7 Habits of Highly Effective Energy Managers

Rick MarshDirector, Industrial EE Network

2

Engineers Design for “Just in Case” not Energy Efficiency

• Fans & Pumps are usually oversized to consider worse case scenarios.

• Furnaces designed for peak product flow but.

3

Air is FREE!(Compressed Air is Very Expensive)

• Compared to electric motors, the work that is conducted by compressed air is 7 times more expensive.

• Poor management of air supply can yield inefficiencies for costs and also in meeting demand events.

• Inappropriate uses and leaks are BIG opportunities

4

Motel 6 Got it Wrong –

Don’t Leave the Lights On

• Changing bulbs is a good first step• All light is not created equal • Sensors and controls

– Occupancy sensors – Daylighting– Timers

5

Reality is Somewhere Between our Expectations & Total Chaos

• Few industrial operations are truly 24/7

• Compressor sequencing & controls can adversely affect energy efficiency

VS

6

Low Hanging Fruit Always

Seems to Grow Back

• Air & steam leaks• HVAC efficiency losses• results of poor maintenance• equipment degradation

= need for a continual management process.

7

Production Needs vs. EE (Can’t We Just All Get Along!)

• Perceived needs

• Refusing to change anything that may cause a production issue often conflicts with energy reduction

• Energy Management

= Opportunity

8

Metering

You Can’t Reduce What You Don’t Measure, and You Can’t Measure What You Don’t

Meter

• Sub-metering helps to align energy consumption with significant energy uses allowing for concentration of effort.

• Measuring energy performance should be calculated as a basis of production (energy intensity) without consideration for rate changes – MMBtu/unit production

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Material Developed By:

Dr. Ken Currie

Director, Center for Manufacturing Research

Associate Director, Industrial Assessment Center

Tennessee Tech University

kcurrie@tntech.edu