System Optimization Library and ISO

1. System Optimization Library and ISO Wayne Perry Technical Director – Kaeser Compressors, Inc.

2. System Optimization Library and ISO • Energy efficiency improvement projects for motor-driven systems in manufacturing facilities face many challenges: • Improvements made during a given production level may not continue when production changes • Training of factory personnel in new operating procedures may not be adequate • Changes in job functions of factory personnel may move trained operators into other areas

3. System Optimization Library and ISO • Energy efficiency improvement projects for motor-driven systems in manufacturing facilities face many challenges: • Future purchases of system components may not consider their effects on system efficiency • Future purchases of production equipment may not consider their effects on system efficiency • Management changes may bring priority changes in maintenance and operations

4. System Optimization Library and ISO • As a result of these and other challenges, system efficiency is often lost over time • It is not uncommon for a factory to spend substantial amounts of money to optimize motor-driven systems, only to find that five years later, the systems are operating as inefficiently as they were prior to the optimization

5. System Optimization Library and ISO • What is needed is a method to permanently change the operating and purchasing culture to one of “Best Practices” and “Life Cycle Cost” and away from “lowest first cost”

6. System Optimization Library and ISO • What is needed is a method to permanently change the operating and purchasing culture to one of “Best Practices” and “Life Cycle Cost” and away from “lowest first cost” • Energy costs, maintenance and productivity (product quality) should all be part of every decision affecting motor-driven systems

7. System Optimization Library and ISO • What is needed is a method to permanently change the operating and purchasing culture to one of “Best Practices” and “Life Cycle Cost” and away from “lowest first cost” • Energy costs, maintenance and productivity (product quality) should all be part of every decision affecting motor-driven systems • Linking established best practices procedures to ISO certification in a factory-specific manner ensures long-term sustainability of efficient operation

8. System Optimization Library and ISO • Components of sustainable improvements: • Trained energy efficiency experts • Consulting group with various specialists • Library of procedures, projects and work instructions • Factory-specific plan for efficient operation • Independent verification of compliance

9. System Optimization Library and ISO • Trained Energy Efficiency Experts • Capable of analyzing various energy systems • Capable of developing improvement programs • Capable of developing long-term operating plans

10. Industrial Standards Framework Team of International System Optimization Experts Governments Capacity-Building Phase (Outputs) Provide System Optimization Training Develop Highly Skilled Core of Practitioners Develop and test tools to support sustainabilitySystem Optimization Library Documentation Hire Experts to Conduct Initial Training Develop Supportive Policy Package Energy Management Standards, Voluntary Agreements, Recognition & Tax incentives, Trading of Energy Efficiency Credits Industrial Plant Engineers Consultants/ Suppliers/ESCOs Develop standardized optimization methodologies IPMVP & ISO compatible Implementation Phase (Outcomes) Conduct plant assessments, train factory personnel, develop & document projects Sell system optimization services develop & document projects Technical Educational Institutions Trained System Optimization Experts Industrial Plant Managers Certifying Organizations (ISO, DNV, others) Governments Train future generations of skilled practitioners Use training, library, & methodologies to develop projects Use trained system optimization experts to develop & document system projects as part of certified continuous improvement process Recognize methodologies/ documentation & integrate into certification process Promote standards, trading of EE Credits & other policies for system optimization projects Integration Phase (Objectives) Industrial System Energy Efficiency becomes “Business as Usual”

11. System Optimization Library and ISO • Industrial Systems Optimization Library • Collection of expert experience of all motor-driven systems • Cataloged for easy reference by consultants and/or trained factory personnel • Easily customized for specific factory needs

12. System Optimization Library and ISO • Industrial Systems Optimization Library • Efficient operating practices written as simple work instructions • Continuous improvements written as simple projects • Multiple department interaction written as procedures

13. System Optimization Library and ISO The Table of Contents would direct consultants or factory personnel to the appropriate projects, procedures, work instructions and forms. If a factory added production equipment, for example, their new ISO procedures would direct them to evaluate their compressed air storage capacity to ensure continued efficient operation.

14. System Optimization Library and ISO The factory would be directed to the work instruction that would define what type of evaluation is required. This work instruction would be written in a format that would be easily transferred from the library to the factory’s ISO manual. In this case, the work instruction would call for an evaluation of their “system” storage capacity.

15. System Optimization Library and ISO The “system” storage work instruction would explain the method they should use to evaluate whether the addition of new production equipment will require the addition of more storage in order to maintain system efficiency. It also directs the factory to an ISO form that they must be completed to determine whether their capacity is sufficient.

16. System Optimization Library and ISO The ISO calculation form, along with the work instructions, must be completed and retained for their annual ISO audit. Because the factory’s ISO procedures require certain steps to be taken each time changes are made to their systems, the operating culture of the factory shifts to one that focuses as much on efficiency as it does on production.

17. System Optimization Library and ISO • Factory-specific Plan for Efficient Operation • Experts analyze current factory operation • Experts develop improvement plan to meet efficiency standards • Experts choose applicable sections from library to ensure on-going efficiency

18. System Optimization Library and ISO • Factory-specific Plan for Efficient Operation • Experts analyze current factory operation • Experts develop improvement plan to meet efficiency standards • Experts choose applicable sections from library to ensure on-going efficiency • Factory includes new work instructions, projects and procedures into current ISO 9000/14000 program

19. System Optimization Library and ISO • Independent verification of compliance • ISO 9000/14000 programs aimed at consistent operating culture and continuous improvement • Audit requirements verify compliance to written procedures and policies • Efficient operation becomes factory culture

20. For more information Aimee T. McKane Lawrence Berkeley National Laboratory P.O. Box 790 Latham, NY 12110 USA 518 782 7002 atmckane@lbl.gov Robert Williams United Nations Industrial Development Organization Vienna, Austria phone: 43 1 26026 3956 rwilliams@unido.org Wayne Perry Kaeser Compressors P.O Box 946 Fredericksburg, VA 22404 USA 540 898 5500 wayne.perry@kaeser.com