a2a user guideline - ifa v1
TRANSCRIPT
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Assessments to Action (A2A)
Toolkit for the IFA:Guidelines for Users
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Guidelines for Users
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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: A2ATA) 4
2.3.2
Generic Measure Library (Excel File: A2A Generic) and AmmoniaMeasure 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
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3.4 Ammonia Sub-Sector Specific Assessment ................................................. 22
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
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Exhibit 27: Productivity Improvement Assessment index table .................................. 33
Exhibit 28: Example of Productivity Improvement Assessment multiple optionselection ..................................................................................................................... 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 indextable 45
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1 Purpose of Guideline
This guideline provides guidance for a user on how to use the Institute of IndustrialProductivity‘s ammonia sector Assessments to Action (A2A) toolkit. The user usingthe toolkit and this guideline needs to be:
Experienced in on-site energy efficiency auditing.
Familiar with industrial manufacturing processes, specifically ammonia
manufacturing.
Familiar with industrial technologies, energy management best practices, and
ISO 50001.
Proficient in using MS Excel.
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 ofthe manual is described in 2.5.
Data obtained from plants are considered to be confidential and a confidentialityagreement can be signed with the company. An example confidentiality agreementtemplate is included in the toolkit and needs to be completed by the company and thecompany using the A2A toolkit to conduct an assessment.
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2 Introduction
2.1 Context and Scope of IIP A2A Toolkit
The Institute for Industrial Productivity (IIP) retained ICF Marbek, a Canadianconsulting firm, to develop an energy performance assessment and continuousimprovement toolkit. The toolkit provides a standardized methodology for industrial
energy performance assessments, and engaging companies to implement acontinuous improvement process to reduce energy use and improve energymanagement. The toolkit is to be used by trained users during on-site assessments ina consultative process to assist a company in implementing a continuous energyefficiency improvement plan.
This version of the toolkit was developed specifically for the ammonia manufacturingsector. 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.
Assess Energy
Performance &
Establish
Indicators
Identify
Opportunities
& Define
Implement
EE&M
Action Plan
Commitment
by Factory
A2A Toolkit
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Exhibit 2 illustrates the tools in the toolkit and how it correlates with the continuousimprovement process, and the results to be achieved. The tools and the use of thetools are described in detail in the guideline, and examples are provided throughoutthe guideline to illustrate the use of the toolkit.
Exhibit 2: Tools in the toolkit and results to be achieved
Obtain Commitment
Assess Performance
and Establish
Indicators
IdentifyOpportunitiesand
Define EE&M Plan
Scope
Technical Assessment
(Includes Energy Use Performance
and Technical Best Practices
Assessment)
Management Assessment
(Includes Technical Management Best
Practices Assessment)
Productivity Improvement
Assessment
Report Card and OpportunitiesIdentification
EE&M Plan Checklist
Company committed to energy
management
and allocating necessary resources
to energy management
Understand current energy use,
productivity and energy
performance.
Derive performanceindicators for
continuous improvement.
Definition and understanding of the
opportunities to improve energyperformance.
A defined scope for the EE&M Plan.
ContinuousImprovement
ProcessToolkit Results
MeasureLibrary(incl. Ammonia
Specific)
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2.2 Assessment Methodology
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 mainproduct only.
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.
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.
This comprehensive approach helps an assessor to understand and explain acompany‘s energy efficiency performance. For example, low implementation of MBPs
and TBPs identify reasons for low energy intensity values, and highlights opportunitiesand management areas for improvement to improve energy intensity values.
To assist companies in continuously improving their energy efficiency and energy
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best practices listed in this toolkit are commercialized, and exclude pilot-test ordemonstration technologies.
2.3.2 Generic Measure Library (Excel File: A2A Generic) and AmmoniaMeasure Library (Excel File: A2A Ammonia)
The measure library provides in format ion abou t each techn ical best pract ice . 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.
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.
2.3.3 Energy Management System Assessment (Excel File: A2A MA)
The energy management assessment tool is used to obtain information to assess theimplementation of energy Management Best Practices (MPBs), illustrated by a highlevel of commitment, awareness, organization and acting in support of energy
management.
Numerous studies have shown that application of energy management practices is acritical success factor for sustained improvement in energy use performance in
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2.3.6 EE&M Plan Checklist (Excel File: A2A Checklist and Action Plan)
The energy efficiency and energy management (EE&M) plan checklist is used todetermine the status of energy management system implementation. Elements thatare not fully implemented are prioritized and then manually transferred to the actionplan 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 inthe same Excel workbook as the EE&M plan checklist. The action plan template isused to guide implementation of the opportunities and outstanding energymanagement system elements. The opportunities and elements are manuallycaptured as action items, responsibilities are assigned, scheduled dates forcompletion 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 releaserevisions of the toolkit. This guide is for the user who will not have to make changes tothe structure or methodology of the toolkit, and will only have to use the toolkit bypopulating 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.
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Tool 1: 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 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 theManagement 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 Improvement Excel workbook.
Tool 5: 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 and energy management plan and an action plan to ensure
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2.6 Common Elements in Tools
Each Excel workbook contains a similar structure and the first few pages in eachworkbook (see Exhibit 4) are:
Revisions: 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 andprovides descriptive names for each of the page tabs.
Instructions: A summary of the instruction to use the tool is provided on this
page.
Exhibit 4: Example of first few tabs in Excel tools
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3 Energy Use Performance and Technical Best Practices Assessment
Exhibit 5: Tool 1 in the sequence
3.1 Description
3.1.1 Objective
The purpose of the energy use performance assessment is to determine the profile of
Energy Use
Performance andTechnical Best
Practices
Assessment
Management
Best Practices
Assessment
ProductivityImprovement
Assessment
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template4
5
6
Technical
Measure Library
1
Management
Best Practices
Assessment
Technical
Measure Library
Management
Best Practices
Assessment
Technical
Measure Library
2
3
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questions pertaining to the overall energy use, production, characteristics of theequipment, and the presence of energy efficiency measures. The Excel workbookincludes the following sections:
Section A 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.Section C 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 emerging technologies.
Section E 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 Assessmenttool as shown in the index tab.
Exhibit 6: Technical best practice assessment index table
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The questionnaire is categorized according to the categories described above. Foreach 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 arealso requested at the end of each section. Enter only operating equipment and do notinclude 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 isimportant to ONLY list energy used as fuel, and EXCLUDE energy used as feedstock
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equipment that provides cooling and heating for occupancy comfort should NOT belisted 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 capacityrepresents a size range; however it is the average value of that size range which mustbe 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 givencategory.
TA 4
Compression Heating Equipment
All equipment related to compression is characterized in this section. This includescompressors for pneumatic equipment and compression systems for process gas orair systems.
For each equipment type, it is possible to give up to four capacities. Each capacityrepresents a size range; however it is the average value of that size range which mustbe 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 givencategory.
TA 5
Motor Related
The parameters of motive power equipment are summarized in this section including
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Exhibit 7: Tools in the toolkit and results to be achieved
Type StandardEnergyEfficient
Fluorescent T17, T12 T5, T8
CFL's All
Metal Halide Mercury Vapour All other
High PressureSodium All
Incandescent All
TA 8
Comfort-HVAC and Air System
Equipment providing heating and cooling for occupancy comfort, is entered in thissection with details on characteristics.
The ventilation data entered in the third table refers only to the motor power. If thereis heating of make-up air, the heating capacity should be entered in the second table(non-packaged HVAC equipment).
TA 9
Other & System Practice
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TA 12
Conversion
In this tab, conversions used in the calculations are provided for reference purposesonly.
3.1.4 Flow of Information Between ToolsThe responses from this questionnaire are used to:
Calculate the energy balance and portion of energy used by each end use and
energy source.
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.
Evaluate the opportunities available to a facility to implement improved TBP
practices (see section 7).
Develop an Energy Efficiency and Management Plan using the checklist and
template tools (see section 8.2).
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.
Sect ion A : Fi rst Quest ion gro up: Purchased Energy
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Sect ion A: Link to water tables for steam enthalpy calculat ion
The energy content or enthalpy of steam can be calculated by linking the technicalassessment to the water97_V13 add-in. This is done as follows:
Copy the water97_V13.xla file to the appropriate directory
Add the water97_V13 file (provided) to Excel Add-in‘s
Select ―Edit links‖ in Excel and change the source link for the water97_V13 file
if necessary
Select ―Open source‖ from the ―Edit links‖ pop-up menu above.
Select ―Enable macros‖ in the technical assessment
Sect ion A: Second Quest ion grou p: Sold and sel f -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
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Exhibit 10: Example of Technical Assessment Sold and self-generated fuel questions
Sect ion A : Four th Quest ion grou p: Purchased Energy for Feedstock
This section is a summary of the fuel used as feedstock in the plant. The total quantityof feedstock and fuel for three main types of fuel are provided at the end of the tablefor verification.
Exhibit 11: Example of Technical Assessment feedstock questions
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Exhibit 12: Example of Technical Assessment equipment features questions (first question group)
This section of the questionnaire is completed by:
Filling in the blank white cells where a response is required.
Selecting from the drop down menu where available as shown below:
Exhibit 13: Example of Technical Assessment drop down menu
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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, 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 efficiencymotors‖ must be ten or less in this capacity r ange.
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
high or premium efficiency, but not both.
Recording 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.
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:
Review of line drawings and determine capacity.
Equipment count lists available from maintenance staff / operators.
Name plate capacity of equipment with multiple motors can be grouped into
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Exhibit 15: Example of Technical Assessment general questions (second question group)
Drop-down menu selections for equipment features have responses with thefollowing implications:
―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 fully adopted.
―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
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these can be omitted by indicating inapplicable sections in the boxes provided at thebeginning of each section.
It is anticipated that completing the questionnaire during an on-site assessmentrequires one to two days, depending on the complexity of the plant, the availability ofthe 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 theresponses available in the menus with all fuels purchased accounted for by theequipment using it.
3.2.1 Average equipment capacities and operating hours
There may be numerous pieces of equipment under each type, and it isrecommended to categorize this by size. Up to six ranges of equipment sizes can beentered, by providing weighted average equipment capacity values and averagehours of operation for each range.
For example, if there are 25 motors ranging in size from 0.3 to 0.5 kW, operatingbetween 500 to 6000 hours per year, the average range of equipment capacity wouldbe:
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
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Exhibit 17: Portion of the energy balance tables
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The 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.
The hours of operation are applied directly to operating time without
adjustment for load factors applied to equipment.
Equipment capacity is assumed to be the rated capacity.If the adjustment factor is much greater than one, the following should be
reviewed to address this:
Review quantity of purchased energy (may be too high).
Review the hours of operation of equipment using the fuel with the discrepant
adjustment factor.
Review the capacity rating of equipment using the fuel with the discrepant
adjustment factor.
Review the quantity of equipment using the fuel with the discrepant adjustment
factor.
Review the firing time and efficiency of equipment where this is reported, such
as for boilers and ovens.
Investigate whether all equipment using this fuel have been accounted for.
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 the following:
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tabs of the questionnaire. Up to five such types of equipment can be detailed, in orderof 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
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4 Technical Measure Library
Exhibit 19: Tool 2 in the sequence
4.1 Description
4.1.1 Objective
The purpose of the Technical Measure Library is to catalogue energy efficient
Energy Use
Performance andTechnical Best
Practices
Assessment
Management
Best Practices
Assessment
Productivity
Improvement
Assessment
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template4
5
6
Technical
Measure Library
1
Management
Best Practices
Assessment
Technical
Measure Library
Management
Best Practices
Assessment
Technical
Measure Library
2
3
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4.1.3 Layout of Tool
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 thefollowing 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 thisgeneric library), percent savings for each fuel type (natural gas, electricity, refinedpetroleum products, other fuel), and finally, the measure life. For more information onnavigating 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 eachenergy efficiency measure.
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Exhibit 20: Example of Measure Library tab
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Low – little or no capital cost would be required. Often involves behavioural
changes and only a rudimentary economic assessment may be needed.
Relat ive imp lementat ion di f f icul ty : 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 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 is usually required.
Low – relatively easy to implement the opportunities and most often involves
maintenance related opportunities and/or behavioural changes. Technical
feasibility studies are generally not required.
Lev el (1 to 5): 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 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
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4.1.5 Using the Tool
This toolkit module can be used to cross reference the energy efficiency measures inthe technical assessment or the opportunities listed in the report card. Each measurelisted in the technical best practice assessment has a number in column L, whichcorresponds to the measure number in the Measure Library. Note: do not changethe Measure Number or the tab numbers, as these are used to link to othertoolkit modules.
The Index tab can be used to easily navigate the library. The first column containsthe 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. Forexample, as shown in Exhibit 20, to view only the measures related to pumps, clickthe filter arrow in the ―Level 4 – Enduse‖ column, un-check ―Select All‖ then check thebox beside ―Pumps‖ and click Ok.
Exhibit 21: Measure Library Index Tab
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Exhibit 23: Management Best Practice Assessment index table
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
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5.1.4 Flow of Information Between Tools
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.
Evaluate the opportunities available to a facility to implement improved MBPpractices (see section 7).
Develop an Energy Efficiency and Management Plan and Action Plan using
the checklist and template tool (see section 8.2).
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.
Selecting from the drop down menu where available as shown in Exhibit 24.
Exhibit 24: Example of Management Assessment drop down menu
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Al l sect ions are required to be filled out for this questionnaire. It is anticipated thatcompleting 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 theresponses available in the menus.
No assumptions need to be made for this toolkit element.
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6 Productivity Improvement Assessment
Exhibit 26: Tool 4 in the sequence
6.1 Description
6.1.1 Objective
The purpose of the Productivity Improvement Assessment questionnaire is toevaluate the implementation and awareness of continuous improvement practices in
i ti Thi t th t t f t ki t t i d ti it ith th
Energy Use
Performance and
Technical BestPractices
Assessment
Management
Best Practices
Assessment
Productivity
Improvement
Assessment
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template4
5
6
Technical
Measure Library
1
Management
Best Practices
Assessment
Technical
Measure Library
Management
Best Practices
Assessment
Technical
Measure Library
2
3
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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 includescompany presence within the country or worldwide, production quantities, andquestions 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
h kli t d t l t t l ( ti 8 2)
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7 Report Card and Opportunity Identification
Exhibit 29: Tool 5 in the sequence
7.1 Description
7.1.1 Objective
The Report Card and Opportunity Identification tool imports data from the assessmenttools, performs calculations to analyse and summarize the data, and presents theresults by means of graphs, charts and tables. The result is a report card which
Energy Use
Performance and
Technical Best
Practices
Assessment
Management
Best PracticesAssessment
Productivity
Improvement
Assessment
Report Card andOpportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template4
5
6
Technical
Measure Library
1
Management
Best PracticesAssessment
Technical
Measure Library
Management
Best PracticesAssessment
Technical
Measure Library
2
3
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Exhibit 30: Report and Opportunity Identification index table
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
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RC 3
Energy Management (EM) Opportunities
The opportunities are listed in order, grouped by categories. Categories are shown incolumns, starting (on the left) with the highest priority. The priority is determinedbased on the best practice score for each category (the category with the lowestscore 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 animported summary of energy use from the Technical Assessment tool (EnergyBalance tab).
RC 5
Reference Data
A summary is provided of greenhouse gas emissions factors for the various energytypes and the reference source of the factor.
RC 6
Best Practice Calcs (Management)
This is where calculations are performed to determine the Management BestP ti Th d t i d i th f ll i
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Maximum score = 1 if the measure is technically feasible or 0 if the measure is
not
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‖
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 coherentplant report card.
The answers from the Technical Assessment and Management Assessments
tools are imported into ―RC 6‖ and ―RC 7‖ tabs where the scores arecalculated.
The energy use for each end-use is imported from the Technical Assessment.
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.
The report card (―RC 1‖) displays these results in the form of charts and tables.
7.1.5 Using the Tool
The Report Card module functions automatically, however a series of steps must be
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Exhibit 31: Report Card “Edit Links” screen
I. Data Edit LinksII. Select ―A2A MA‖ from the list of sources
III. Click the ―Change Source …‖ button
IV. Select the Management Assessment file and press OkV. 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
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Exhibit 32: Report card macro button on Tab RC 2
After running the macro, the report card is created. However, there are someadditional 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 isprovided in Appendix A.
Tab ―RC 2‖
The technical opportunities are grouped by end-use. The end-uses are listedin order from highest potential opportunity to the lowest. The following exhibitshows the first end-use group after running the macro. There are two things todo/check on this tab after running the macro:
I. The column with maximum savings is left blank, and mu st be f i l led inmanual ly for each opportunity (in the example below, the first threesavings have been entered, and three more remain to be entered). Notethat the savings is given in the description. Sometimes this savings isgiven 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 perton of ammonia production (eg. 0.4 GJ/t_NH3). Where savings areprovided in percent of energy use convert this to energy units per ton of
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Tab ―RC 3‖
The management opportunities are shown in tables in tab ―RC 3‖ as shown inthe following exhibit. The opportunities are grouped into categories andordered by those categories starting with the highest potential opportunity forimprovement in the left column, and decreasing to the right. There is noadditional data to enter on this tab, but it should be checked to ensure that notext is cut off by the grid (increase row height if necessary).
Exhibit 34: Report card opportunities table to be completed manually
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Exhibit 35: Report Card plant information to be checked
Below the pie charts, product should be shown, followed by energyuse per (main) unit of production. If div#/0! is shown, the productquantity was not entered in table A.3 of the Technical BestPractices Assessment tool.
Exhibit 36: Report Card product information and energy use per unit of production
Check the energy intensity number and ensure that the units are
suitable (GJ/t_NH3), and that only one decimal or no decimals areshown.
ii. Check the leader lines on the pie charts; they may need adjusting ifth l ll i h t ti l t h th
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converted to PDF format; these PDFs can then be included in summary reports forthe participating company. To make the PDFs using MS Excel 2007, ensure thatthe add-in for this version of Excel is installed and follow the steps below. Forolder versions of Excel, ensure you have the appropriate printer drivers installed tosave 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)
III. Under ―Save as type‖, select ―PDF‖
Exhibit 39: Converting to PDF (steps 3 and 4)
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8 Energy Efficiency and Management (EE&M) Plan and Action Plan
Exhibit 40: Tool 6 in the sequence
8.1 Description
8.1.1 Objective
The purpose of the Energy Efficiency and Management plan checklist and Action Plant l t i t i t i ti i d l i E M t Pl d
Energy Use
Performance and
Technical BestPractices
Assessment
Management
Best Practices
Assessment
Productivity
Improvement
Assessment
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template4
5
6
Technical
Measure Library
1
Management
Best Practices
Assessment
Technical
Measure Library
Management
Best Practices
Assessment
Technical
Measure Library
2
3
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Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan index table
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
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48
Exhibit 43: Example EE&M Action Plan template.
EE&M
Element
Responsibility
Assigned to
Scheduled
Date
Status or
Date
Completed
Actions/
Comments
Do Do Check Act
5
9
Relative
Implementation
Difficulty1
Relative
Implementation Cost2
Maximum
Potential Energy
Savings3,4
[TCE]
Maximum
Potential
Energy Cost
Savings4
Responsibility
Assigned to:
Scheduled
Date
Status or
Date Completed
Actions/
Comments
Ammonia
Production
High emissivity coating of
radiant section refractory: 2 -
5% reformer heating energysavings 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
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.
Implementation of Identified Opportunities
(Including Technical Best Practices and
Productivity Improvement)
Time Frame
Action Item (from EE&M Plan Checklist)
Plan
Project Management
Parameters to be considered in identifying Energy management project opportunities can include fuel substitution
and use of renewable energy.
Library
Reference #Library Description
AM-54
High emissivity coating of the refractory surfaces in the radiant section of the primary reformer reduces the radiant heat
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.
AM-34
Steam turbine drivers can be modified with updated designs for rotors and stationary parts to increase horsepower rating
while reducing the water rate and saving energy.
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8.2 Accuracy, Detail and Making Assumptions
This questionnaire requires that ALL sections to be filled in using one of theresponses available in the menus.
No assumptions need to be made for this toolkit element.
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9 Glossary
5S
A program of 'industrial housekeeping', the 5S's are 5 Japanese words which help toguide organizations to increased levels of cleanliness, organization, & efficiency.
Category (plant informat ion)
Grouping category provided when the enterprise was registered to obtain theirbusiness 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 intensi ty
The energy use per unit of product produced is referred to as the energy intensity. Inthis assessment energy intensity is determined by evaluating energy use against the
main product only.
Energy management system
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High Ef f ic iency Equipm ent
Equipment that by design and function consumes less energy than conventionalequipment for the same function. This equipment can be specified by its design forefficient use of energy and in some cases, identified by a national efficiency rating orlabel.
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 thecustomer wants, when they want it, tin the quantity they want. The key elements ofJIT 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 Bl i tz
Kaizan in lean terminology means 'continuous, incremental improvement' implyingeveryone applying small (low impact & low cost) improvements each and every day. Applied in this manner, kaizen can have the same effect as large, costly, infrequentchanges. 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, itwas intended to communicate a change in demand or supply. In application, it isgenerally used to trigger the movement of material to or through a process.
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Retrof i t measure/technology
An energy efficiency measure/technology that can be used to upgrade an existingpiece of equipment, as opposed to replacing it. Retrofit measures are applied on a fullcost basis and may be implemented immediately.
Six sigma
Refers to six standard deviations from mean. Six sigma methodology provides thetechniques and tools to improve the capability and reduce the defects in any process.
Standardized wo rk inst ruct ions
Specific instructions that allow processes to be completed in a consistent, timely, andrepeatable manner. By implementing SWI‘s employees will increase production,improve quality, and enjoy a safer, predictable working environment.
Technical best p ract ice
A set of energy efficiency measures that represent the most advanced technologyavailable.
TPM
Total Productive Maintenance: preventative maintenance carried out by all
employees. It is equipment maintenance performed on a company wide basis.
Value st ream mapping
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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
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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.For the Technical Assessment, verify that for all applicable sections B to E, theequipment feature questions at the end of each section are ALL be answeredincluding all features questions in Section D (TA 9); input either the level ofimplementation or NTF (not technically feasible).
Verify that the Technical and Management Assessments are saved with thecorrect name (following an established naming convention). If not, change thefile name.
Close the Technical and Management Assessments, and open the ReportCard template file (A2A RCOI).
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.
Save the file with the appropriate name (following an established namingconvention).
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.
i. Data Edit Linksii. Select ―A2A MA‖ from the list of sources iii. Click the ―Change Source …‖ button iv Select the Management Assessment file and press Ok
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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 asuitable length, etc)
Graph axes and axis titles are not cut off
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‖ andpress ―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‖
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A2A Toolkit
Energy and Technical Best Practice Assessment
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Energy and Technical Best Practice Assessment
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
Name of Auditor Direct Telephone Number
Auditor's Organization /
Company NameFax Number
Title of Auditor E-mail address
Date of AuditEvaluation 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.
Confidential Plant Information
Auditor Information
Industrial Energy Use and Technical Best Practice Assessment
STEP 1 - Please complete the contact information requested on this page.STEP 2 - Review instruction sheet and complete the questions on the next pages.
TO DO:
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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).
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
This section includes energy used at your facility:- the purchased, self generated and sold energy products.
Fuel Type Units
LHV*
GJ per
[kg or m3]
Quantity Cost ($)Cost/unit (current year)
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A.3. PRODUCTION and PLANT DATA
2009 2008 2009 2008 2009 2008
Actual
Equivalent
Actual
Equivalent
A.4 FEEDSTOCK FUEL
2009 2008 2009 2008
Natural Gas 0.03897 m3 0 0
*LHV's can be overwritten for coal or other fuels which may vary in energy content
What type and quantity of feedstock do you presently use at your facility?
Fuel Type
LHV*
GJ per
[kg or m3]
Quantity
Units
Total fuel and feedstock
What are the main products produced at your facility, and what is the annual volume? Please list the most important products first and the reported annual energy consumption
in GJ.
Quantity
Annual Energy Consumption (all fuel
and feedstock)
[GJ]
Energy Consumption (all fuel and
feedstock) [GJ per unit of product]
Industrial Output ($)
Sales Revenue ($)
2009 2008
Share of energy consumption cost (%)
Specific industrial output energy
consumption (GJ/$)
% Change
Units
[please provide]
Energy Consumption cost ($)
Comprehensive energy consumption
(GJ)
Product Description
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B.1 COOLING and HEATING SYSTEMS
I do not have this equipment--------> Go to Section B-2
Total: 0.0E+00
-
-
-
-
Total: 0.0E+00
-
-
-
-
Total: 0.0E+00
-
-
-
-
* NTF = Not technically Feasible
Annual Energy
Use
[GJ]
Average Age of
Equipment
[years]
Total number
of equipment
in each
Capacity
Range
COOLING / REFRIGERATION COMPRESSORS
BOILERS
What are the energy sources and features of your equipment? Exclude HVAC related equipment Please indicate the features that are not technically feasible.
Energy Source
[nat.gas / elec. /
etc]
This section includes Cooling and Heating equipment (excluding HVAC) at your facility.
This includes refrigeration compressors, ovens/dryers/kilns/furnaces and boilers.
Equipment
Nameplate Capacity
enter average value
of up to four ranges
Units
[ kW / MW]
OVENS / DRYERS / KILNS / FURNACES
Annual
Operating
Time
[hrs]
Number of high
efficiency
equipment
[enter number
or NTF*]
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Appendix E A2A Checklist and Action Plan Template
A2A Toolkit
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Are the following features included in your respective systems?
B.1.12
B.1.13
B.1.14
B.1.15
B.1.16
B.1.17
B.1.18
B.1.19
B.1.20
B.1.21
B.1.22
B.1.23
B.1.24
B.1.25
B.1.26
B.1.27
B.1.28
B.1.29
OVENS / DRYERS / KILNS / FURNACES
BOILERS
Features
Air curtains or other methods are used at the inlet/outlet of the oven/dryer to minimise
loss of hot air.
Equipment is included in regularly scheduled preventative maintenance program and
includes combustion efficiency testing.
Advanced/Automated boiler controls (e.g. linkage less control)
Boiler water treatment to remove impurities
Deaerator vent losses are minimized through regular inspection or automation
Condensate is returned to the boiler where it is technically feasible
Steam trap surveys completed within past 2 years and faulty traps were repaired
Boilers are included in regularly scheduled preventative maintenance program
At least 90% of insulation is in good condition
Systems have advanced heating/process controls
Adjust air-fuel ratio to optimize combustion efficiency
Automated blowdown control
Makeup water is preheated with heat recovered from other heat sources
Boiler load assessment was conducted when boiler was installed to ensure it is optimumsize.
For multiple boilers load management study was conducted to define optimum load
management strategy.
At least 90% of insulation is in good condition
Infrared or radiant heating is used instead of convection heating
Heat from the flue gas is recovered and used
Rating
Rating
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OVENS / DRYERS / KILNS / FURNACES
Additional Opportunities Identified (Describe)
BOILERS
COOLING / REFRIGERATION COMPRESSORS
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B.2 COMPRESSION SYSTEMS
I do not have this equipment--------> Go to Section B-3
Total: 0.0E+00
-
-
-
-
Total: 0.0E+00
-
-
-
-
* NTF = Not technically Feasible
This section includes Compression Systems at your facility.
This includes air compressors used for pneumatic equipment and air/gas compressors used for process.
What are the energy sources and features of your equipment?
Please indicate the features that are not technically feasible.
Equipment
Nameplate Capacity
[enter average value of
up to four ranges]
Units
[ kW / MW]
Total number
of equipment
in each
Capacity
Range
Energy Source
[nat.gas / elec. /
etc]
Number of high
efficiency
equipment
[enter number or
NTF*]
Average Age of
Equipment
[years]
Annual
Operating
Time
[hrs]
Annual Energy
Use
[GJ]
AIR COMPRESSORS FOR PNEUMATIC EQUIPMENT
AIR OR GAS COMPRESSORS FOR PROCESS
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AIR OR GAS COMPRESSORS FOR PROCESS
Additional Opportunities Identified (Describe)
AIR COMPRESSORS FOR PNEUMATIC EQUIPMENT
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B.3 MOTORS, PUMPS, FANS and CONVEYORS
Please indicate the inventory of Motors, Conveyors, Pumps and Fans and their features?
If you do not have a list of this inventory, please provide your best estimate. Exclude equipment related to HVAC.
Average Rated
Capacity Range
[kW]
(enter average
value of up to six
ranges)
Total number of
equipment ineach Capacity
Range
Number with VFDs
/ ASDs[enter number or
NTF]
Number of Class
2 Motors[enter number
or NTF*]
Average Ageof Equipment
[years]
Number of
Motors with
Synchronous
Belts
[enter number or
NTF*]
Number of Class
1 Motors[enter number
or NTF*]
Annual
OperatingTime
[hrs]
AnnualEnergy Use
[GJ]
Total: 0.0E+00
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
* NTF = Not technically Feasible
This section includes motors and motor-related equipment (fans, pumps, conveyors) at your facility.
PUMPS
FANS
OTHER MOTORS (including those for conveyors)
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B 4 ONSITE TRANSPORT EQUIPMENT
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B.4 ONSITE TRANSPORT EQUIPMENT
I do not have this equipment--------> Go to Section C-1
Please list the onsite transport equipment used at your facility. Please indicate the features that are not technically feasible.
Annual Energy
Use [GJ]
Rated CapacityUnits
[kW / MW]Total: 0.0E+00
-
-
-
-
-* NTF = Not technically Feasible
Are the following features included in your onsite transport equipment systems?
B.4.1
B.4.2
B.4.3
B.4.4
Transport Equipment Opportunities Identified (Describe)
Alternative fuelled vehicles or hybrid technology adopted to reduce energy
consumption
Minimal idling
Preventative vehicle maintenance program
Category or Type of
vehicle
[eg. excavator,
truck, forklift]
Energy Source
[nat.gas / diesel /etc]
Number of
vehicles ofthis type
Average Equipment Rating (incl.
auxiliary equipment)
High Efficiency Battery Chargers for forklift type vehicles
Features
This section includes onsite transport vehicles used at your facility.
Number of high
efficiency
equipment[enter number or
NTF*]
Annual
Operating
Time
[hrs]
Rating
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C.1 LIGHTING
This section includes lighting system features in the entire facility
What lighting is present at the facility?
Annual Energy Use
[GJ]Total: 0.0E+00
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Does your lighting system include the following?
RatingLocation
[interior / exterior /
both
Latest system design
change
MM YYC.1.1
C.1.2
C.1.3
C.1.4
C.1.5 Lighting (auditing) survey completed
Average Rated Capacity
[Watts]
Number of Lamps
that are EnergyEfficient
Fluorescent and
CFL's
Metal Halide
High Pressure
Sodium
Incandescent and
Other
Occupancy sensors
On/off timer settings
Annual Operating
Time[hrs]
Features
High-efficiency ballasts for lighting
Control of lighting system according to zones
or production areas
Total Number of
LampsType of Lighting
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Other:
Equipment / Technology:
Control:
Lighting System Energy Efficiency Opportunities Identified (Describe)
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C 2 HEATING VENTILATION and AIR CONDITIONING (HVAC)
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C.2 HEATING, VENTILATION and AIR CONDITIONING (HVAC)
Please list any HVAC equipment (equipment with the highest energy-use).
I do not have this equipment
Rated
Capacity
Units
[ kW /
MW]
Rated
Capacity
Units
[cooling ton
/ kW / HP]
-
-
-
-
- * NTF = Not technically Feasible Total: 0.0E+00
Does your plant contain any /all equipment below for ventilation?
I do not have this equipment
Rated
Capacity
Units
[ kW /
MW]
-
-Total: 0.0E+00
Average
Equipment
Age
[years]
Average
Equipment
Age
[years]
Air exhaust system(s)
Total Motor Power
Energy Source
[nat.gas / elec / etc]Process equipment description
Annual
Operating
Time
[hrs]
Air make-up system(s)
Annual
Energy Use
[GJ]
Avg Unit Cooling
Capacity
Number of
high efficiencyequipment
[enter number
or NTF*]
Annual
Energy Use
[GJ]
Annual
Operating
Time
[hrs]
This section includes all HVAC equipment in the facility, including that used in offices and the plant.
Energy Source
[nat.gas / elec /
etc]
Avg Unit Heating
CapacityNumber of
equipment
in of this
type
Categories / Typesof Equipment
[eg. radiant heaters/
convection heaters /
chillers / window air
conditioning]
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Does your HVAC system include the following?
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Does your HVAC system include the following?
C.2.1
C.2.2
C.2.3
C.2.4
C.2.5
C.2.6
C.2.7
C.2.8
C.2.9
C.2.10
C.2.11
C.2.12
C.2.13
C.2.14
C.2.15
C.2.16
Radiant heaters are used in areas close to loading dock doors and where
convection heating is not required
Loading docks are well insulated, sealed and managed to minimise loss of
heated/cooled air
Within last 3 years an assessment was conducted to determine ventilation
requirements and ventilation system was optimised.
Recover heat from process or exhaust gas to heat make-up air
Premium efficiency motors on fans
System uses free cooling
System uses variable speed fans
Destratification fans are used to reduce air stratification in large areas.
System uses demand-controlled ventilation
The HVAC system is included in scheduled preventative maintenance
program.
An assessment was made to install solar walls to heat ventilation air
Features Rating
Heat pumps for cooling/heating
Different heating and cooling set points for seasonal and daily fluctuations
Set back temperatures when facility is not occupied, e.g. during weekends
Recover heat from exhaust flow
Automated plant HVAC control system
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HVAC Opportunities Identified (Describe)
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HVAC
Other Heating Equipment
Air Make-up and Exhaust
Other
HVAC Opportunities Identified (Describe)
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D.2 GENERAL FACILITY PRACTICESPlease indicate if your facility practices include any of the following?
D.2.1
D.2.2
D.2.3
D.2.4
D.2.5
D.2.6 Heat exchanger maintenance and repair is
D.2.7 Heat exchanger optimization completed periodically
D.2.8D.2.9
D.3 EMERGING TECHNOLOGY Are there any other emerging technologies you are considering or you have implemented in your facility?
Features
What is the power factor for your facility? (enter value
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E.2 AMMONIA PROCESS PRACTICES - GeneralPlease indicate if your facility practices include any of the following?
E.2.1
E.2.2
E.2.3
E.2.4
E.2.5
E.2.6
E.2.7
E.2.8
E.2.9
E.2.10
E.2.11
E.2.12
E.2.13E.2.14
E.2.15
E.2.16
E.2.17
E.2.18
E.2.19
E.2.20
E.2.21
E.2.22
E.2.23E.2.24
E.2.25
E.2.26
E.2.27
E.2.28
Optimized Refrigeration Levels
Retrofit of Gas Turbine for improved Efficiency
Supplemental reboiler to heat CO2 removal condensate
2 Stage Stripping for CO2 Removal Solvent in the process
CO2 Removal Condensate Reboiler installed
Synthesis Gas Molecular Sieve Dryer and Direct Synthesis Converter Feed in process
Optimized Control of Refrigeration Inerts
Warm Ammonia Delivery to Consumers
Compressor Seal Gas Leakoff Recovery
Low-Pressure difference synthesis reactor
Waste Heat Recovery from Lean Solvent
Optimized Loop Recycle Flow
Recovery and Recycle of Flashed gases
Improved steam turbine design to improve efficiency
Axial-radial flow converter to improve conversion efficiency and reduce pressure drop
High Efficiency Packings and Internals for CO2 Removal Columns
Pressure Swing Adsorption for product purification
Improved catalysts in Shift Process
Hydrogen separation and recovery from synthesis gases
RatingFeatures
Installation of Gas Turbine to drive process air compression, using hot exhaust gases
Improved Ammonia synthesis catalysts
Improved Design for Shift Converter Gas Distributor and Collector
Flash of CO2 Solvent with Ejectors or Mechanical Recompression
Isothermal CO converter with built in heat exchanger
Enhanced CO2 removal solvents
High Conversion Synthesis Reactor (indirect cooling) to remove reaction heat
Waste heat recovery from compressor synthesis gas
Advanced Process Control to optimize Ammonia synthesis process
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E.3 AMMONIA PROCESS PRACTICES - Natural Gas
This type of fuel is NOT used --> This is the last page of the survey
Please indicate if your facility practices include any of the following?
E.3.1
E.3.2E.3.3
E.3.4
E.3.5
E.3.6
E.3.7
E.3.8
E.3.9
E.3.10
E.3.11
E.3.12
E.3.13
E.3.14
E.3.15
E.3.16
E.3.17
E.3.18
E.3.19
E.3.20
Reformer tubes are made of micro alloys with minimum permitted wall thickness
Improved catalysts in reforming process
Saturation of feed gas with recycle process condensate to allow export of steam
Radian section of primary reformer refractory has high emissivity coating
Increase mixed feed preheat temperature, convection modifications to optimize process energy use in process
Improved secondary reformer burner design to optimize reform reaction equilibrium at exit.
Optimize (reduce) secondary reformer catalyst volume/ redesigned collector
Recycle of hydrogen to primary reformer improves catalyst performance
Improved arch seals at primary reformer that reduce leakage while permitting thermal movement of tubes
Rating
Modified reformer operating Pressure
High Pressure water power recovery turbine to drive absorbent liquid pump
Lower reformer steam-carbon ratio to reduce primary reformer heat demand
Waste Heat to preheat fuel gas
Adiabatic pre-reformer to reduce primary reformer duty
Waste heat recovery from reformer using heat exchanger reactorWaste Heat Recovery from reformer flue Gas
Improved insulation of reformer furnace
Expansion of fuel gas for power recovery
Features
Optimized shift reformer duty balance between primary and secondary reformer
Other Notes or Remarks
This is the last page of this survey. Thank you very much for your time and assistance.
Isobaric ammonia manufacturing
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Energy Balance
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Equipment energy-reported GJ/yr1 2 3 4 5 6 8 7
Electricity Natural Gas Diesel Fuel Oil Gasoline PropaneBiomass /
Other fuelSteam
Cooling / Refrigeration - - - - - - -
Boilers - - - - - - - -
Ovens / Dryers / Kilns / Furnaces - - - - - - - -
Pneumatic Compressors - - - - - - - Air or Gas Compressors - - - - - - - -
Fans, Motors, Pumps -
Heavy Transport - - - - - -
HVAC and Air System - - - - - - - -
System & Other Process - - - - - - - -
Ammonia production - - - - - - - -
Lighting -
Total energy/year - - - - - - - -
Energy Balance
Electricity Natural Gas Diesel Fuel Oil Gasoline Propane Other fuels Steam
Purchased Energy (GJ/yr) - - - - - - - - Sold Energy* (GJ/yr) - - - - - - - -
Net Purchased Energy (GJ/yr) - - - - - - - -
Self Generated Energy (GJ/yr) - -
Net Imported Energy (GJ/yr) - - - - - - - -
Adjustment Factor - - - - - - - -
Equipment / Purchased ratio - - - - - - - - * Energy content of sold steam is converted back to the fuel used to generate steam with an adjustment factor for efficiency of conversion (see TA2)
Equipment energy-adjusted GJ/yr
Electricity Natural Gas Diesel Fuel Oil Gasoline Propane Other fuels Steam
Cooling / Refrigeration - - - - - - - -
Boilers - - - - - - - -
Ovens / Dryers / Kilns / Furnaces - - - - - - - -
Pneumatic Compressors - - - - - - - -
Air or Gas Compressors - - - - - - - -
Fans, Motors, Pumps - - - - - - - -
Heavy Transport - - - - - - - -
HVAC and Air System - - - - - - - -
System & Other Process - - - - - - - -
Ammonia production - - - - - - - -
Lighting - - - - - - - -
Total energy/year - - - - - - - -
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Energy Share By End Use Steam energy by end useAll Energy GJ/year % of Total GJ/year % of Total
Cooling / Refrigeration #N/A #N/A #N/A #N/A
Boilers #N/A #N/A #N/A #N/A
Ovens / Dryers / Kilns / Furnaces #N/A #N/A #N/A #N/A
Pneumatic Compressors #N/A #N/A #N/A #N/A
Air or Gas Compressors #N/A #N/A #N/A #N/A
Fans, Motors, Pumps #N/A #N/A #N/A #N/AHeavy Transport #N/A #N/A #N/A #N/A
HVAC and Air System #N/A #N/A #N/A #N/A
System & Other Process #N/A #N/A #N/A #N/A
Ammonia production #N/A #N/A #N/A #N/A
Lighting #N/A #N/A #N/A #N/A
Total - -
Purchased Energy By Fuel Typennua et
Purchased
Energy [GJ]
Annual Purchased
Energy Cost [$]
GJ Cost ($)
Electricity #N/A -
Natural Gas #N/A -
Diesel #N/A -
Fuel Oil #N/A -
Gasoline #N/A -
Propane #N/A -
Other fuels #N/A -
Steam #N/A -
Total - -
Energy Share By End Use
Electricity
0%
Natural Gas
0%
Diesel
0%
Fuel Oil
0%
Gasoline
0%
Propane
0%
Other fuels
0%
Steam
0%
Annual Purchased Energy Cost
[$]
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Energy1,2
GJ Weight1
kg Volume1
L Power Units1
kW Energy1,2
TCE
GJ 1 ton (metric) 1000 gallon 3.785 BHP 0.746 GJ 0.034129693
kWh 0.0036 ton [short] 907 ft3 28.317 HP 0.7355 kWh 0.000122867
kVA 0.0036 ton [long] 1,016 L 1 BTU/hr 0.000293 kVA 0.000122867
TCE 29.3 kg 1 m3 1000 MMBTU/hr 293.0711 TCE 1
kgCE 0.0293 lbs 0.454 Cooling Ton 3.517 kgCE 0.001BTU 1.05506E-06 lb 0.454 Boiler HP 9.8095 BTU 3.60087E-08
kCal 4.19E-06 kW 1 kCal 1.42867E-07
MMBTU 1.05506 MW 1000 MMBTU 0.036008874
References
1. www.engineeringtoolbox.com
2. LBNL BEST tool
Conversion Tables (Multiplication Factors)
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Appendix C A2A Energy Management System Assessment
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Energy Management System Assessment
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Plant Name
Company Name
Sub-sector (choose from menu)
Plant Address:
Street and number
City
Province
Postal codePlant Telephone Number
Name
Title (Position)
E-mail Address
Telephone Number
Name of Auditor
Title of Auditor
Auditor's Organization / Company Name
Direct Telephone Number
E-mail address
Date of Audit
Confidential Plant Information
Auditor Information
Plant Contact Info
Institute for Industrial Productivity
Energy Management System Assessment
TO DO:
STEP 1 - Please complete the contact information requested on this page.
STEP 2 - Review instructions sheet and complete the questions on the next pages.
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.
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1.1
1.2
1.3
1.4
1.5
%
1.6
1.7
1.8
1.9
1.10
1.11
If no, does the company intend to develop a carbon management plan?
Has the company calculated the GHG footprint of the plant, company or both?
What is the plant’s current annual operating cost reduction target? [%/year]
What percentage of the plant’s total operating costs in the latest fiscal year was represented by purchased energy
costs?
1.0 Corporate Information
Does the company have a plan to phase out old equipment over a specific period of time?
What is the company’s desired return on investment on a capital project designed to improve energy use
performance and reduce energy operating costs? (Can be expressed in terms of simple payback, NPV or IRR)
Has the plant adopted any elements of a nationally recognised Energy Management standard?
What is the company’s current annual operating cost reducti