creating efficiency and business value through smart energy and water management

Antea USA, Inc.Antea USA, Inc.

Leveraging Resources Efficiencies and Savings Across the Organization

Honda Sustainability Symposium

November 3, 2015Eric Malinowski


Local Expertise & Experienced Professionals

Eric Malinowski – Antea Group

35 years industry experience.

Former corporate executive with steel industry and food & beverage companies.

Wide variety of energy and resource efficiency project experience.

International expertise spanning all six major continents.

Conducted 60+ resource assessments and training workshops in manufacturing facilities in Asia, Africa, Europe, South Pacific and North and South America.


Agenda

• Benefits of Resource management in Sustainability Plan

• Resource management for Continual Cost Savings

• Resource Assessment Purpose, Objectives, Results

• Energy

• Water

• Creating a Energy & Water efficiency and conservation culture across the organization

• Summary


Energy and Water Management System


Sustainability Simplified: What Are Priorities Now?

1. How do we ensure it’s safe to make, move and use, reinforcing our company’s great reputation?

• Reducing risks across the value chain helps to ensure the longevity of our business

2. Can we make it with less and exceed our business objectives?

• Drive economic savings through efficiency & changes to make the company more productive/competitive

3. How do we ensure our sustainability actions and communications extend the trust customers have for us?

• Clear, credible and transparent proof of our efforts furthers trust and helps deliver the promise

4. Can we make a better choice for today and tomorrow, creating capacity for long-term growth?

• A commitment to customer focus and sustainability will build our brand and enable a brighter future for all stakeholders

5. How do we find new methods to meet evolving market demands for sustainable products before our rivals

• Sustainability efforts that change the basis of competition drive extraordinary value


Key Initiative –– Improving the capability and use of energy & water data to increase efficiency

• Create a cultural in which efficient energy & water practices and continual reduction in energy consumption are embedded into the day to day operations

Objective

• Long term goals established, short term targets in place and accepted

• Efficient energy & water consumption cultural established, Champion and team(s) engaged

• Continuous improvement is documented, verified and published

• Program completely integrated into plant wide operations culture

Success

• Establish energy & water management practices (establish culture and continuity)

• Data Collection / KPI’s / Targets (road map. verification, purpose)

• Analysis (ensure progress and help align reduction efforts when required)

• Benchmarking both internal and external (ensures continuous improvement )

• Best Practice Implemented (reduce time to reap savings benefits)

• Identify, evaluate and prioritize new savings opportunities (required to meet targets)

• Regular reporting , follow up and communication of program results (management)

How


Efficient Resource Management Program

Energy & Water Usage Goals

Define Targets /Assign

Champion

Measure / Monitor /

Benchmark

Identification of Savings

Opportunities

Evaluation & Implementation

Review / Assess & Adjust

Continuity Plan for Long Term

Success

Voluntary Energy Program Options• EPA Energy Star• ISO 50001


The Business Value

Direct Benefits

Indirect Benefits

Business Value

Direct Benefits• Controllable energy

& water usage and costs

• Improved operational efficiency

• Reduced environmental impact

• Sustainable energy consumption

Indirect Benefits• Increase in cross functional

communication• Improved relationships with

resource and equipment suppliers

• Improved risk management• Improvement employee

involvement and increased morale

• Translate lessons learned from resource reduction opportunities to enhance production, throughput and quality through out the facility


Efficient management of Energy and Water resources through a data driven lean approach

Establish inventory of measurement points

Trend and benchmark measurement points

Develop targets for measurement points and establish KPIs

Report KPIs; make operational changes to improve performance

Develop facility energy & water capital plan based upon targets and KPIs

Execute targeted engineering studies to support project development

Feed opportunities items into capital plan

Scope and execute projects

Data Analysis Phase

ProjectPhase

3 421

8 7 6 5

3 421

Phase 1

Phase 2


Two Main Elements to Achieving Energy & Water Efficiency

Resource Management System Savings Opportunities

Position Statement - Scope

Infrastructure / Human Resources

KPI’s, Goals and Targets,

Energy & Water Profile and Baseline

Measurement/Benchmarking/Reporting

Awareness/ Training / Education

Roles and Responsibilities

Reducing Air Pressure

Fixing Air, Water, Nitrogen Leaks

Capturing steam condensate

HVAC Maintenance/Adjustments

Leaning out processes and eliminatingprocess steps

Reclaim and reuse of water

Conservation


The Rewards

Long term goals are established, short term targets in place and accepted.

Resource Champions and teams are in place and engaged.

Energy & Water efficiency management practices are documented, verified and published.

Resource management program is completely integrated into the operations and culture and is no longer considered a separate program.

An resource conservation and efficiency culture is established among all stakeholders.

Continual operating cost reductions are realized annually.


Measures of Success

Senior management portrays clear commitment to the success of energy program.

All plants and division management teams are committed to sustainable energy & water reduction by deploying resources, utilizing energy & water metrics, KPI’s and benchmarking practices to ensure sustainable progress.

Individual roles and responsibilities are clearly defined, and implemented for all persons charged with energy strategy implementation.


Measures of Success

Clear and defined reduction targets and goals are implemented, tracked and communicated on a regular basis at least once a quarter

Regular meetings are held to review energy & water metrics and KPI’s to ensure that stated goals and targets are on track and assigned corrective action plans are implemented when necessary to achieve success

Equipment procurement and engineering design standards are aligned with procedure to include provisions for energy efficiency in equipment purchases and capital project designs.


Primary Areas of Focus for Reducing Energy and Water Consumption

Areas of Focus• Production• Water Systems• Steam Systems• Chilling System• Compressed Air• HVAC• Lighting Systems• Building

TOP 10 Energy Measures• Detect Air Leaks• Detect Steam Leaks• Upgrade Insulation• Air Pressure• Use blowers in place

of compressed air• Efficient Lighting• Maintain HVAC• Condensate Return• Evaluate Set Points• Employee

Awareness

Top 10 Water Measures• Filtration System• Backwash Optimization• Water Leaks• Lubrication / Equipment

Cooling Optimization• Cooling Towers• Pump Seals• Sanitary Facilities• Cleaning Spray nozzles, • Leaks & Water Recovery• Reclaim & Reuse (Rain

water capture, HVAC condensate capture, once through systems etc.)


WATER & ENERGY INFORMATION: TYPICAL DATA COLLECTION SOURCES

Water / Wastewater Sources:

• In-line flow measurement devices

• Production/operations records

• Design and nameplate information

• Tank level and stopwatch tests

• Bucket and stopwatch tests

• Interviews with operators

• Engineering judgment

Energy Sources:

• Utility metering

• Main electrical load center

• Distribution Load Center

• Equipment meters

• Design information

• Temporary kWh meters

• Data collection / trends / reports

• Maintenance records


Identifying Saving Opportunities through Resource Assessment


Energy & Water Assessments

• Focus on energy & water users

• Look for opportunities that stand out lights on when nothing is happening, equipment running when it should be shutdown, leaks at equipment, water running when equipment is shut down etc.

• Take notes, pictures and identify potential savings (electricity or thermal ,water, wastewater)during walk through.

• Capture all opportunities and do not analyze during the identification phase.

• Place opportunity into category – compressed air, heating water reclaim etc.

• Prioritize opportunities to better manage implementation.


Assessment Findings

Align saving opportunities into a category and prioritize

• Low Cost / Low Effort – Return on investment immediate to six months, opportunity can be implemented with minimal effort

• Intermediate / Low to Medium effort – Return on investment six months to 24 months, opportunity may require engineering, and capital resources to implement

• Future / medium to major effort – Return on investment 24 months or longer, opportunity may require engineering, major capital and plant and contractor resources to implement.


Production Opportunities (Energy & Water Opportunities)

Day to Day Best Practices:

• Monitor and elevate water and energy set points regularly (at least twice a year) monthly would be preferred

• Challenge changes to set points that impact energy and water usage

• Inspect for water, air, and steam leaks

• Turn off lighting, conveyors , fans, & pumps and other equipment when not in use.

• Optimize cleaning processes

• Monitor energy and water KPI’s that can be used to benchmark performance

• Awareness - Regularly communicate reduction goals, and status updates to employees

• Seek suggestions on how to efficiently deploy energy and water resources


Water Savings Best Practices

Rel

ati

ve V

alu

eHigh Value / Difficult High Value Easy

Relative Ease

Automatic Faucets Low Flow Nozzles

Fix Water Leaks

Optimize flow ratesWater Reclaim & Reuse

Pump Seals

Cleaning Optimization

Interlocks

Eliminate Once Through With closed loop

Install Dry Lube

Lower Value / Hard Lower Value / Easy


Steam System Best Practices

Reduce STM Pressure

Reduce HTW Temp

Insulation STM & HTW Pipes

Repair Condensate System

Upgrade Burners

Excess Air / VFD

Combustion Fan control

Boiler Tuning

Steam Leaks

Boiler Stack Economizer

Direct fired WTR HTR

Rel

ati

ve V

alu

eHigh Value / Hard

Relative EaseLower Value / Hard

High Value Easy

Low Value Easy


Compressed Air System Best Practices

Change Filters

Air LeaksReduce Air Pressure

Replace Air Knives

Optimize Compressor Controls

Use Blowers to Convey Caps

Eliminate air motors,

Add outside air to Compressor inlet

Optimize air piping & storage

Reclaim Waste Heat

Energy Efficiency Strategies Efficient Use of Compressed Air. Generating compressed air accounts for more than 12% of total electricity consumption, or more than 5% of total energy use. Steps to reduce compressed air generation energy have focused on better management of compressed air systems to provide the right pressure to the right areas at the right times

High Value / Hard High Value / Ease

Rel

ati

ve V

alu

e

Lower Value / Hard Lower Value / EaseRelative Ease

Source: Driving for Green (Case Study)By: Karen HeyobHigh Performance Buildings Magazine Winter 2011


Building System Best Practices

Change Filters & Keep HVAC Unit Coils

Cleaned

Inspect Doors and Windows

Turn off Unused Lighting

Used auto setback for HVAC control

Ensure all walls and ceilings for conditioned

rooms are properly insulated

Use reclaim water for cooling towers

(if possible)

Install LED Lighting & Controls,

Install VFDs on HVAC Supply &

Return Fans

Install White Roof

Remove heat sources from conditioned

rooms

Install Building Management

System

High Value / Hard High Value / Ease

Rel

ati

ve V

alu

e

Lower Value / Hard Lower Value / EaseRelative Ease


Creating Energy and Water Efficiency and Conservation Culture


Rolling out Resource Efficiency Across the Organization

Focus on the culture change – move from current state to a conservation culture where all employees are on the look out for resource savings opportunities at all process, admin and support operations within the facility.

Energy & Water team(s) is a vital cog in the wheel of transformation, the integration of multiple plant personnel and a passion to instill energy & water efficiency in every aspect of the business will go a long way in changing peoples mind sets.

Develop programs that will help educate and train employees on the benefits of energy & water efficiency practices.

On a regular schedule (at least once a month) review energy & water data and action plans to ensure that progress towards resource reduction goals are on track.


Measures of Success Energy & Water management practices and culture are

fully embedded in the day to day business functions for

the plant (no longer a special program).

All departments recognize the importance of energy &

water efficiency and incorporate the practices into their

daily activities.

Procurement specifications and engineering standards

have energy & water efficiency guidelines included in

their standards and procedures.

Resource Champion(s) and Energy Team(s) are

established, roles and responsibilities are documented

and the Energy & Water Team(s) is the cultural leader

for energy & water efficiency practices throughout the

site.

Energy & Water team(s) regularly communicates

program status and progress towards achieving

reduction targets on a regular basis.Source: Driving for Green (Case Study)By: Karen HeyobHigh Performance Buildings Magazine Winter 2011

creating efficiency and business value through smart energy and water management

Environment