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Resource Efficiency Training

Resource Efficiency Training. Add venue Name of advisors. Introductions. Name & Job / Role Company name & brief description of operations What is your company’s major waste? What do you hope to get out of today?. Module 1 - Energy. Learning objectives. To gain a basic understanding of:

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Resource Efficiency Training

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  1. Resource Efficiency Training Add venue Name of advisors

  2. Introductions • Name & Job / Role • Company name & brief description of operations • What is your company’s major waste? • What do you hope to get out of today? ENWORKS Resource Efficiency Programme

  3. Module 1 - Energy

  4. Learning objectives • To gain a basic understanding of: • energy consumption • monitoring • control • Identify potential savings & share best practice ENWORKS Resource Efficiency Programme

  5. Why focus on energy? • All companies use some form of energy – gas, electricity & fuel • Because most companies can reduce their energy bills by 20% • Because legislation and other Government initiatives are forcing us • Often a company’s major environmental impact • Because £12 billion of energy is wasted in the UK every year (Action Energy) ENWORKS Resource Efficiency Programme

  6. Impact of electricity • Company paying £5,000/year • Equivalent to: • 100,000 kW consumption (5p per kW) • 44 tonnes of carbon dioxide (or 12 solid tonnes of carbon) • Volume of 250 double-decker buses (CO2) • Weight of 8.1 elephants (or 587 men) • 73,997 miles in a car using petrol at 30mpg • Running Titanic for 2.6 hours on full steam ENWORKS Resource Efficiency Programme

  7. What are the benefits of reducing consumption? ENWORKS Resource Efficiency Programme

  8. Example of savings potential • Turnover £1 million • Profit (10%) £100,000 • Energy Cost (4%) £40,000 • Savings potential (20%) £8,000 • Equivalent to 8% rise in profits • Turnover increase of £80,000 ENWORKS Resource Efficiency Programme

  9. Other benefits • Improved reliability – plant/service • Better working environment • Increased output • Competitive advantage ENWORKS Resource Efficiency Programme

  10. Energy management • Make someone responsible • Establish the facts • Compare your performance • Plan & Organise • Pay less for your energy • Use less energy • Control & Monitor ENWORKS Resource Efficiency Programme

  11. Or • Consider: • Management • Monitoring • Actions • People ENWORKS Resource Efficiency Programme

  12. Management - Buy it cheaper • Energy contract negotiation • Simple tendering process • Make sure you are familiar with components of energy bills • beware of estimates • electricity maximum demand • Checking the small print (e.g. notice required) ENWORKS Resource Efficiency Programme

  13. Monitoring - Where is it being used? • 3 main areas: • Process – machines, tools, process heating, furnaces • Services – compressed air, steam, hot/cold water • Building Services – space heating, ventilation, lighting ENWORKS Resource Efficiency Programme

  14. Monitoring - Where is it being used? • Produce an energy map • Identify the five biggest energy consumers in your company • Use pareto rule 80% of energy used by 20% of process ENWORKS Resource Efficiency Programme

  15. What to monitor? • Electricity • Day Units • Night Units • Availability & Maximum Demand • Power factor • Gas • Units • Degree Days ENWORKS Resource Efficiency Programme

  16. Monitoring - Day and night units ENWORKS Resource Efficiency Programme

  17. Monitoring Maximum Demand • The peak instantaneous demand during a specific period (kW or kVA) ENWORKS Resource Efficiency Programme

  18. Monitoring Availability • The reservation of an agreed capacity with your supply company (kVA) • Should be set at approximately 10% above maximum demand ENWORKS Resource Efficiency Programme

  19. Cause of problem: Equipment failure Additional cost due to equipment failure Availability and maximum demand ENWORKS Resource Efficiency Programme

  20. Beer Monitoring Power Factor & Reactive Power Charge Froth (kVArh) Real Beer (kWh) (kVA) ENWORKS Resource Efficiency Programme

  21. Equipment Failure Power factor ENWORKS Resource Efficiency Programme

  22. Monitoring - Half-hourly Metering • Available to above 100 kW Maximum Demand market • Approximately £1,000 per month • Metering company take a reading every ½ hour • Smaller consumers can hire portable metering equipment ENWORKS Resource Efficiency Programme

  23. Data received in spreadsheet form ENWORKS Resource Efficiency Programme

  24. ENWORKS Resource Efficiency Programme

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  28. How does consumption vary against production? • Monitoring against time valuable • However, peaks and troughs can be misleading A B ENWORKS Resource Efficiency Programme

  29. How does consumption vary against production? (A) (B) KWh to Oven (C) Production figures ENWORKS Resource Efficiency Programme

  30. m1 m2 C Y = 22x + 789 ENWORKS Resource Efficiency Programme

  31. Base load - Fixed costs • C on the graph • Start-up losses • Operating losses such as compressed air leaks • Equipment running despite absence of any load • The use of any equipment that doesn’t add value to the product - ancillary equipment ENWORKS Resource Efficiency Programme

  32. Unit costs - Variable costs • M on the graph • Process Yield • Off-spec, scrap or non-saleable product • Product re-working • Product finishing ENWORKS Resource Efficiency Programme

  33. Monitoring - Sub-metering • Separate specific areas • Office • Production area • Data loggers • Specific pieces of plant, machinery ENWORKS Resource Efficiency Programme

  34. MonitoringCompare performance - Benchmarking ENWORKS Resource Efficiency Programme

  35. Actions No & low cost solutions • Energy walk-round • Procedures ignored? • Repairs or maintenance needed • Overheating • Lighting • Draughts • Regular maintenance/servicing ENWORKS Resource Efficiency Programme

  36. No & low cost solutionsElectric motors • Often account for 60% of electricity costs • Common problems • Oversized motors • Poor power factor/performance • Common solutions • Motor audit – numbers, size • Maintenance • Buy high-efficiency ENWORKS Resource Efficiency Programme

  37. No & low cost solutions Compressed air • 10 times more expensive than electricity • hole the size of pinprick in an air line can =£120 per year • 30-40% compressed air leakage rate is common - 10-15% should be the target • Good housekeeping • Turn off when not needed • Leakage detection • Minimise • Audit – see manual ENWORKS Resource Efficiency Programme

  38. No & low cost solutions Fuel use • Regular servicing • Monitor MPG / driver performance • Route planning • software • Conversion to cleaner fuels • Powershift ENWORKS Resource Efficiency Programme

  39. Actions - Equipment investment • High efficiency motors • Variable speed drives • Energy efficient lighting • Building insulation • Financial assistance • Enhanced capital allowances • Loans • Capital grants ENWORKS Resource Efficiency Programme

  40. People - Myths and legends • “Leaving the lights on is more economical than switching them off” • “Leaving equipment such as compressors, machine tools and other motors on is more economical than switching them on and off all the time” • “Office equipment such as computers use hardly any electricity” ENWORKS Resource Efficiency Programme

  41. People - Get them involved • Measuring • Monitoring • Awareness raising • Maintenance • Planning ENWORKS Resource Efficiency Programme

  42. Case Study - Wild Manufacturing • Presswork company – 180 employees • EMS driven – energy was key cost/environmental impact • Formed committee • Measured • Set targets • 10% utilities reduction in first year • Awareness raising campaigns • “switch off, turn off, save it” ENWORKS Resource Efficiency Programme

  43. Case Study - Wild Manufacturing • What they did • Focused on ‘common sense’ housekeeping issues • Check & repair procedures for compressors • Fitted light sensors • Sealed gaps around windows & doors • Kept traffic doors shut as much as possible • Publicised consumption data to staff ENWORKS Resource Efficiency Programme

  44. Case Study - Wild Manufacturing • What they achieved (first year) • Reduced electricity costs by 13% • Reduced gas costs by 7% • Vastly improved staff awareness • SAVINGS IN £££££££ ENWORKS Resource Efficiency Programme

  45. Energy support • Action Energy • Helpline – 0800 58 57 94 • Publications • Interest Free Loans • On-site surveys • Must have consumption £50,000+ • www.actionenergy.org.uk ENWORKS Resource Efficiency Programme

  46. Workshop 1 Energy Auditing

  47. Workshop 2 Understanding Your Energy Bills

  48. Workshop 3 Energy Efficiency Action Plan

  49. Module 2 - Packaging

  50. Why focus on packaging? • Legislation • It is expensive • As a raw material • To dispose of • Offers a lot of opportunity ENWORKS Resource Efficiency Programme

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