Oak Ridge
National Laboratory
NGA Meeting
October 17, 2012
Thomas Wenning
Program Manager
Commercial, Residential and
Industrial Energy Efficiency
Overview
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IACs
Industry Insights
National Lab Capabilities
DOE Tools
DOE's Industrial Assessment Centers (IACs)
• IACs provide practical in-plant training to engineering students at 24
universities.
• Train 360-480 new engineering students per year for careers in industrial
energy efficiency and energy management
• Provide assessments to small and medium-size plants (energy costs below
$3 million per year)
– Conduct ~480 energy assessments per
year
– Identify $175,000 to $200,000 in potential
annual energy savings per plant (average
implementation rate: 35% to 45%)
• Help university professors stay connected
to the technical needs in manufacturing
• Work with private sector partners to
support workforce development
• Open to collaboration
http://www1.eere.energy.gov/industry/bestpractices/iacs.html
IAC Locations
Workforce Development
• IAC students have
participated in more than
15,000 assessments
• Provided nearly 114,000
recommendations for
small and medium-sized
plants.
• IACs have trained more
than 3,000 students to
become the next
generation of energy
engineers.
• Nearly 60% of IAC
graduates go on to
careers in the energy
industry.
IACs (2012-2016)
IAC Assessments (through
2012)
http://www1.eere.energy.gov/manufacturing/tech_deployment/iacs.html
IAC Assessment Components (1-day)
• Client Solicitation
• Pre-visit preparation
– Pre-assessment data collection
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Intake interview
Plant Tour
Recommendation brainstorming
Onsite Data Collection
Exit Interview
Post Assessment Report Workup
Review of assessment impact
– Implementation callback (about 1 year after plant visit)
The IAC DATABASE
• Publicly Available
• Contains:
– Facility data
– Recommendation data
– Implementation data
• Searchable by
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Size (in energy usage, employees, etc…)
Industry Type (NAICS or SIC)
Location
Recommendation Type
• Updated in Real-Time as the assessments are
completed
Industry Insights
Barriers
&
Best Practices
Better Plants Partners
Facilities across the United States
Implementation Barriers
 Unattractive evaluated return on investment
 Lack of manpower or personnel changes
 Change in policy or funding for energy reduction
 Process related limitations
 Concerns regarding operational changes
 Limitations of current available technology
 Red Flags by the employees
 Political issues
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Corporate Best Practices
• Hold Senior Managers accountable for Energy
Efficiency – compensation at risk
• New Projects and New Products must pass
energy efficiency reviews
• Sustainability as an umbrella
• Supplier / Customer outreach – Customer
retention
• Dedicated Energy Funds
The Search for Revolutionary Technologies
Costs
+%
0
Utilizing Best
Practices
Revolutionary
Technologies
Investment
-50%
0
Years
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AMO Resources & Key Tools
DOE’s Advanced Manufacturing Office (AMO) hosts over 40 software
tools on its website. These tools provide manufacturers with a wide variety
of measurement, calculation, and tracking capabilities related to energy
management and energy efficiency.
Energy Performance Tracking
Energy Management
Energy Performance Indicator
v.2.0 Tool
eGuide for ISO 50001
Project Opportunities Tracker
eGuide Lite
Corporate Energy Performance
Tracking for Better Plants Partners
Facility Energy Performance
Tracking for Superior Energy
Performance
ePEP (Plant Energy Profiler)
Energy Systems Analysis
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Motors
Pumps
Fans
Compressed Air
Steam
Process Heating
Data Centers
Simple Calculators
http://www1.eere.energy.gov/industry/bestpractices/software.html
eGuide & eGuide Lite
The eGuide/eGuide Lite* is a comprehensive resource for implementation
of an EnMS based on a continual improvement framework. The step by
step approach of the eGuide is based on the PLAN-DO-CHECK-ACT
requirements of ISO 50001.
Systematic approach to Energy Management
New to Energy Management
*Note: Use of the eGuide does not itself guarantee that the implementing organization will attain third-party ISO 50001 certification.
https://save-energy-now.org/EM/SSPM/Pages/home.aspx
DOE eGuide Lite Tool
Thank You!
Thomas Wenning
Program Manager
Commercial, Residential and Industrial Energy Efficiency
Oak Ridge National Laboratory
865.241.8676
wenningtj@ornl.gov
Industry Breakdown
Number of U.S. Plants
U.S. Manufacturing Plants: By Size
250000
200,710
Percent of Total U.S.
Manufacturing Energy
200000
Small 5%
150000
84,298
112,398
100000
Large
58%
50000
4,014
0
Small
Plants
Crosscutting
Assessments
Mid-Size
Plants
Large
Plants
All
Plants
System-Specific
Assessments
Mid-Size
37%
DOE’s National Laboratories:
A comprehensive research system employing
30,000+ scientists and engineers
Fermi Lab
Pacific
Northwest
Argonne
Idaho
National
Energy
Technology
Lab
Ames
Brookhaven
Lawrence
Berkeley
Princeton
Stanford
Thomas
Jefferson
Lawrence
Livermore
National
Renewable
Energy Lab
National
Security
Sandia
Los Alamos
Science
Cleanup
Energy
Oak Ridge
Savannah
River
Superior Energy Performance: Piloting and Demonstrations
States, regions, and utilities are partnering
with U.S. DOE on Superior Energy
Performance demonstrations with companies
across the country. The program was initially
piloted by five facilities in Texas from 20082010 using ANSI/MSE 2000:2008.
Industrial Participants:
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3M
Alcoa
Allsteel
Amcor PET
Ascend Performance
Materials
Bentley Prince Street
Bridgestone Tire
Coca-Cola
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Cook Composites &
Polymers
Cooper Tire
Cummins
Didion Milling, Inc
Dixie Chemical
Dow Chemical
Eaton
Freescale Semiconductors
General Dynamics
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Harbec Inc.
Haynes International
Holcim
Ingersoll Rand
Kenworth Trucks
Lockheed Martin
MedImmune
Neenah Foundry
Company
Nissan
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OLAM Spices
Owens Corning
Republic Conduit
Schneider Electric
Spirax Sarco
Traco
UTC/Sikorsky
United States Mint
Volvo
World Kitchen
http://www.eere.energy.gov/industry/energymanagementdemonstrations/
Implementation Guide Overview
Guiding Principles for Successfully Implementing Industrial Energy
Assessment Recommendations
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Recent resource for industry
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Identifies key principles and actions that lead
to successful implementation of energy
assessment recommendations
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Connects readers with a variety of trusted
resources
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Simple tools for supporting energy
management programs and continuous
energy performance improvement efforts
The guide is available for download from
AMO’s Publication and Product Library at:
http://www.eere.energy.gov/industry/pdfs/impl
ementation_guidebook.pdf
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11 Assessment to Implementation
Guidebook Principles
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Integrate the process of identifying energy-savings
opportunities with the process of implementing energysavings opportunities
Assign clear accountability to those participating in the
assessment
Explain and communicate the implications of performing an
assessment
Understand the company scheduled to conduct the
assessment
Perform an assessment only if the plant welcomes it and
demonstrates its commitment to implementation
Organize assessment logistics to promote a successful
identification process for opportunities
11 Assessment to Implementation
Guidebook Principles (cont’d)
7.
Employ an assessment process that moves smoothly from
identifying to implementing opportunities
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Maintain continued momentum from the assessment to the
implementation of approved energy-savings projects
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Quantify energy-savings benefits from assessments
10. Publicize successful implementation results and recognize
employee contributions
11. Identify lessons learned to ensure success