and
Sustainable Energy Curriculum
A training program for industrial workers
TECHNICAL ASSISTANCE PROGRAM
GOALS:
Train workers throughout the region
in Energy Efficiency Practices
Develop a curriculum for industrial
energy efficiency
Identify $1,000,000 in Energy
Savings for industries within the
region
Energy Efficiency-to date:
4 New Curricula Developed
Over 20 companies Engaged
14 Companies implemented projects
115 Workers Trained
137 Workers Received Certification
101 Participation certificates
36 Implementation certificates
Left: At the Process Heating Assessment & Scoping (PHAST)
workshop in Kokomo, Indiana, instructor John Clarke
demonstrates how to use the software tool to determine
potential natural gas savings by properly controlling the
mixture of fuel and air in a furnace.
Developed and Piloted
‘Energy Use Mapping’ tool
Value Stream Mapping (VSM) is to “walk the
line” collecting data on the Current State of a
process.
The Infrared Imager camera can see both
visible and infrared light, overlay them in a
single image, and identify an overloaded
‘hot’ circuit.
Return on Investment from
Energy cost savings expected to
exceed
$2.3M
per year.
•Over $5 million in potential energy cost reduction identified
Sustainability:
•Purdue Technical Assistance Program is pursuing additional
US Department of Energy, Department of Labor, and State of
Indiana funding to leverage the materials developed under
this project to provide additional training throughout the
State of Indiana
•Energy Efficiency Practitioner and Energy Efficiency Survey
Boot camp programs were both developed under this project
and will be provided on an ongoing basis by Purdue TAP’s
Energy Efficiency Services program
•NOTE: Detailed documents for the following overviews are
provided in a separate pdf document.
For more information:
Randy Hountz
Associate Director -- Technical
Assistance Program
Purdue University
Phone: (765) 494-0766
Fax: (765) 494-9187
Email: rhountz@purdue.edu
“This product was funded by a grant awarded under the Workforce Innovation in Regional Economic
Development (WIRED) Initiative as implemented by the U.S. Department of Labor’s Employment & Training
Administration. The information contained in this product was created by a grantee organization and does not
necessarily reflect the official position of the U.S. Department of Labor. All references to non-governmental companies
or organizations, their services, products, or resources are offered for informational purposes and should not be
construed as an endorsement by the Department of Labor. This product is copyrighted by the institution that created
it and is intended for individual organizational, non-commercial use only.”
WIRED Industrial Energy Efficiency
Practitioner worker certificate program
1.0 Energy Efficiency Practitioner worker certificate program
1.1 WIRED IEEP Program Agenda
1.2 WIRED IEEP Workbook
1.3 WIRED IEEP QuickPEP Worksheet
1.4 WIRED IEEP Wrap-Up Meeting Agenda
1.5 WIRED IEEP RFP Brochures
1.6 WIRED IEEP Certificate
2.0 Energy Boot camp
2.1 Energy Boot Camp Program Agenda
2.2 Energy Boot Camp PPT
2.3 General Improvement Plan spreadsheet
2.4 Waste Stream Mapping map
3.0 Heat Recovery
3.1 Heat Recovery PPT part 1
3.2 Heat Recovery PPT part 2
3.3 Heat Recovery Analysis
3.4 Heat Recovery Analysis Manual
Step 1:Program Overview and Plant Energy Profile
Discuss client expectations and team responsibilities.
Collect data and perform a data gap analysis.
Site tour.
Perform a Quick Plant Energy Profiler analysis
Teach use of the tool.
Identify opportunities and prioritize
Step 2: Systems workshops
Set up a matrix of team members and workshops.
Identify goals for attending each workshop.
Identify information necessary to bring to workshops
Perform a cost benefit analysis
Implement a project
Measure energy savings and calculate cost savings
Report
Step 3: Management System for Energy / General Energy Education
General education of macro and micro energy issues
Electricity and natural gas purchasing and risk management
Measurement & Validation protocols for energy savings contracts
Cost benefit analysis
Step 4: Energy Use Mapping
Day 1: Educate team on the VSM tool
Develop a map of the “current state” of an energy intensive process
Identify opportunities to save energy
Day 2: Develop a “future state” map
Quantify the energy cost savings potential of projects
Qualify possible solutions
Prioritize
Step 5: Implementation
Identify a project for the team to work on
Identify a solution
Perform a cost benefit analysis
Implement a project
Measure energy savings and calculate cost savings
Report
Go Back
1. Review the program purpose and events – what workshops attended,
work done on-site, etc.
2. Document any projects using the Project Implementation Report. (Have
some on hand.)
a. Who: which team members
b. What: problem and solution
c. When: started and finished
d. How much: energy (e- or g+) saved and how much $ saved
e. As for success story
3. Talk about goals identified in application and which were achieved.
4. Present certificates if not already mailed
5. How would they improve the program?
6. Discuss future IEEP events and workshops
7. Discuss Green program, ask if they would like to participate
Go Back
Go Back
Energy Boot Camp Program Agenda
Day 1
8:00 am
Program launch: Managing energy for cost reduction
•Who should attend:
all energy team members,
Optional: plant manager, financial officer, HR manager
•Program overview
Map out plan of action for four days
•Establish expectations
Your expectations and our capabilities
Review past projects & discuss planned projects
Agree how the program can provide value
•Energy overview
Overview of energy terms and measurements
Review of utility bills
(Optional: perform Quick Plant Energy Profiler analysis)
•Life Cycle Cost
Discuss life cycle costs
Preventive & predictive maintenance
Review case studies or client examples
•Prioritizing projects
Scoring projects
Combining projects vs. cherry picking
3:30-4 pm Wrap-up
Energy Boot Camp Program Agenda
Day 2
8:00 am
Energy Survey
•Survey planning
Safety review
Identify systems of interest
Identify information to
collect
•Initial Plant tour
Look at energy intensive
systems
Focus on systems already
prioritized for improvement
•Tour review
List all possible projects
Filter & sort
Preliminary energy
calculations
Data gap analysis
•Score & prioritize
Score projects for potential
Assign future actions
3:30-4 pmWrap-up
Day 3 & 4
8:00 am
Waste Stream Mapping
•Establish a current state
Select waste stream
Identify processes
Develop process flow maps
Identify inputs and outputs
Quantify
(Optional) re-tour plant to
collect additional information
•Establish future state
Identify opportunities from
process flow maps
Match projects from survey
Calculate impacts
Identify resources needed
Score & prioritize projects
•Create a preliminary report
3:30-4 pmWrap-up
Go Back
2.3 General Improvement Plan spreadsheet
Plant: Andersons
Team: Logansport
Action Items
Impact
(H, M, L)
Cost/Effort
(H, M, L)
Owner
1
Consider RO to replace DI -on demand water
H
H
Zac
2
On-Site Water Storage-Tower or Tank
H
H
Zac
3
Use De-icer heat to heat Urea 50/50
H
L
Zac
4
Optimize cleaning process-mixers
H
L
Zac
5
Consider new tank to consolidate cleaning water
H
L
Zac
6
Reuse Cleaning water from totes (in process)
H
L
Zac
7
Comprehensive plan to eliminate totes in waste water
H
M
Zac
8
Error-proof/Train to deter false Regens on DI
L
L
Zac
9
Look at Reject Pump on DI
L
L
Zac
10
Paint Urea Tank Top Black
L
L
Zac
11
Trench in Packaging Room
L
L
Zac
12
Programmable Thermostats
L
L
Zac
13
Formalize Recycling Plan
L
L
Zac
14
Recycle Plastic Containers
L
L
Zac
15
Investigate Waste Exchange for Totes
L
L
Zac
16
? Bailer or compactor to reduce number of pulls- Solid waste
L
L
Zac
17
Seal Dike in Packaging
L
L
Zac
18
Automated Doors to minimize heat loss
L
L
Zac
19
Solar Thermal Hose on Pre-heat DI before heat
L
M
Zac
20
Use Daylight or EE Fluorescent to reduce energy costs
L
M
Zac
21
Minimize Leakage in Mixer Area
L
M
Zac
22
Investigate Economizer on Boiler
M
L
Zac
23
Investigate Dedicate Totes work w/Suppliers
M
L
Zac
24
Request Iron sulfate(FeSO4) in Super Sack
M
L
Zac
Date: 7/28/2009
Target Date
Note
$150k
Go Back