly update the toolkit and release revisions of the toolkit. This guide is for the user who will not have to make changes to the structure or methodology of the toolkit, and will only have to use the toolkit by populating it with data and information. IIP will provide training for users to use the A2A toolkit.

2.5 Structure of Guideline

Exhibit 3 illustrates the logical sequential flow of how the tools are used by a user.

Exhibit 3: Sequential use of tools

1 Energy Use Performance and 5 Technical Best Report Card and Practices Opportunity Assessment Identification
1
Energy Use
Performance and
5
Technical Best
Report Card and
Practices
Opportunity
Assessment
Identification
6
EE&M Plan
2
Checklist and
Technical
Action Plan
Measure Library
Template
4
Productivity
Improvement
3
Management
Assessment
Best Practices
Assessment
Tool 1: The technical best practices and energy use performance assessment is completed though an

Tool 1: The technical best practices and energy use performance assessment is completed though an on-site assessment, The technical best practices and energy use performance assessment is completed though an on-site assessment, using the Technical Assessment Excel workbook. The on-site assessment generally takes one to two days, depending on the complexity of the plant. To optimize the time during the on- site assessment a pre-site visit information request and site visit agenda are send to the plant well in advance of the site visit. Examples of the information request and agenda are included in the toolkit.

Tool 2: The technical measure library (included in the Measure Library Excel workbook) and the ammonia specific The technical measure library (included in the Measure Library Excel workbook) and the ammonia specific measure library (included in the Measure Library Ammonia Specific Excel workbook) are used as supporting references for the technical best practices assessment conducted in Tool 1 above. The best practices are cross referenced in the Technical Assessment workbook.

Tool 3: The energy management best practices assessment (which uses the Management Assessment Excel workbook) is generally The energy management best practices assessment (which uses the Management Assessment Excel workbook) is generally completed first in a workshop setting with representatives from different levels in the organization and who is using the energy management system of the plant.

Tool 4: Information is obtained regarding productivity improvement during the on-site assessment using the Productivity Information is obtained regarding productivity improvement during the on-site assessment using the Productivity Improvement Excel workbook.

Tool 5: Using the data, information and results from Tools 1, 2 and 3 the report card Using the data, information and results from Tools 1, 2 and 3 the report card is generated and opportunities are identified, using the Report Card and OI (OI: Opportunity Identification) Excel workbook.

Tool 6: The results from all the tools are used to manually develop both an energy efficiency The results from all the tools are used to manually develop both an energy efficiency and energy management plan and an action plan to ensure implementation of the actions. The EEM Plan Checklist and Action Plan Template Excel workbook is used to develop the plans in consultation with the plant. This development process is an iterative process and may require a number of meetings with the plant to complete the development of the plans.

Experience has shown that it is easier for a user to first be familiarized with the technical best practices and energy performance assessment, before building competence in energy management best practices assessment. The guideline follows this approach and will first discuss TBP and energy performance assessment, followed by the discussion on MBP assessment. Tools 4 and 5 are discussed in sequence as the last three sections of the guideline. Many guidelines exist to assist assessors in conducting an industrial energy assessment1, and this A2A guideline assumes that the user already has the necessary skills (see Section 1).

1 Office of Industrial Productivity and Energy Assessment, 2001. (US). Modern Industrial Assessments:

A Training Manual NRCan (Canada), 2007. Energy Savings Toolbox An Energy Audit Manual and Tool LBNL (US), 2010. Industrial Energy Audit Guidebook: Guidelines for conducting and Energy Audit in Industrial Facilities. EECA, 2007. Energy Audit Manual, New Zealand.

2.6

Common Elements in Tools

2.6 Common Elements in Tools Each Excel workbook contains a similar structure and the first few

Each Excel workbook contains a similar structure and the first few pages in each workbook (see Exhibit 4) are:

Revisions: This page tracks the revisions that are made in the workbook and is only to This page tracks the revisions that are made in the workbook and is only to be managed by IIP.

Index: This page contains an outline of the pages in the Excel workbook and provides descriptive This page contains an outline of the pages in the Excel workbook and provides descriptive names for each of the page tabs.

Instructions: A summary of the instruction to use the tool is provided on this page.workbook and provides descriptive names for each of the page tabs. Exhibit 4: Example of first

Exhibit 4: Example of first few tabs in Excel tools

summary of the instruction to use the tool is provided on this page. Exhibit 4: Example

8

3

Energy Use Performance and Technical Best Practices Assessment

Use Performance and Technical Best Practices Assessment Exhibit 5: Tool 1 in the sequence 1 Energy

Exhibit 5: Tool 1 in the sequence

1 Energy Use Performance and 5 Technical Best Report Card and Practices Opportunity Assessment Identification
1
Energy Use
Performance and
5
Technical Best
Report Card and
Practices
Opportunity
Assessment
Identification
6
EE&M Plan
2
Checklist and
Technical
Technical
Technical
Action Plan
Measure Library
Measure Library
Measure Library
Template
4
Productivity
Improvement
3
Management
Management
Management
Assessment
Best Practices
Best Practices
Best Practices
Assessment
Assessment
Assessment

3.1

Description

3.1.1 Objective

The purpose of the energy use performance assessment is to determine the profile of energy use by end use and energy source, and the overall plant energy intensity. The energy use profile is based on an energy balance, which is calculated using the actual annual purchased energy amounts and the estimated energy used by equipment in the facility. The energy intensity is an indication of the energy used per production unit.

The energy use profile assists in identifying the end uses that use the largest amount of energy and guide prioritization of the opportunities. Implementing energy efficiency opportunities at the end uses that consume the most energy will result in the most significant energy and cost savings.

The overall plant energy intensity is a key performance indicator for the plant and can be compared with the requirements national standards, and international best practice plants.

The purpose of the technical best practice (TBPs) assessment is to determine which TBPs are implemented at the plant, and to develop benchmarks for the plant. The benchmarks highlights the areas where opportunities exist to implement TBPs, and indicate the potential that still exist to implement TBPs.

3.1.2 Variables Collected

The Energy Technical Assessment questionnaire collects information on energy purchased and the energy used by equipment in the plant. The questionnaire includes

questions pertaining to the overall energy use, production, characteristics of the equipment, and the presence

questions pertaining to the overall energy use, production, characteristics of the equipment, and the presence of energy efficiency measures. The Excel workbook includes the following sections:

Section A gathers general information regarding the facility production and procurement of energy. gathers general information regarding the facility production and procurement of energy.

Section B is specifically related to generic equipment, such as cooling, heating and motive power. is specifically related to generic equipment, such as cooling, heating and motive power.

Section C outlines types of heating, ventilation and air conditioning systems specifically associated with occupancy comfort. outlines types of heating, ventilation and air conditioning systems specifically associated with occupancy comfort.

Section D is an overview of system practices, other major energy consuming equipment, and the implementation of is an overview of system practices, other major energy consuming equipment, and the implementation of emerging technologies.

Section E collects data on ammonia production practices only. collects data on ammonia production practices only.

3.1.3 Layout of the Tool

The following exhibit illustrates the layout of the Technical Best Practice Assessment tool as shown in the index tab.

Exhibit 6: Technical best practice assessment index table

Exhibit 6: Technical best practice assessment index table The end uses referred to in the Index

The end uses referred to in the Index Table are:

Process: Energy end uses applicable to the manufacturing processes and generic to different manufacturing plants. Energy end uses applicable to the manufacturing processes and generic to different manufacturing plants.

Comfort: Energy end uses that support the comfort of the employees, such as lighting, space heating Energy end uses that support the comfort of the employees, such as lighting, space heating and cooling, and air ventilation to maintain appropriate air quality for employees.

Other: Energy end uses applicable to processes not covered by ―process‖ and ―comfort‖ end uses, and Energy end uses applicable to processes not covered by ―process‖ and ―comfort‖ end uses, and non-generic energy end uses specific to the processes in a specific manufacturing sector.

The questionnaire is categorized according to the categories described above. For each Section B to

The questionnaire is categorized according to the categories described above. For each Section B to E, the equipment number, type, operating hours and fuel-type used (where applicable) is requested. The energy efficiency features of the equipment are also requested at the end of each section. Enter only operating equipment and do not include back-up equipment. The Excel workbook contains the following sheets:

Revisions

See section 2.6

Index

See section 2.6

Instructions

See section 2.6

TA 1

Plant information

Enter general information about the plant and its operation.

TA 2

Energy and Production Data

In Section A.1, statistics on the company purchases of energy is collected. It is important to ONLY list energy used as fuel, and EXCLUDE energy used as feedstock in the production of ammonia. The lower heating value (LHV) is required to determine the fuel energy content to use in the Energy Balance tab. The source used for LHVs is the ―BEST Cement for China‖ tool developed by Lawrence Berkeley National Laboratory. The LHV for some fuels may vary in energy content and can be overwritten if necessary. The quantity of fuel and its units are required, as well as the purchased cost. The cost per unit of fuel is summarized in the final column of the table in A.1, and used to provide a verification of reported data.

In section A.2, itemize the possible types of non-purchased fuel and self-generated power. The fuel lower heating value (LHV) is not provided and must be entered.

In Section A.3, provide the production data for the plant for the five most important products, listing the highest revenue generator first, followed by the others in descending order.

In section A.4, provide the quantity and LHV of the fuels used as feedstock (raw material used in the production process). The feedstock fuel should be distinguished from that used as fuel.

TA 3

Cooling and Heating Equipment

In this section, the questionnaire requires characteristics of the following equipment:

cooling/refrigerating equipment, ovens, dryers, kilns, furnaces and boilers. All

equipment that provides cooling and heating for occupancy comfort should NOT be listed in this

equipment that provides cooling and heating for occupancy comfort should NOT be listed in this section but in sections C.1 and C.2.

For each equipment type, it is possible to give up to four capacities. Each capacity represents a size range; however it is the average value of that size range which must be entered. See section 3.2 for more detail on average capacities.

The features questions should be left blank if the plant has no equipment in the given category.

TA 4

Compression Heating Equipment

All equipment related to compression is characterized in this section. This includes compressors for pneumatic equipment and compression systems for process gas or air systems.

For each equipment type, it is possible to give up to four capacities. Each capacity represents a size range; however it is the average value of that size range which must be entered. See section 3.2 for more detail on average capacities.

The features questions should be left blank if the plant has no equipment in the given category.

TA 5

Motor Related

The parameters of motive power equipment are summarized in this section, including fans, pumps, motors and conveyors. See section 3.2 for accuracy and assumptions.

TA 6

Onsite Transport

This section requires the characteristics of the vehicles used on-site for production related purposes, such as forklifts and cranes and excludes vehicles used off-site or delivery fleets.

TA 7

Comfort-Lighting

For all lighting fixtures, their characteristics are entered in this section. See section 3.2 for accuracy and assumptions.

The number of lamps refers to both standard and high efficient types (i.e. if there are 10 metal halide lamps, all of which are high efficiency, 10 should be entered in both columns).

The classification of lamps as energy efficient is at the discretion of the user. However the following table can be used as a rough guideline for that allocation

Exhibit 7: Tools in the toolkit and results to be achieved   Energy Type Standard

Exhibit 7: Tools in the toolkit and results to be achieved

 

Energy

Type

Standard

Efficient

Fluorescent

T17, T12

T5, T8

CFL's

All

Metal Halide

Mercury Vapour

All other

High Pressure

Sodium

All

Incandescent

All

TA 8

Comfort-HVAC and Air System

Equipment providing heating and cooling for occupancy comfort, is entered in this section with details on characteristics.

The ventilation data entered in the third table refers only to the motor power. If there is heating of make-up air, the heating capacity should be entered in the second table (non-packaged HVAC equipment).

TA 9

Other & System Practice

All equipment that does not fit into the other categories and is not specifically related to ammonia production is outlined in this section, e.g. scrubbers, miscellaneous machines. Up to five pieces of these types of equipment can be entered, as it is expected that most equipment will be captured in the other sections.

TA 10

Ammonia Production

In this section, all ammonia manufacturing specific equipment with characteristics that do not fit into other sections is summarized here e.g. cryogenic purifier. More details are in section 3.4.

TA 11

Energy Balance

In this tab, the energy balance of the purchased energy and the energy used by the reported equipment is determined (see section 3.2.2 for details on the calculation of energy balance)

TA 12

TA 12 Conversion In this tab, conversions used in the calculations are provided for reference purposes

Conversion

In this tab, conversions used in the calculations are provided for reference purposes only.

3.1.4 Flow of Information Between Tools

The responses from this questionnaire are used to:

Calculate the energy balance and portion of energy used by each end use and energy source.Tools The responses from this questionnaire are used to: Calculate the technical best practice scores in

Calculate the technical best practice scores in the Report Card and Opportunity Identification tool (see section 7), where a score for each TBP category is determined.portion of energy used by each end use and energy source. Evaluate the opportunities available to

Evaluate the opportunities available to a facility to implement improved TBP practices (see section 7).7), where a score for each TBP category is determined. Develop an Energy Efficiency and Management

Develop an Energy Efficiency and Management Plan using the checklist and template tools (see section 8.2).to implement improved TBP practices (see section 7). 3.1.5 Using the Tool The equipment related tabs

3.1.5 Using the Tool

The equipment related tabs (TA 3 to TA 10) are divided into two groups of questions, followed by a table where additional opportunities can be entered.

Section A: First Question group: Purchased Energy

The first part of this group of questions requires details on the purchased energy at your facility including the quantity (with fixed units) and cost. The cost per unit is provided to verify the data, by checking that this is a reasonable value.

The lower heating value of the fuel (LHV) is provided as reference, but may be overwritten to customize it for the fuel type. The first selections are common energy types and drop down menus provide additional fuel-type selections.

Exhibit 8: Example of Technical Assessment Purchased fuel questions

8: Example of Technical Assessment Purchased fuel questions The quantity of steam purchased can also be

The quantity of steam purchased can also be entered here, provided that the steam temperature (in degree Kelvin) and pressure (in bar) are available. The LHV (or enthalpy) of the steam can be calculated by linking to the ―water97_V13‖ file (as described below) or by entering the known LHV of the steam.

Section A: Link to water tables for steam enthalpy calculation The energy content or enthalpy

Section A: Link to water tables for steam enthalpy calculation

The energy content or enthalpy of steam can be calculated by linking the technical assessment to the water97_V13 add-in. This is done as follows:

Copy the water97_V13.xla file to the appropriate directoryto the water97_V13 add-in. This is done as follows: Add the water97_V13 file (provided) to Excel

Add the water97_V13 file (provided) to Excel Add-in‘s in‘s

Select ―Edit links‖ in Excel and change the source link for the water97_V13 file if necessary if necessary

Select ―Open source‖ from the ―Edit links‖ pop-up menu above. -up menu above.

Select ―Enable macros‖ in the technical assessmentsource‖ from the ―Edit links‖ pop -up menu above. Section A: Second Question group: Sold and

Section A: Second Question group: Sold and self-generated Energy

The second part of this section is the documentation of sold fuel from the facility, including self-generated electricity and steam generated on-site.

Exhibit 9: Example of Technical Assessment Sold and self-generated fuel questions

Technical Assessment Sold and self-generated fuel questions Section A: Third Question group: Production Data This

Section A: Third Question group: Production Data

This section is the production summary of the products in the facility. In the first table, list the products produced beginning with the most important. Specifics on the output, sales and energy consumption may be listed in the table.

Exhibit 10: Example of Technical Assessment Sold and self-generated fuel questions Section A: Fourth Question

Exhibit 10: Example of Technical Assessment Sold and self-generated fuel questions

Technical Assessment Sold and self-generated fuel questions Section A: Fourth Question group: Purchased Energy for

Section A: Fourth Question group: Purchased Energy for Feedstock

This section is a summary of the fuel used as feedstock in the plant. The total quantity of feedstock and fuel for three main types of fuel are provided at the end of the table for verification.

Exhibit 11: Example of Technical Assessment feedstock questions

11: Example of Technical Assessment feedstock questions Sections B, C, D and E are structured in

Sections B, C, D and E are structured in the same format and are described generally below.

Sections B to E: First Question Group Equipment Information

The first question group requires detailed equipment data as shown in the following exhibit.

Exhibit 12: Example of Technical Assessment equipment features questions (first question group) This section of

Exhibit 12: Example of Technical Assessment equipment features questions (first question group)

equipment features questions (first question group) This section of the questionnaire is completed by: Filling

This section of the questionnaire is completed by:

Filling in the blank white cells where a response is required. white cells where a response is required.

Selecting from the drop down menu where available as shown below:in the blank white cells where a response is required. Exhibit 13: Example of Technical Assessment

Exhibit 13: Example of Technical Assessment drop down menu

Exhibit 13: Example of Technical Assessment drop down menu Indicating that a section is not applicable

Indicating that a section is not applicable by selecting the ―I do not have this equ ipment‖ box at the beginning of most sections: equipment‖ box at the beginning of most sections:

Exhibit 14: Example of Technical Assessment “section not applicable” box

of Technical Assessment “section not applicable” box Some grey cells have an autofill , and do

Some grey cells have an autofill , and do not require user input (i.e. the ―Annual Energy Use‖ column in autofill, and do not require user input (i.e. the ―Annual Energy Use‖ column in Exhibit 12). Therefore it is important to fill out the questionnaire in order.

For each piece of equipment that is entered, all information in that row pertaining to the equipment is required (eg. fuel type, operating hours, efficiency rating) to avoid subsequent calculation errors (such as energy balance and best practice scores). Please take special note of the following specific examples:the ―Annual Energy Use‖ column in Exhibit 12). Therefore it is important to fill out the

If there is no equipment meeting criteria requested for the featured equipment in the plant,

If there is no equipment meeting criteria requested for the featured equipment in the plant, enter ―0‖ in these cells (e.g. If there are 15 fluorescent lamps, in the plant, enter ―0‖ in these cells (e.g. If there are 15 fluorescent lamps, and none are high efficient, enter ―15‖ for ―number of (fluorescent) lamps, and enter ―0‖ for ―number of efficient lamps‖).

The number of high efficiency equipment must not exceed the number of equipment for each capacity range. For example: in Exhibit 12, there are ten 2kW pumps. The sum of ―high efficiency motors‖ and ―premium efficiency motors‖ must be ten 2kW pumps. The sum of ―high efficiency motors‖ and ―premium efficiency motors‖ must be ten or less in this capacity range.

If there is an option for ―high efficiency‖ as well as ―premium efficiency‖ as is the case in Exhibit 12 for pumps, you can consider a piece of equipment as the case in Exhibit 12 for pumps, you can consider a piece of equipment as high or premium efficiency, but not both.

Recording equipment as ―high‖ or ―premium‖ efficiency is left to the discretion of the user. In equipment as ―high‖ or ―premium‖ efficiency is left to the discretion of the user. In some cases, guidelines are given in the manual for the given measure. In general, it is unlikely that old equipment (greater than 10 to 15 years, depending on the type of equipment) can be considered ―high efficiency‖

NTF (Not Technically Feasible) should be entered if the measure is not applicable for the given piece of equipment.type of equipment) can be considered ―high efficiency‖ For large counts of equipment, where it is

For large counts of equipment, where it is difficult to provide and exact number of equipment (eg number of motors or light fixtures), a best estimate can be provided. The following can be used to provide this estimate:measure is not applicable for the given piece of equipment. Review of line drawings and determine

Review of line drawings and determine capacity.The following can be used to provide this estimate: Equipment count lists available from maintenance staff

Equipment count lists available from maintenance staff / operators.estimate: Review of line drawings and determine capacity. Name plate capacity of equipment with multiple motors

Name plate capacity of equipment with multiple motors can be grouped into one piece of equipment.count lists available from maintenance staff / operators. Estimate equipment count/capacity rating/efficiency rating

Estimate equipment count/capacity rating/efficiency rating during walk-through audits and consult with staff on count/ratings of equipmentmultiple motors can be grouped into one piece of equipment. Boilers require special attention, due to

Boilers require special attention, due to a large number of features that can be applied:audits and consult with staff on count/ratings of equipment As explained in 3.1.3, it is possible

As explained in 3.1.3, it is possible to give up to four capacities, each capacity representing a size range. However, in the case of boilers, it is recommendable to only group boilers if there are more boilers than the number of lines provided. If grouping is required, they should be grouped not only by size, but also according to boiler type and economizer type (as entered in cells G35 to H38 in TA 3). For example, if the plant has two 15 MW boilers, one with a standard economizer and the other with a condensing economizer, these two boilers should be entered on separate lines, despite being the same size).due to a large number of features that can be applied: Sections B to E: Second

Sections B to E: Second Question Group Features Questions

The second question group refers to the entire system of a given end-use. I.e. in the exhibit below the questions refer to all pumps, fans, etc.

Exhibit 15: Example of Technical Assessment general questions (second question group) Drop-down following implications:

Exhibit 15: Example of Technical Assessment general questions (second question group)

Assessment general questions (second question group) Drop-down following implications: menu selections for

Drop-down

following implications:

menu

selections

for

equipment

features

have

responses

with

the

No Implementation ‖ implies that the measure is applicable but not implemented. No Implementation‖ implies that the measure is applicable but not implemented.

Partially Adopted ‖ implies that the measure has been considered and introduced but is not Partially Adopted‖ implies that the measure has been considered and introduced but is not fully adopted.

Fully Adopted ‖ implies that the measure has been fully adopted in the plant, with Fully Adopted‖ implies that the measure has been fully adopted in the plant, with controls and verification in place where applicable.

Not Technically Feasible ‖ implies that the measure is not an option due to technical Not Technically Feasible‖ implies that the measure is not an option due to technical limitations. Enter ―NTFfor measures with this qualification.

Sections B to E: Additional Opportunities

The bottom section of each tab allows the user to record any additional opportunities he/she noticed but weren‘t covered in the first two question groups.

Exhibit 16: Example of Additional Opportunities boxes

Exhibit 16: Example of Additional Opportunities boxes All sections B to E need to be reviewed,

All sections B to E need to be reviewed, and those that are applicable to be filled in with equipment type, characteristics, number, and hours of operation. For the Technical Assessment, verify that for all applicable sections B to E, the equipment feature questions at the end of each section are ALL be answered, including all features questions in Section D (TA 9); input either the level of implementation or NTF (not technically feasible). In sections where the equipment is not installed in the plant,

these can be omitted by indicating inapplicable sections in the boxes provided at the beginning

these can be omitted by indicating inapplicable sections in the boxes provided at the beginning of each section.

It is anticipated that completing the questionnaire during an on-site assessment requires one to two days, depending on the complexity of the plant, the availability of the data, and verification of the energy balance (see section 3.2).

3.2 Accuracy, Detail and Making Assumptions

This questionnaire requires that ALL applicable sections to be filled in using one of the responses available in the menus with all fuels purchased accounted for by the equipment using it.

3.2.1 Average equipment capacities and operating hours

There may be numerous pieces of equipment under each type, and it is recommended to categorize this by size. Up to six ranges of equipment sizes can be entered, by providing weighted average equipment capacity values and average hours of operation for each range.

For example, if there are 25 motors ranging in size from 0.3 to 0.5 kW, operating between 500 to 6000 hours per year, the average range of equipment capacity would be:

Average range [kw] =

(motor power [kw]) x (motor hours of operation [h]) hours of operation [h]])

The hours of operation entry would be the average hours for all the motors in that range.

3.2.2 Energy Balance

The following exhibit shows the energy balance tables, however most of the end-uses and some of the energy types were hidden for this example.

Exhibit 17: Portion of the energy balance tables The fuel purchased is balanced against the

Exhibit 17: Portion of the energy balance tables

Exhibit 17: Portion of the energy balance tables The fuel purchased is balanced against the fuel

The fuel purchased is balanced against the fuel used by each of the equipment in the plant, by each fuel types categorized as follows: Electricity, Natural, Gas, Steam, Fuel Oil No.2, Fuel Oil No.6, Gasoline, Propane, Other (fuel that does not fit into the previous categories).

The energy content of the purchased fuels is determined by summing the energy content of each fuel type.Other (fuel that does not fit into the previous categories). The sold energy is the summation

The sold energy is the summation of the energy content of the sold fuels. For sold energy products such as steam, the energy value of the steam is allocated to the type of fuel used to generate the steam, with an adjustment applied to account for the conversion of fuel to steam. This adjustment is assumed to be 0.9, which is typical of boilers and reformer conversion.determined by summing the energy content of each fuel type. Self-generated energy is the total steam

Self-generated energy is the total steam and electricity generated on-site.be 0.9, which is typical of boilers and reformer conversion. Net-imported energy is the net purchased

Net-imported energy is the net purchased energy minus self-generated energyenergy is the total steam and electricity generated on-site. The energy used by fuel type is

The energy used by fuel type is determined by summing the energy use per equipment end-use for that fuel type.steam and electricity generated on-site. Net-imported energy is the net purchased energy minus self-generated energy 21

The adjustment factor is the ratio of net imported fuel to utilized fuel for each

The adjustment factor is the ratio of net imported fuel to utilized fuel for each fuel, adjustment factor is the ratio of net imported fuel to utilized fuel for each fuel, and should always be less than one because of the following assumptions:

Equipment is assumed to be 100% efficient.be less than one because of the following assumptions: The hours of operation are applied directly

The hours of operation are applied directly to operating time without adjustment for load factors applied to equipment.assumptions: Equipment is assumed to be 100% efficient. Equipment capacity is assumed to be the rated

Equipment capacity is assumed to be the rated capacity.without adjustment for load factors applied to equipment. If the adjustment factor is much greater than

If the adjustment factor is much greater than one, the following should be reviewed to address this: adjustment factor is much greater than one, the following should be reviewed to address this:

Review quantity of purchased energy (may be too high).than one, the following should be reviewed to address this: Review the hours of operation of

Review the hours of operation of equipment using the fuel with the discrepant adjustment factor.this: Review quantity of purchased energy (may be too high). Review the capacity rating of equipment

Review the capacity rating of equipment using the fuel with the discrepant adjustment factor.using the fuel with the discrepant adjustment factor. Review the quantity of equipment using the fuel

Review the quantity of equipment using the fuel with the discrepant adjustment factor.using the fuel with the discrepant adjustment factor. Review the firing time and efficiency of equipment

Review the firing time and efficiency of equipment where this is reported, such as for boilers and ovens.using the fuel with the discrepant adjustment factor. Investigate whether all equipment using this fuel have

Investigate whether all equipment using this fuel have been accounted for.where this is reported, such as for boilers and ovens. When the adjustment factor is close

When the adjustment factor is close to one, then all purchased energy is being accounted for by all reported equipment.

If the adjustment factor for steam as a fuel is much greater or less than one, review adjustment factor for steam as a fuel is much greater or less than one, review the following:

That the source of the steam has been correctly identified in TA2fuel is much greater or less than one, review the following: That the fuel used as

That the fuel used as steam has not been generated using another source fuel accounted for elsewhere (e. g. natural gas generated steam) and therefore added twice in the energy balancethe source of the steam has been correctly identified in TA2 3.3 Technical Best Practices Assessment

3.3 Technical Best Practices Assessment

As discussed in section 3.1.3, each tab of the Energy Technical Assessment questionnaire presents best practices (energy efficiency measures) associated with each major equipment end-use. For each of these sections, a rating of the adoption level of these practices is required to be entered in the questionnaire (section 3.1.5).

The score of best practices per end use is the ratio of the applied best practices to the total applicable best practices. The results of this evaluation is to provide a report of how many of the applicable technical best practices have been implemented and outline the opportunities available to the facility (section 7).

3.4 Ammonia Sub-Sector Specific Assessment

The ammonia subsector energy use and best practice assessment is presented in

It is possible to list

equipment associated with ammonia specific processes that do not fit in the other

section E of the Energy Technical Assessment questionnaire.

tabs of the questionnaire. Up to five such types of equipment can be detailed, in

tabs of the questionnaire. Up to five such types of equipment can be detailed, in order of energy use. It is expected that most equipment will be captured in tabs B.1 to C.2.

The ammonia specific table is shown in the exhibit below.

Exhibit 18: Ammonia sub-sector specific data table

to C.2. The ammonia specific table is shown in the exhibit below. Exhibit 18: Ammonia sub-sector

4

Technical Measure Library

4 Technical Measure Library Exhibit 19: Tool 2 in the sequence 1 Energy Use Performance and

Exhibit 19: Tool 2 in the sequence

1 Energy Use Performance and 5 Technical Best Report Card and Practices Opportunity Assessment Identification
1
Energy Use
Performance and
5
Technical Best
Report Card and
Practices
Opportunity
Assessment
Identification
6
EE&M Plan
2
Checklist and
Technical
Technical
Technical
Action Plan
Measure Library
Measure Library
Measure Library
Template
4
Productivity
Improvement
3
Management
Management
Management
Assessment
Best Practices
Best Practices
Best Practices
Assessment
Assessment
Assessment

4.1

Description

4.1.1 Objective

The purpose of the Technical Measure Library is to catalogue energy efficient technical best practice measures in a standard format. This library lists new technology, improvements in existing technology and operational and maintenance best practices that improve energy efficiency and/or energy intensity. Each of these measures is cross-referenced in the Energy Technical Assessment in each of the questions on the equipment features. They form the basis of technical best practice assessment (see section 3.3).

There are two measure libraries, the Generic Technology Measures Library that can apply to all industries, and the Ammonia Specific Technology Measure Library that applies to ammonia manufacturing sector only.

4.1.2 Variables Collected

The library organizes energy efficiency technical best practices by end use and several process levels. Each energy savings measure is entered in a separate tab with its associated parameters, providing the energy savings, the fuel type saved, and a detailed description of the measure along with the reference sources of information.

4.1.3

Layout of Tool

4.1.3 Layout of Tool There are two types of tabs in the Excel spreadsheet of this

There are two types of tabs in the Excel spreadsheet of this toolkit module:

Index

This is a summary of all the energy efficient measures in the library. It lists the following for each measure: Tab number, Measure Description, a breakdown of applicable plant level to which this measure is applied (Plant Region, Plant Area, System, End Use, Other grouping), the applicable Industry (typically all for this generic library), percent savings for each fuel type (natural gas, electricity, refined petroleum products, other fuel), and finally, the measure life. For more information on navigating through the Measure Library using the Index tab see section 4.1.5.

Tabs 1 to 144

Each tab in this library has the same format. It is a repository of the details of each energy efficiency measure.

Exhibit 20: Example of Measure Library tab The measure information provided includes: Profile type: each

Exhibit 20: Example of Measure Library tab

Exhibit 20: Example of Measure Library tab The measure information provided includes: Profile type: each measure

The measure information provided includes:

Profile type: each measure is classified as either technology, operating, behavioural or maintenance. each measure is classified as either technology, operating, behavioural or maintenance.

Relative implementation cost: each measure is rated as high, medium or low to indicate the relative cost of each measure is rated as high, medium or low to indicate the relative cost of implementation:

High – there would be significant investment to implement the measure. A detailed economic feasibility study there would be significant investment to implement the measure. A detailed economic feasibility study would generally be required. Most measures in this category would involve the replacement of large equipment, or large retrofit projects.

Medium – may involve inexpensive equipment replacement or retrofits. An economic feasibility study is generally advisable. may involve inexpensive equipment replacement or retrofits. An economic feasibility study is generally advisable.

Low – little or no capital cost would be required. Often involves behavioural changes and

Low – little or no capital cost would be required. Often involves behavioural changes and only little or no capital cost would be required. Often involves behavioural changes and only a rudimentary economic assessment may be needed.

Relative implementation difficulty: each measure is rated as high, medium or low to indicate the relative difficulty of each measure is rated as high, medium or low to indicate the relative difficulty of implementation:

High – the implementation of the measure involves complex change to the plant. The measure may the implementation of the measure involves complex change to the plant. The measure may involve redesign, and a detailed engineering feasibility assessment would be required.

Medium – may involve small equipment replacement or simple retrofits. A less extensive technical feasibility assessment may involve small equipment replacement or simple retrofits. A less extensive technical feasibility assessment is usually required.

Low – relatively easy to implement the opportunities and most often involves maintenance related opportunities and/or relatively easy to implement the opportunities and most often involves maintenance related opportunities and/or behavioural changes. Technical feasibility studies are generally not required.

Level (1 to 5): further describe each measure based on which part of the plant and which category of further describe each measure based on which part of the plant and which category of equipment the measure is relevant to. This allows the user to filter the measure list on the Index tab by a variety of criteria.

Energy type: five energy types are listed: natural gas, electricity, refined petroleum products, and other. Measure savings five energy types are listed: natural gas, electricity, refined petroleum products, and other. Measure savings are shown for each fuel type. As illustrated in Exhibit 20 (boiler economizer), some measures show savings for more than one energy type. This indicates that there are multiple energy source options for the given end-use; the savings will be calculated for the energy source selected in the Technical Assessment, not all of the energy sources listed in the library. For the measures which may save other types of energy than those listed, the fuel type is entered in the ―Other fuel‖ line.

Savings percentage: the amount of energy that would be saved for that particular fuel type. The savings the amount of energy that would be saved for that particular fuel type. The savings is given as a percentage of the end-use consumption (not the total plant energy use). Savings are dependent on site specific conditions and the savings indicated in the measure library provides only typical values, or ranges of savings for implementation of a specific measure, as guidance. These values are reported in literature or obtained from industrial experts. Savings are provided per opportunity and are not additive. Furthermore, interactive effects will reduce the total potential savings if more than one opportunity is implemented.

Description: explanation of the measure, and the means by which the measure saves energy. explanation of the measure, and the means by which the measure saves energy.

Reference Sources: the source of the savings percentage and measure life. the source of the savings percentage and measure life.

4.1.4 Flow of information Between the Tools

The measures from this library are used to:

Supporting references to assist in populating the Energy Technical Assessment (see section 3.3).the Tools The measures from this library are used to: Populate the opportunities available to a

Populate the opportunities available to a facility to implement improved TBP practices (see section 7).library are used to: Supporting references to assist in populating the Energy Technical Assessment (see section

4.1.5

Using the Tool

4.1.5 Using the Tool This toolkit module can be used to cross reference the energy efficiency

This toolkit module can be used to cross reference the energy efficiency measures in the technical assessment or the opportunities listed in the report card. Each measure listed in the technical best practice assessment has a number in column L, which corresponds to the measure number in the Measure Library. Note: do not change the Measure Number or the tab numbers, as these are used to link to other toolkit modules.

The Index tab can be used to easily navigate the library. The first column contains the Tab Numbers (measure number) which can be clicked to view that particular tab. Filters are set up to show the measures by groups, or to sort measures as desired:

click the down-arrow on any of the column headings to view the filter options. For example, as shown in Exhibit 20, to view only the measures related to pumps, click the filter arrow in the ―Level 4 – Enduse‖ column, un-check ―Select All‖ then check the box beside ―Pumps‖ and click Ok.

Exhibit 21: Measure Library Index Tab

un - check ―Select All‖ then check the box beside ―Pumps‖ and click Ok. Exhibit 21:

5

Management Best Practices Assessment

5 Management Best Practices Assessment Exhibit 22: Tool 3 in the sequence 1 Energy Use Performance

Exhibit 22: Tool 3 in the sequence

1 Energy Use Performance and 5 Technical Best Report Card and Practices Opportunity Assessment Identification
1
Energy Use
Performance and
5
Technical Best
Report Card and
Practices
Opportunity
Assessment
Identification
6
EE&M Plan
2
Checklist and
Technical
Technical
Technical
Action Plan
Measure Library
Measure Library
Measure Library
Template
4
Productivity
Improvement
3
Management
Management
Management
Assessment
Best Practices
Best Practices
Best Practices
Assessment
Assessment
Assessment

5.1

Description

5.1.1 Objective

The purpose of the energy management assessment questionnaire is to evaluate the implementation of energy management best practices in an organization. This sets the context for taking steps to improve Energy Management at both the corporate and facility level with the additional support provided by the Energy Efficiency and Management Plan and Action Plan tool (see section 8.2).

5.1.2 Variables collected

The questionnaire organizes management best practices into a set of seven categoriescommitment, planning, organization, project development, financing, measurement and reporting, communicationeach of which implies roles, responsibilities, procedures and competencies. The management best practice analysis is applied at two levels: corporate level and plant level.

Additional information on the quality systems in the plant is also gathered, which will tie into the productivity improvement system assessment (see section 0).

5.1.3 Layout

The following exhibit illustrates the layout of the Management Best Practice Assessment tool as shown in the index tab.

Exhibit 23: Management Best Practice Assessment index table There are seven tabs in the Excel

Exhibit 23: Management Best Practice Assessment index table

Exhibit 23: Management Best Practice Assessment index table There are seven tabs in the Excel spreadsheet

There are seven tabs in the Excel spreadsheet of this toolkit module:

Revisions

See section 2.6

Index

See section 2.6

Instructions

See section 2.6

MA 1

Contact information

Enter general information about the plant and its operation.

MA 2

Corporate improvement

Obtain general information about the operation of the company.

MA 3

Corporate survey

Energy Management best practices at the corporate level. The information collected in this tab will disclose the level of importance or priority that is given to energy management and energy conservation by assessing the energy management systems in place at a corporate level.

MA 4

Plant survey

Energy Management best practices at the plant/facility level. The information collected in this tab is another indication of the company‘s commitment to energy management, but in this case by assessing the energy management systems in place a plant level.

5.1.4

Flow of Information Between Tools

5.1.4 Flow of Information Between Tools The responses from this questionnaire are used to: Calculate the

The responses from this questionnaire are used to:

Calculate the management best practice scores in the Report Card and Opportunity Identification tool (see section 7), where a score for each MBP category is determined.Tools The responses from this questionnaire are used to: Evaluate the opportunities available to a facility

Evaluate the opportunities available to a facility to implement improved MBP practices (see section 7).7), where a score for each MBP category is determined. Develop an Energy Efficiency and Management

Develop an Energy Efficiency and Management Plan and Action Plan using the checklist and template tool (see section 8.2).to implement improved MBP practices (see section 7). 5.1.5 Using the Tool This section of the

5.1.5 Using the Tool

This section of the questionnaire is completed by:

Filling in the blank white cells where a response is required.the Tool This section of the questionnaire is completed by: Selecting from the drop down menu

Selecting from the drop down menu where available as shown in Exhibit 24.in the blank white cells where a response is required. Exhibit 24: Example of Management Assessment

Exhibit 24: Example of Management Assessment drop down menu

Exhibit 24: Example of Management Assessment drop down menu Selection from the buttons provided. Exhibit 25:

Selection from the buttons provided.Exhibit 24: Example of Management Assessment drop down menu Exhibit 25: Example of Management Assessment button

Exhibit 25: Example of Management Assessment button selection

25: Example of Management Assessment button selection Drop down menu selections for equipment features have

Drop down menu selections for equipment features have responses with the following implications

― Yes ‖ response implies that the measure is fully implemented.

Yes‖ response implies that the measure is fully implemented.

A ― Partially ‖ response implies that the measure has been considered or

A

Partially‖ response implies that the measure has been considered or

introduced but is not fully adopted.

A ― No ‖ response implies that the measure is not considered or adopted.

A

No‖ response implies that the measure is not considered or adopted.

All sections are required to be filled out for this questionnaire. It is anticipated that

All sections are required to be filled out for this questionnaire. It is anticipated that completing the questionnaire takes 45-60 minutes.

5.2 Accuracy, Detail and Making Assumptions

This questionnaire requires that ALL sections to be filled in using one of the responses available in the menus.

No assumptions need to be made for this toolkit element.

6

Productivity Improvement Assessment

6 Productivity Improvement Assessment Exhibit 26: Tool 4 in the sequence 1 Energy Use Performance and

Exhibit 26: Tool 4 in the sequence

1 Energy Use Performance and 5 Technical Best Report Card and Practices Opportunity Assessment Identification
1
Energy Use
Performance and
5
Technical Best
Report Card and
Practices
Opportunity
Assessment
Identification
6
EE&M Plan
2
Checklist and
Technical
Technical
Technical
Action Plan
Measure Library
Measure Library
Measure Library
Template
4
Productivity
Improvement
3
Management
Assessment
Management
Management
Best Practices
Best Practices
Best Practices
Assessment
Assessment
Assessment

6.1

Description

6.1.1 Objective

The purpose of the Productivity Improvement Assessment questionnaire is to evaluate the implementation and awareness of continuous improvement practices in an organization. This sets the context for taking steps to improve productivity with the additional support provided by the Energy Efficiency and Management Plan and Action Plan checklist and template tool (see section 8.2).

6.1.2 Variables collected

The questionnaire organizes productivity improvement practices by sustainability actions and the methods/tools used to achieve continuous improvement.

Additional information on the management systems in the plant is gathered under the Energy Management Assessment (see section 5).

6.1.3 Layout

The following exhibit illustrates the layout of the Productivity Improvement Assessment tool as shown in the index tab.

Exhibit 27: Productivity Improvement Assessment index table

Improvement Assessment tool as shown in the index tab. Exhibit 27: Productivity Improvement Assessment index table
There are four tabs in the Excel spreadsheet of this toolkit module: Revisions See section

There are four tabs in the Excel spreadsheet of this toolkit module:

Revisions

See section 2.6

Index

See section 2.6

PI 1

Plant information

Enter general information about the plant.

PI 2

Productivity improvement

Enter more detailed information about the company and plant. This section includes company presence within the country or worldwide, production quantities, and questions related to productivity and profitability.

6.1.4 Flow of information Between Tools

The responses from this questionnaire are used to:

Define an Energy Efficiency and Management Plan and Action Plan using the checklist and template tool (see section 8.2).Tools The responses from this questionnaire are used to: 6.1.5 Using the Tool This section of

6.1.5 Using the Tool

This section of the questionnaire is completed by:

Filling in the blank white cells where a response is required.the Tool This section of the questionnaire is completed by: Selecting from the drop down menu

Selecting from the drop down menu where available.in the blank white cells where a response is required. Selection from the buttons provided. Selecting

Selection from the buttons provided.required. Selecting from the drop down menu where available. Selecting (by clicking) from the list of

Selecting (by clicking) from the list of options given (questions 2.2.2 to 2.2.4). Note: more than one option can be selected in these questions as shown below.menu where available. Selection from the buttons provided. Exhibit 28: Example of Productivity Improvement Assessment

Exhibit 28: Example of Productivity Improvement Assessment multiple option selection

Improvement Assessment multiple option selection All sections are required to be filled out for this

All sections are required to be filled out for this questionnaire. It is anticipated that completing the questionnaire takes 20-30 minutes.

7

Report Card and Opportunity Identification

7 Report Card and Opportunity Identification Exhibit 29: Tool 5 in the sequence 1 Energy Use

Exhibit 29: Tool 5 in the sequence

1 Energy Use Performance and 5 Technical Best Report Card and Practices Opportunity Assessment Identification
1
Energy Use
Performance and
5
Technical Best
Report Card and
Practices
Opportunity
Assessment
Identification
6
EE&M Plan
2
Checklist and
Technical
Technical
Technical
Action Plan
Measure Library
Measure Library
Measure Library
Template
4
Productivity
Improvement
3
Management
Management
Management
Assessment
Best Practices
Best Practices
Best Practices
Assessment
Assessment
Assessment

7.1

Description

7.1.1 Objective

The Report Card and Opportunity Identification tool imports data from the assessment tools, performs calculations to analyse and summarize the data, and presents the results by means of graphs, charts and tables. The result is a report card which displays a breakdown of energy consumed, technical and best practice scores, and a summary of prioritized energy management opportunities and their potential savings.

7.1.2 Variables collected

All variables are automatically imported from the Technical Assessment and Management Assessment tools, and the measure library. There is no requirement to gather and enter data for this tool.

7.1.3 Layout

The following exhibit illustrates the layout of the Report Card and Opportunity Identification tool as shown in the index tab.

Exhibit 30: Report and Opportunity Identification index table There are five tabs in the Report

Exhibit 30: Report and Opportunity Identification index table

Exhibit 30: Report and Opportunity Identification index table There are five tabs in the Report Card

There are five tabs in the Report Card and Opportunity Identification tool:

Revisions

See section 2.6

Index

See section 2.6

RC 1

Report card

This is the final summary of the plant‘s energy use and energy saving opportunities. It is populated automatically, importing data from the subsequent tabs. A completed report card is presented in Appendix A.

RC 2

Technical Energy Management Opportunities

The opportunities are listed in order, starting with the highest priority. The priority is determined based on the energy consumed and the opportunity to implement technical best practices in the facility. For example, if an end-use consumes a large amount of energy, and scores poorly on the best practices (that is, the opportunity to implement energy efficiencies is high, compared to all available energy efficiency opportunities in the plant), it will be given a high priority because there is a large potential for energy savings. The designation of high, medium and low priority are based on a threshold defined by a function of the proportion of energy use and opportunity ratio.

RC 3

RC 3 Energy Management (EM) Opportunities The opportunities are listed in order, grouped by categories. Categories

Energy Management (EM) Opportunities

The opportunities are listed in order, grouped by categories. Categories are shown in columns, starting (on the left) with the highest priority. The priority is determined based on the best practice score for each category (the category with the lowest score is given the highest priority).

RC 4

Technical Energy Management Calculation Summary

This tab is a summary of the calculations from the subsequent tabs, as well as an imported summary of energy use from the Technical Assessment tool (Energy Balance tab).

RC 5

Reference Data

A summary is provided of greenhouse gas emissions factors for the various energy types and the reference source of the factor.

RC 6

Best Practice Calcs (Management)

This is where calculations are performed to determine the Management Best Practices score. The scores are determined in the following manner:

Maximum score = 2 for all questionsscore. The scores are determined in the following manner: Achieved score = 0 if the question

Achieved score = 0 if the question is answered ―no‖, 1 if the question is answered ―partially‖ and 2 if the question is answered ―yes‖in the following manner: Maximum score = 2 for all questions A score is calculated for

A score is calculated for each category of questions.

RC 7

Best Practice Calcs (Technical)

This is where calculations are performed to determine the Technical Best Practices score for each end-use. The scores for each end-use are determined in the following manner:

Features intermediate score:

Maximum score = 1 if there is equipment in that end-use, and if high efficiency equipment in that end-use is feasible. Otherwise the score is 0in the following manner: Features intermediate score: Achieved score = the number of high efficiency equipment

Achieved score = the number of high efficiency equipment / the total number of equipment that could feasibly be high efficiencyand if high efficiency equipment in that end-use is feasible. Otherwise the score is 0 Practices

Practices intermediate score:

Maximum score = 1 if the measure is technically feasible or 0 if the measure

Maximum score = 1 if the measure is technically feasible or 0 if the measure is notAchieved score = 0 if the question is answered ―no implementation‖, 0.5 if the question

Achieved score = 0 if the question is answered ―no implementation‖, 0.5 if the question is answered ―partial adopted‖ or 1 if the question is answered ―fully adopted‖measure is technically feasible or 0 if the measure is not A combined score is calculated

A

combined score is calculated by dividing the sum of the achieved scores by the sum

of

the maximum scores.

7.1.4 Flow of information Between Tools

This toolkit imports data and finally summarizes the data in a concise and coherent plant report card.

The answers from the Technical Assessment and Management Assessments tools are imported into ―RC 6‖ and ―RC 7‖ tabs where the scores are calculated. tools are imported into ―RC 6‖ and ―RC 7‖ tabs where the scores are calculated.

The energy use for each end-use is imported from the Technical Assessment.6‖ and ―RC 7‖ tabs where the scores are calculated. The tool calculates best practices scores

The tool calculates best practices scores and uses them together with energy use by end use to determine energy savings potential for each end-use, and to prioritize the opportunities.for each end-use is imported from the Technical Assessment. The report card (―RC 1‖) displays these

The report card (―RC 1‖) displays these results in the form of charts and tables.for each end-use, and to prioritize the opportunities. 7.1.5 Using the Tool The Report Card module

7.1.5 Using the Tool

The Report Card module functions automatically, however a series of steps must be followed to correctly link the toolkit, and subsequently to ensure that the data is correct, and presentable.

Instructions for generating the Report Card:

Review the Technical and Management Assessments to ensure that the data contained is valid for analysis.presentable. Instructions for generating the Report Card: Verify that the Technical and Management Assessments are

Verify that the Technical and Management Assessments are saved with the correct name (following an established naming convention). If not, change the file name.to ensure that the data contained is valid for analysis. Close the Technical and Management Assessments,

Close the Technical and Management Assessments, and open the Report Card template file (A2A RCOI).naming convention). If not, change the file name. If the Excel default is to disable macros,

If the Excel default is to disable macros, a security warning will appear, followed by an ―options‖ button. Click the button and enable the macros. followed by an ―options‖ button. Click the button and enable the macros.

Save the file with the appropriate name (following an established naming convention).button. Click the button and enable the macros. Link the Report Card to the appropriate Technical

Link the Report Card to the appropriate Technical and Management Assessments, and open the files. The following exhibit shows the ―Edit Links‖ screen where the subsequent steps are performed. . The following exhibit shows the ―Edit Links‖ screen where the subsequent steps are performed.

Exhibit 31: Report Card “Edit Links” screen I. Data Edit Links II. Select ―A2A MA‖

Exhibit 31: Report Card “Edit Links” screen

Exhibit 31: Report Card “Edit Links” screen I. Data Edit Links II. Select ―A2A MA‖ from

I.

Data Edit Links

Data Edit Links

II.

Select ―A2A MA‖ from the list of sources

III.

Click the ―Change Source …‖ button

IV.

Select the Management Assessment file and press Ok

V.

Click the ―Open Source‖, then go back to the Report Card Screen

VI.

Select ―A2A TA‖ from the list of sources

VII.

Click the ―Change Source …‖ button

VIII.

Select the Technical Assessment file and press Ok

IX.

Click the ―Open Source‖ button, then go back to the Report Card screen

X.

Select ―A2A Ammonia Library‖ from the list of sources

XI.

Click ―Update values‖

XII.

Select ―A2A Generic Library‖ from the list of sources

XIII.

Click ―Update values‖

XIV.

Keep the Technical Assessment file (A2A TA) open for subsequent

the Technical Assessment file (A2A TA) open for subsequent steps. The other files can be closed

steps. The other files can be closed Run the macro on the tab ―RC 2‖ by pressing the button as shown in the following exhibit. The macro should take a few seconds to run. It imports the

relevant opportunities to the tables in ―RC 2‖ and the relevant management opportunities to the tables in ―RC 3‖. The macro also resets the ‗maximum potential energy savings‘ values (if they have been inputted).

Exhibit 32: Report card macro button on Tab RC 2

Exhibit 32: Report card macro button on Tab RC 2 After running the macro, the report
Exhibit 32: Report card macro button on Tab RC 2 After running the macro, the report

After running the macro, the report card is created. However, there are some additional steps and/or checks to ensure the report is complete and presentable. These steps are outlined in detail below. In addition, a more concise checklist is provided in Appendix A.

a more concise checklist is provided in Appendix A. Tab ―RC 2‖ The technical opportunities are

Tab ―RC 2‖

The technical opportunities are grouped by end-use. The end-uses are listed in order from highest potential opportunity to the lowest. The following exhibit shows the first end-use group after running the macro. There are two things to do/check on this tab after running the macro:

I. The column with maximum savings is left blank, and must be filled in manually for each opportunity (in the example below, the first three savings have been entered, and three more remain to be entered). Note that the savings is given in the description. Sometimes this savings is given as a range; in that case, enter the maximum savings in the range.

NOTE: for the ammonia savings, the entry must be in energy units per ton of ammonia production (eg. 0.4 GJ/t_NH3). Where savings are provided in percent of energy use, convert this to energy units per ton of ammonia, based on the energy consumption per unit of ammonia production (eg. 11.7 GJ/t_NH3) and measure savings is 4% of energy use, then enter 0.47 GJ/t_NH3 (0.04*11.7 GJ/t_NH3).

II. Check that the text is not cut off by the grid; increase the appropriate row height if necessary.

Exhibit 33: Report card opportunities table to be completed manually

increase the appropriate row height if necessary. Exhibit 33: Report card opportunities table to be completed
Tab ―RC 3‖ The management opportunities are shown in tables in tab ―RC 3‖ as

Tab ―RC 3‖The management opportunities are shown in tables in tab ―RC 3‖ as s hown in

The management opportunities are shown in tables in tab ―RC 3‖ as shown in the following exhibit. The opportunities are grouped into categories and ordered by those categories starting with the highest potential opportunity for improvement in the left column, and decreasing to the right. There is no additional data to enter on this tab, but it should be checked to ensure that no text is cut off by the grid (increase row height if necessary).

Exhibit 34: Report card opportunities table to be completed manually

34: Report card opportunities table to be completed manually Tab ―RC 1‖. The report card does

Tab ―RC 1‖.34: Report card opportunities table to be completed manually The report card does not require any

The report card does not require any additional data inputs, but several checks and possible aesthetic adjustments will need to be performed:

i. Check over the report card for missing information. There are some cells to check in particular that will be blank or show errors if the assessment tools were not filled out properly:

o Plant information, user information and date should be shown at the top of the sheet:

Exhibit 35: Report Card plant information to be checked Below the pie charts, product should

Exhibit 35: Report Card plant information to be checked

Exhibit 35: Report Card plant information to be checked Below the pie charts, product should be

Below the pie charts, product should be shown, followed by energy use per (main) unit of production. If div#/0! is shown, the product quantity was not entered in table A.3 of the Technical Best Practices Assessment tool.Exhibit 35: Report Card plant information to be checked Exhibit 36: Report Card product information and

Exhibit 36: Report Card product information and energy use per unit of production

product information and energy use per unit of production Check the energy intensity number and ensure

Check the energy intensity number and ensure that the units are suitable (GJ/t_NH3), and that only one decimal or no decimals are shown.product information and energy use per unit of production ii. Check the leader lines on the

ii. Check the leader lines on the pie charts; they may need adjusting if there are several small pie chart portions close to each other.

Exhibit 37: Report Card pie charts

close to each other. Exhibit 37: Report Card pie charts iii. Check that the graph axes

iii. Check that the graph axes are not cut off

pie charts iii. Check that the graph axes are not cut off PDFs The results are

PDFs

The results are recommended be presented in PDF format. There are three tabs (RC 1, RC 2 and RC 3) from the Report Card and Opportunity Identification tool be

converted to PDF format; these PDFs can then be included in summary reports for the

converted to PDF format; these PDFs can then be included in summary reports for the participating company. To make the PDFs using MS Excel 2007, ensure that the add-in for this version of Excel is installed and follow the steps below. For older versions of Excel, ensure you have the appropriate printer drivers installed to save the file as a PDF.

I. Select tab ―RC 1‖.

II. From the ―Save as‖ menu, select ―PDF or XPS‖

Exhibit 38: Converting to PDF (step 2)

―PDF or XPS‖ Exhibit 38: Converting to PDF (step 2) III. Under ―Save as type‖, select

III. Under ―Save as type‖, select ―PDF‖

Exhibit 39: Converting to PDF (steps 3 and 4)

―PDF‖ Exhibit 39: Converting to PDF (steps 3 and 4) IV. Click the options button. Under

IV. Click the options button. Under ―Publish what‖, choose ―Active sheets‖ and press ―ok‖

V. Click the ―Publish‖ button to create the PDF.

VI. Repeat these steps for tabs ―RC 2‖ and ―RC 3‖. Alternatively, select ―RC 1‖, and then press the Ctrl button on the keyboard while selecting ―RC 2‖ and ―RC 3‖ simultaneously and carry out the steps above. All three tabs will be printed into one document.

8

Energy Efficiency and Management (EE&M) Plan and Action Plan

Efficiency and Management (EE&M) Plan and Action Plan Exhibit 40: Tool 6 in the sequence 1

Exhibit 40: Tool 6 in the sequence

1 Energy Use Performance and 5 Technical Best Report Card and Practices Opportunity Assessment Identification
1
Energy Use
Performance and
5
Technical Best
Report Card and
Practices
Opportunity
Assessment
Identification
6
EE&M Plan
2
Checklist and
Technical
Technical
Technical
Action Plan
Measure Library
Measure Library
Measure Library
Template
4
Productivity
Improvement
3
Management
Management
Management
Assessment
Best Practices
Best Practices
Best Practices
Assessment
Assessment
Assessment

8.1

Description

8.1.1 Objective

The purpose of the Energy Efficiency and Management plan checklist and Action Plan template is to assist an organization in developing an Energy Management Plan, and setting priority and defining responsibility and a timeline for carrying out activities to achieve and sustain energy efficiency improvement while considering productivity improvement aspects.

8.1.2 Variables collected

The questionnaire lists elements to consider when developing and implementing both an energy management plan and an action plan. The identified opportunities resulting from using the previously discussed tools, are to be included in the development of the plans. The plans are developed in consultation and collaboration with the plant, and may require a number of meetings to be developed and completed.

8.1.3 Layout

The following exhibit illustrates the layout of the Energy Efficiency and Management Plan and Action Plan tool as shown in the index tab.

Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan index table There are

Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan index table

and Management Plan (EE&M) and Action Plan index table There are three tabs in the Excel

There are three tabs in the Excel spreadsheet of this toolkit module:

AP 1

Plant Information

Enter general information about the plant and its operation.

AP 2

Outline of EE&M Plan

An outline of the elements of the Energy Efficiency and Management Plan.

AP 3

EE&M Plan Checklist

This tab contains checklist of elements of an Energy Management and Continuous Improvement Plan with a section to set the priority of the actions. Descriptions of each element are also provided.

AP 4

EE&M Action Plan

This tab is a blank template to assist in developing actions to implement the EE&M Plan. The EE&M Action Plan includes a timeframe, responsibilities, and budget for each action. Actions are developed from the actions identified in the EE&M Plan checklist.

8.1.4 Flow of Information Between Tools

The results of the Report Card and Opportunities Identification tool are used to complete the EE&M Plan checklist. The prioritized elements of the EE&M Plan Checklist are used to prepare an action plan to implement the opportunities, using the EE&M Action Plan template.

8.1.5

Using the toolkit module

8.1.5 Using the toolkit module EE&M Plan Checklist The following exhibit shows a partially filled in

EE&M Plan Checklist

The following exhibit shows a partially filled in EE&M plan checklist.

Exhibit 42: Example of EE&M Plan Checklist

checklist. Exhibit 42: Example of EE&M Plan Checklist The EE&M Plan Checklist section of the questionnaire

The EE&M Plan Checklist section of the questionnaire is completed by:

Filling in the blank white cells where a response is required.Plan Checklist section of the questionnaire is completed by: Selecting from the menu where available. Drop-down

Selecting from the menu where available.in the blank white cells where a response is required. Drop-down menu selections for energy management

Drop-down menu selections for energy management (EM) elements have responses with the following implications:

― Yes ‖ response implies that the element is fully implemented.

Yes‖ response implies that the element is fully implemented.

A ― Partially ‖ response implies that the element has been considered or

A

Partially‖ response implies that the element has been considered or

introduced but is not fully adopted.

A ― No ‖ response implies that the element is not considered or adopted.

A

No‖ response implies that the element is not considered or adopted.

All questions are required to be filled out. It is anticipated that completing the checklist takes 45-60 minutes.

EE&M Action Plan The EE&M Action Plan is completed with input from both the EE&M

EE&M Action Plan

The EE&M Action Plan is completed with input from both the EE&M Plan Checklist and the Report Card and Opportunity Identification tools. The high priority elements defined in the EE&M Plan Checklist, followed by the medium and low priority elements, are manually transferred to the Action Plan (tab AP 4). The energy management elements are captured in the first eight action item categories, which corresponds with the EE&M Plan Checklist:

1. Policy

2. Planning

3. Organization and Accountability

4. Financing

5. Project Management

6. Monitoring

7. Reporting and Communication

8. Training and Capacity Building

The ninth and last action item category is for the technical best practices opportunities. Here the technical best practices opportunities identified in the Report Card and Opportunity Identifications (RCOI) are manually transferred. The RCOI list the opportunities by end uses, and include the cost savings, relative implementation cost and relative implementation difficulty. All these elements are manually copied by the user from the RCOI to the Action Plan together with the applicable library reference and description (see the example provided below in Exhibit 37). The user needs to prioritize the list by arranging the opportunities by each end use starting with the opportunity that has the largest energy savings first, followed sequentially with the opportunities with lower energy savings and ending with the opportunity with the smallest energy savings. The user highlights in yellow the four opportunities that has the largest energy savings.

Once the EE&M Action Plan template is completed, it is recommended that the prioritized actions are reviewed, and discussed with senior management. Responsibility can then be assigned to personnel who will ensure that the action is carried out, as well as a scheduled date for the completed action. This task is accomplished working in consultation with the enterprise. This action plan allows entry of the status of updates to be carried out after monthly, semi-annual or scheduled review. The action plan is a working document and needs to be revised and updated in a collaborative effort between the user and the enterprise.

Exhibit 43: Example EE&M Action Plan template. Energy Efficiency and Management (EE&M) Action Plan Template

Exhibit 43: Example EE&M Action Plan template.

Energy Efficiency and Management (EE&M) Action Plan Template

The following Energy Efficiency and Management (EE&M) Action Plan template is to assist your enterprise in developing actions to implement the EE&M Plan. The EE&M

Action Plan includes a timeframe, responsibilities, and budget for each action. Actions are developed from the actions identified in the EE&M Plan checklist.

 

Time Frame

 
 

EE&M

Action Item (from EE&M Plan Checklist)

 

Responsibility

Scheduled

Status or

Actions/

Element

Assigned to

Date

Date

Comments

 

Completed

 

Plan

Do

Do

Check

Act

5

Project Management

 
 

Parameters to be considered in identifying Energy management project opportunities can include fuel substitution

       

and use of renewable energy.

9

Implementation of Identified Opportunities

               

(Including Technical Best Practices and

Relative

Maximum

Maximum

 

Productivity Improvement)

Implementation

Relative

Potential Energy

Potential

Responsibility

Scheduled

Status or

Actions/

 

Difficulty 1

Implementation Cost 2

Savings 3,4

[TCE]

Energy Cost

Savings 4

Assigned to:

Date

Date Completed

Comments

 

Ammonia

High emissivity coating of

               

Production

radiant section refractory: 2 -

5% reformer heating energy

savings

Low

Medium

451

465,988

Modify steam turbine drivers

               

to improve efficiency: 0 - 9.5

GH/t_NH3 energy savings

Medium

Medium

10,654

11,012,533

Library

Reference #

Library Description

High emissivity coating of the refractory surfaces in the radiant section of the primary reformer reduces the radiant heat

AM-54

reabsorbed by the combustion flame and flue gases. This increases the radiant section efficiency and reduces the reformer

bridgewall temperature. Less fuel is thus required to achieve a given reformer process outlet temperature. Fuel savings of 2-

5% have been demonstrated.

Steam turbine drivers can be modified with updated designs for rotors and stationary parts to increase horsepower rating

AM-34

while reducing the water rate and saving energy.

8.2 Accuracy, Detail and Making Assumptions This questionnaire requires that ALL sections to be filled

8.2 Accuracy, Detail and Making Assumptions

This questionnaire requires that ALL sections to be filled in using one of the responses available in the menus.

No assumptions need to be made for this toolkit element.

9 5S Glossary A program of 'industrial housekeeping', the 5S's are 5 Japanese words which

9

5S

Glossary

A program of 'industrial housekeeping', the 5S's are 5 Japanese words which help to guide organizations to increased levels of cleanliness, organization, & efficiency.

Category (plant information)

Grouping category provided when the enterprise was registered to obtain their business license from the government

Code of region

Regional code provided by the National Bureau of Statistics

End use

The final application or final use to which energy is applied, such as motors, boilers, and air compressors.

Energy intensity

The energy use per unit of product produced is referred to as the energy intensity. In this assessment energy intensity is determined by evaluating energy use against the main product only.

Energy management system

A set of interrelated or interacting elements to establish an energy policy and energy objectives, and processes and procedures to achieve those objectives. (Draft ISO

50001)

Energy use profile

The percentage breakdown, by fuel type, of energy use for a generic plant in a given sub-sector.

Energy source

Refers to the sources of energy, such as, electricity, natural gas and oil.

High Efficiency Equipment Equipment that by design and function consumes less energy than conventional equipment

High Efficiency Equipment

Equipment that by design and function consumes less energy than conventional equipment for the same function. This equipment can be specified by its design for efficient use of energy and in some cases, identified by a national efficiency rating or label.

JIT

Just in Time: a strategy that exposes waste, makes continuous improvement a reality, and relies on total employee involvement. It concentrates on delivering what the customer wants, when they want it, tin the quantity they want. The key elements of JIT are flow, pull, standard work (with standard in-process inventories), and takt time (takt time is a calculated value: available production time / customer demand).

Kaizan Blitz

Kaizan in lean terminology means 'continuous, incremental improvement' implying everyone applying small (low impact & low cost) improvements each and every day. Applied in this manner, kaizen can have the same effect as large, costly, infrequent changes. A Kaizan Blitz refers to ―improvement workshops‖.

Kanban

Designates a pull production means of communicating need or service. Originally developed as a means to communicate between operations in different locations, it was intended to communicate a change in demand or supply. In application, it is generally used to trigger the movement of material to or through a process.

Management best practice

Management Best Practices address the people aspect in reducing energy use. In an industrial organization, management best practice is illustrated by a high level of commitment, awareness, organization and action in support of energy efficiency. An example of energy management best practices is having a policy and plan to manage energy.

Registered date / capital

The date and the city for which the plant registered to get its business operation license (official establishment date)

Replacement measure/technology

An energy efficiency measure/technology that can be installed to replace a less efficient piece of equipment. Replacement measures are applied on an incremental cost basis, as they are normally implemented once the existing piece of equipment has reached the end of its useful life and would have to be replaced any way.

Retrofit measure/technology An energy efficiency measure/technology that can be used to upgrade an existing piece

Retrofit measure/technology

An energy efficiency measure/technology that can be used to upgrade an existing piece of equipment, as opposed to replacing it. Retrofit measures are applied on a full cost basis and may be implemented immediately.

Six sigma

Refers to six standard deviations from mean. Six sigma methodology provides the techniques and tools to improve the capability and reduce the defects in any process.

Standardized work instructions

Specific instructions that allow processes to be completed in a consistent, timely, and repeatable manner. By implementing SWI‘s employees will increase production, improve quality, and enjoy a safer, predictable working environment.

Technical best practice

A set of energy efficiency measures that represent the most advanced technology

available.

TPM

Total Productive Maintenance: preventative maintenance carried out by all employees. It is equipment maintenance performed on a company wide basis.

Value stream mapping

Identification of all the specific activities occurring along a value stream for a product

The output should be a

list of action items to be done to improve the process.

or product family. This is part of creating a lean enterprise.

10 Abbreviations A2A : Assessments to action A2A MA : Energy management assessment tool of

10 Abbreviations

A2A: Assessments to action

A2A MA: Energy management assessment tool of the A2A Toolkit

A2A PIA: Productivity improvement assessment tool of the A2A Toolkit

A2A RCOI: Report card and opportunity identification tool of the A2A Toolkit

A2A TA: Technical assessment tool of the A2A Toolkit

EE&M: Energy efficiency and management

EM: Energy management

h: hours

HVAC: Heating, ventilation and air conditioning

kW: kilowatts

IIP: Institute for Industrial Productivity

ISO 50001: Energy Management of the International Organization for Standardization

LHV: Lower heating value

MBP: Management best practices

MW: megawatts

NPV: Net present value

NTF: Not technical feasible

RPP: Refined petroleum products

SME: Small and medium enterprises

TBP: Technical best practices

TCE: Tons coal equivalent

TPM: Total product maintenance

11 Appendices Appendix A Report Card checklist and Completed Report Card Linking and running macro

11 Appendices

Appendix A

Report Card checklist and Completed Report Card

Linking and running macro

Review the Technical and Management Assessments to ensure that the data contained is valid for analysis.and Completed Report Card Linking and running macro For the Technical Assessment, verify that for all

For the Technical Assessment, verify that for all applicable sections B to E, the equipment feature questions at the end of each section are ALL be answered including all features questions in Section D (TA 9); input either the level of implementation or NTF (not technically feasible).to ensure that the data contained is valid for analysis. Verify that the Technical and Management

Verify that the Technical and Management Assessments are saved with the correct name (following an established naming convention). If not, change the file name.level of implementation or NTF (not technically feasible). Close the Technical and Management Assessments, and open

Close the Technical and Management Assessments, and open the Report Card template file (A2A RCOI).naming convention). If not, change the file name. If the Excel default is to disable macros,

If the Excel default is to disable macros, a security warning will appear, followed by an ―options‖ button. Click the button and enable the macros. followed by an ―options‖ button. Click the button and enable the macros.

Save the file with the appropriate name (following an established naming convention).button. Click the button and enable the macros. Link the Report Card to the appropriate Technical

Link the Report Card to the appropriate Technical and Management Assessments, and open the files. The following exhibit shows the ―Edit Links‖ screen where the Assessments, and open the files. The following exhibit shows the ―Edit Links‖ screen where the subsequent steps are performed.

i.

ii. Select ―A2A MA‖ from the list of sources

iii. Click the ―Change Source …‖ button

iv. Select the Management Assessment file and press Ok

v. Click the ―Open Source‖, then go back to the Report Card Screen

vi. Select ―A2A TA‖ from the list of sources

vii. Click the ―Change Source …‖ button

viii. Select the Technical Assessment file and press Ok

ix. Click the ―Open Source‖ button, then go back to the Report Card screen

x. Select ―A2A Ammonia Library‖ from the list of sources

xi. Click ―Update values‖

xii. Select ―A2A Generic Library‖ from the list of sources

xiii. Click ―Update values‖

xiv. Keep the Technical Assessment file (A2A TA) open for subsequent steps. The other files can be closed

Data

Edit Links

Run the macro on the tab ―RC 2‖ by pressing the button as shown in the following exhibit. The macro should take a few seconds to run. It imports the relevant following exhibit. The macro should take a few seconds to run. It imports the relevant opportunities to the tables in ―RC 2‖ and the relevant management opportunities to the tables in ―RC 3‖. The macro also resets the ‗maximum potential energy savings‘ values (if they have been inputted).

Checklist after running macro Tab ―RC 2‖ All savings are filled in (manually) Text is

Checklist after running macro

Tab ―RC 2‖ All savings are filled in (manually) Text is not cut off by grid Tab ―RC 3‖ Text is not cut off by grid Tab ―RC 1‖ No missing information (blank cells where there should be information provided) Energy use per unit of production: not div#/0!, has suitable units, set to one decimal or no decimal places Pie chart labels are legible and appropriately situated (i.e. not overlapping with other labels) Pie chart leader lines are appropriately situated (i.e. do not cover labels, are a suitable length, etc) Graph axes and axis titles are not cut off

length, etc) Graph axes and axis titles are not cut off Creating a PDF (using Excel
length, etc) Graph axes and axis titles are not cut off Creating a PDF (using Excel
length, etc) Graph axes and axis titles are not cut off Creating a PDF (using Excel
length, etc) Graph axes and axis titles are not cut off Creating a PDF (using Excel
length, etc) Graph axes and axis titles are not cut off Creating a PDF (using Excel
length, etc) Graph axes and axis titles are not cut off Creating a PDF (using Excel
length, etc) Graph axes and axis titles are not cut off Creating a PDF (using Excel
length, etc) Graph axes and axis titles are not cut off Creating a PDF (using Excel

Creating a PDF (using Excel 2007 or higher)

1. Select tab ―RC 1‖.

2. From the ―Save as‖ menu, select ―PDF or XPS‖

3. Under ―Save as type‖, select ―PDF‖

4. Click the options button. Under ―Publish what‖, choose ―Active sheets‖ and press ―ok‖

5. Click the ―Publish‖ button to create the PDF.

6. Repeat these steps for tabs ―RC 2‖ and ―RC 3‖. Alternatively, select ―RC 1‖, and then press the Ctrl button on the keyboard while selecting ―RC 2‖ and ―RC 3‖ simultaneously and carry out the steps above. All three tabs will be printed into one document.

Appendix B A2A Energy Use and Technical Best Practice Assessment 56

Appendix B

A2A Energy Use and Technical Best Practice Assessment

A2A Toolkit Energy and Technical Best Practice Assessment Industrial Energy Use and Technical Best Practice

A2A Toolkit Energy and Technical Best Practice Assessment

Industrial Energy Use and Technical Best Practice Assessment

TO DO:

STEP 1 - Please complete the contact information requested on this page. STEP 2 - Review instruction sheet and complete the questions on the next pages.

 

Confidential Plant Information

Location

 

Industry

Organization Name

 

Category

Registration Date

 

Registrated Capital

Name of Legal Person

 

Contact Phone Number

Address

 

Code of Region

 

Post Code

Phone number

 

Fax Number

Energy conservation Manager (primary)

 

Energy conservation Manager (secondary)

Phone number

 

Phone number

E-mail address

 

E-mail address

 

Auditor Information

Name of Auditor

 

Direct Telephone Number

Auditor's Organization / Company Name

 

Fax Number

Title of Auditor

 

E-mail address

Date of Audit

   

Evaluation year (for purchased & utilized energy)

2009

The survey questionnaire is the ownership of IIP and ICF Marbek. Any use of the survey by another party requires to be granted permission by IIP or ICF Marbek prior to use.

A2A Toolkit Energy and Technical Best Practice Assessment This section includes energy used at your

A2A Toolkit Energy and Technical Best Practice Assessment

A2A Toolkit Energy and Technical Best Practice Assessment This section includes energy used at your facility:-

This section includes energy used at your facility:- the purchased, self generated and sold energy products. A.1. PURCHASED ENERGY (exclude energy purchased for use as raw material feedstock in ammonia production)

What sources of purchased energy do you presently use at your facility? Please indicate all types of purchased energy sources, quantities used and purchase totals (including taxes).

Fuel Type

LHV* GJ per [kg or m3]

Quantity

Units

Cost ($)

Cost/unit (current year)

2009

2008

2009

2008

$

per

Electricity

-

   

kWh

       

Natural Gas

0.03897

   

m3

       

Gasoline

0.04311

   

ton (metric)

       

Diesel Oil (transport)

0.04269

   

ton (metric)

       

LPG

0.05023

   

ton (metric)

       

Fuel Oil type (select)

-

   

ton (metric)

       

Fuel Oil type (select)

-

   

ton (metric)

       

Gas type (select)

-

   

m3

       

Gas type (select)

-

   

m3

       

Gas type (select)

-

   

m3

       

Biomass type (select)

-

   

ton (metric)

       

Biomass type (select)

-

   

ton (metric)

       

Other Fuel (select)

-

   

ton (metric)

       

Other Fuel (select)

-

   

ton (metric)

       

Steam quantity

0.00090

   

ton (metric)

       

Steam Temp [k]

483 K

 

Steam Pressure[bar]

22 bar

*LHV's can be overwritten for coal or other fuels which may vary in energy content

A.2. NON-PURCHASED FUEL and SELF-GENERATION of ELECTRICITY A2A Toolkit Energy and Technical Best Practice Assessment

A.2. NON-PURCHASED FUEL and SELF-GENERATION of ELECTRICITY

A2A Toolkit Energy and Technical Best Practice Assessment

Only purchased fuel used. Go to A.2.2-----> No co-generation at this facility. Go to A.2.3---->

Only purchased fuel used. Go to A.2.2----->

No co-generation at this facility. Go to A.2.3---->

No energy products sold at this facility. Go to A.3

If the following are applicable, please indicate the type, quantity and units of each fuel used in your facility.

   

LHV* GJ per [kg or m3]

Quantity

Units

Fuel Type

2009

2008

[ton or k m3]

A.2.1 Non-Purchased Fuel

         

NON-RENEWABLE (eg. coke, oven gas, still gas), BIOMASS (eg.hog fuel, pulping liquor) or RENEWABLE FUEL (eg. wind, geothermal, solar)

         
         
         

A.2.2 Co-generation Energy Form

Electricity

-

   

kWh

Steam

0.00090

   

ton (metric)

 

Steam Temp [k]

483

K

     

Steam Pressure[bar]

22

bar

A.2.3 Sold Energy Products

Electricity

-

   

kWh

Steam Quantity

0.00090

   

ton (metric)

 

Steam Source fuel

       

Steam Temp [k]

483

K

     

Steam Pressure[bar]

22

bar

     
 

Coke

0.02846

   

ton (metric)

 

Biomass

     

ton (metric)

A2A Toolkit Energy and Technical Best Practice Assessment A.3. PRODUCTION and PLANT DATA What are

A2A Toolkit Energy and Technical Best Practice Assessment

A.3. PRODUCTION and PLANT DATA

What are the main products produced at your facility, and what is the annual volume? Please list the most important products first and the reported annual energy consumption in GJ.

 

Units

Quantity

Annual Energy Consumption (all fuel and feedstock) [GJ]

Energy Consumption (all fuel and feedstock) [GJ per unit of product]

Product Description

[please provide]

2009

2008

2009

2008

2009

2008

 

2009

 

2008

% Change

 

Industrial Output ($)

     
 

Sales Revenue ($)

     

Comprehensive energy consumption (GJ)

Actual

     

Equivalent

     

Specific industrial output energy consumption (GJ/$)

Actual

     

Equivalent

     

Energy Consumption cost ($)

     

Share of energy consumption cost (%)

     

A.4 FEEDSTOCK FUEL

What type and quantity of feedstock do you presently use at your facility?

 
 

LHV* GJ per [kg or m3]