Certifying U'S' Manufacturing Plants for Energy Efficiency

1

• Certifying U.S. Manufacturing Plants for Energy
  Efficiency
• Aimee T. McKane,
• Lawrence Berkeley National Laboratory
• Consortium for Energy Efficiency
• May 29, 2008 Webcast

2
Superior Energy Performance Partnership and
Certifying U.S. Manufacturing Plants forEnergy
Efficiency

• Superior Energy Performance Partnership
• Plant Certification
• Energy Management Standard
• System Assessment Standards
• MV Protocol
• Certified Practitioner Program
• Third-Party Certification

3
Superior Energy Performance Partnership

• Collaboration of industry, government, and
  non-profit organizations
• Seeks to improve the energy intensity of U.S.
  manufacturing through a series of initiatives.
• Supports ANSI-accredited Plant Certification
  program

www.superiorenergyperformance.net
4
SEP Working Groups
5
Quick Start Website

• Comprehensive listing of energy efficiency
  resources from public and non-profit sources -
  documents, software, training, case studies, tip
  sheets, experts, and calculators
• Save Energy Now
• Best Practices, technologies, tools, and
  resources that a plant engineer can use today -
  creating a baseline on energy use, assessing
  opportunities and implementing Best Practices
• Manage Your Energy Program
• Step-by-step process, as well as tools and
  resource, to evaluate, implement or improve the
  plant or corporations energy management system
• Assistance and Resources
• Tools, case studies, training, experts, and
  technologies that will give you a Quick Start to
  achieving Superior Energy Performance
• http//www.energyquickstart.org/quickstart/

6
Strategic Goals of Plant Certification

• Fosters an organizational culture of continuous
  improvement in energy efficiency
• Develops a transparent system to validate energy
  intensity improvements and management practices,
  and thus
• Creates a verified record of energy source fuel
  savings and carbon emission reductions with
  potential market value that could be recognized
  both nationally and internationally

7
Benefits of Plant Certification

• Establishes systematic means to achieve
  continuous improvement
• Standards for energy management and system
  assessments
• Tools and resources to assist in implementation
• Process for validation
• Focus on reducing energy intensity per unit of
  output
• Helps plants get on the path to improvement by
  adopting tools and resources
• Promotes buy-in to energy efficiency
• Applies to most companies (a wide range of
  industries)
• Delivers value to all plants, not just those that
  pursue certification
• Creates a transparent way to compare energy
  efficiency

8
Certifying Plants for Energy Efficiency
Energy Management Standard
System Assessment Standards
Plant Certification Program Design
Measurement Verification Protocol
9
What Is an ANSI-Accredited Certified Plant?

• Complies with ANSI MSE 20002008 Energy
  Management Standard (eventually an ISO standard)
• Achieves a minimum energy intensity improvement
  over the past two years
• May apply System Assessment Standards for energy
  systems in plant facilities (initially pumping,
  compressed air, steam, process heating)
• May use certified practitionersrecognized by
  third partyto assist in complying with standards
• Uses measurement and validation
  expertsrecognized by a third partyto verify
  implemented energy savings
• Uses ANSI-accredited process to achieve
  third-party plant certification

10
Requirements for Certification

• For initial certification, the plant
• Complies with the energy management standard, and
• Achieves validated energy intensity performance
  by
• Demonstrating energy intensity improvement of gt5
  over the previous 24 month period OR
• Assessing any energy system which uses greater
  than 10 of total plant energy use (not including
  feedstocks) and demonstrating that the plant
  has
• Implemented gt30 of total Btu energy savings
  opportunities that meet the companys internal
  rate of return (IRR) and are identified through
  application of system assessment standards, OR
• Met or exceeded the Energy Management Best
  Practice threshold for systems for which Best
  Practices exist.

Energy Management Best Practice threshold is
still to be defined
11
Basic Elements of ANSI Management System for
Energy (MSE 20002008)
www.ansi.org
12
Lessons Learned

• Benefits and cost savings derived from energy
  management systems are easily understood by
  organizations
• Payback is typically less than 2 years on
  investment in adopting MSE
• Many companies recognize value of added
  environmental benefits
• There is a lack of incentives and public policies
  inhibiting marketplace to adopting MSE

13
Lessons Learned

• Top management at corporate level must buy-in and
  commit resources
• Immediate energy savings can derail the systems
  continual improvement focus and reinforce a
  limited project mindset
• MSE is data driven, but new programs must not be
  overwhelmed by too much information
• Other management systems compete for resources
  ISO9001, ISO14001, Six Sigma
• Less energy intensive organizations may include
  energy within their Environmental Management
  System, but frequently do not

14
ISO Management System for Energy

• International Energy Management Standard
• UNIDO Expert Group, Vienna, March 21-22, 2007
• ANSI (U.S.) / ABNT (Brazil) leadership proposal
• ISO Project Committee - PC 242 formed
• First Meeting of ISO PC 242 - September 2008,
  Washington, DC
• UNIDO / CSC Working Group Meeting
• Discuss similarities and differences
• Preparatory harmonization
• Detailed Summary Comparisons developed
• Framework for Action

15
Why System Energy Efficiency Matters

• IIndustrial systems include those systems that
  contribute to industrial production processes,
  such as motor systems (pumping, compressed air,
  and fan), steam systems, and process heating
  systems.

Manufacturing Energy Use by Type of System1

• Energy Efficiency
• Improvement Opportunities
• 20 or more typical for motor systems
• 10 or more for steam process heating systems
• Most plants do not manage these systems for
  energy efficiency2

1 Does not include offsite losses 2 2002 MECS
plants indicated energy management activities for
6.3 steam, 16,6 compressed air, 7.5 process
heating systems
16
What is a System Assessment?

• System Assessment Standards
• Are designed to create a market threshold for
  industrial energy efficiency assessments from the
  current body of expert knowledge
• Provide a standardized framework for conducting
  assessments of industrial systems
• Establish minimum requirements and guidance for
• organizing and conducting assessments,
• analyzing the data collected, and
• reporting and documentation,

17
System Assessment Standards

• Goals
• To create and test standards for conducting
  industrial energy system assessments
• Initial portfolio of four (4) standards (pumping,
  compressed air, steam, and process heating) and
  corresponding guidance documents that become the
  industry standard for these system types.
• Builds off previous experience through USDOEs
  Save Energy Now
• To define a set of skills and a qualifying
  process required to recognize individuals as
  Certified Practitioners in the application of
  each system standard.
• To identify not-for-profit organizations to
• Manage and maintain the quality of the system
  assessment standards and guidance and
• Offer a program to qualify and maintain the
  professional credentials of Certified
  Practitioners

18
Measurement and Verification Protocol

• Verify results and impacts of energy efficiency
  projects
• Specify parameters required to quantify facility
  energy efficiency
• Track energy efficiency/intensity changes over
  time
• Build off experience IPMVP, utility experience,
  OSHA Star, etc.
• Balance credibility of validated performance and
  overall cost to become certified

19
Certified Practitioners
Third Party Certifying Organization
(TBD)
Energy Management Practitioners
Manufacturing Plants Seeking Certification
System Assessment Practitioners
Measurement Verification Certifiers
20
Looking Forward Key Milestones

• Dec. 2009 Begin training certified practitioners
  in energy management and system assessments
• Feb. 2010 First plants are ANSI certified for
  energy efficiency, based on pilot program results
• Sept. 2010 National launch of third-party
  certification program
• Sept. 2011 Third party fee-based, certification
  business model established

• June 2008 Texas Pilot project begins field
  testing ANSI energy management standard and
  system assessment standards
• Feb. 2009 Select third-party certifying
  organization
• May 2009 Begin field testing of measurement and
  verification methodology in pilot plants

21
For More Information
www.superiorenergyperformance.net
Aimee T. McKane, Lawrence Berkeley National
Laboratory atmckane_at_lbl.gov 518-782-7002
Paul Scheihing, US DOE paul.scheihing_at_ee.doe.gov 2
02-586-7234