Resources for Industrial Facilities
Additional resources on energy management at industrial facilities are available on the Department of Energy's (DOE) Advanced Manufacturing Office (AMO) Website. The site gives Federal agencies access to the same training and resources offered to AMO's private-sector customers. These resources include:
Publications
Technical publications pertaining to industrial facilities are available on the ITP BestPractices Web site. Available publications include technical fact sheets, handbooks, and self-assessment manuals covering steam system efficiency, fundamentals of compressed air systems, motor systems management, and other topics.
Software Tools
The ITP BestPractices Web site offers valuable software tools for evaluating industrial system operations and maximizing energy efficiency. The software tools described below are the most commonly used. To get the software tools, please register on each download page.
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The Steam Systems Scoping Tool (SSST) is designed to help steam system energy managers and operations personnel for large industrial plants. This spreadsheet program profiles and ranks steam system operations and management. It helps evaluate steam system operations against identified best practices.
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The Steam System Assessment Tool (SSAT) allows steam analysts to develop approximate models of real steam systems. Using these models, analysts can apply SSAT to quantify the magnitude of key potential steam improvement opportunities, including energy, cost, and emissions savings. SSAT contains the key features of typical steam systems.
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3EPlus (for Steam Systems) helps to easily determine whether steam systems can be optimized through the insulation of boiler steam lines. The program calculates the most economical thickness of industrial insulation for a variety of operating conditions. Users can make calculations using the built-in thermal performance relationships of generic insulation materials or supply conductivity data for other materials.
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AIRMaster+ (for Compressed Air Systems) is a comprehensive air system energy management program that enables auditors to assess compressed air systems, model existing and future system upgrades, and evaluate the energy savings and cost-effectiveness of energy efficiency measures.
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The Pump System Assessment Tool (PSAT) helps industrial users assess the overall efficiency of pumping system operation based on a limited number of on-site measurements. PSAT uses achievable pump performance data from Hydraulic Institute Standards and motor performance data from the Motor Master database to calculate potential energy and cost savings.
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The Process Heating Assessment and Survey Tool (PHAST) provides an introduction to process heating methods and tools to improve thermal efficiency of heating equipment. The tool surveys process heating equipment that uses fuel, steam, or electricity, and identifies the most energy-intensive equipment. It also performs an energy (heat) balance on selected equipment (furnaces) to identify and reduce non-productive energy use. PHAST also compares performance of the furnace under various operating conditions and test "what-if" scenarios.
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MotorMaster+3.0 is an energy-efficient motor selection and management tool. Designed for utility auditors, industrial plant energy coordinators, and consulting engineers, MotorMaster can identify inefficient or oversized motors and compute the energy and demand savings associated with selection of energy-efficient replacements. Version 3.0 includes a catalog of more than 20,000 AC motors.
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The Quick Plant Energy Profiler, or Quick PEP, (version 1.1.3) is an online software tool that helps industrial plant personnel quickly understand how energy is being used at their plant and how they might save energy and money. Quick PEP can help quickly diagnose the energy situation at the plant. The tool gives an overview of the energy that a plant purchases and the major systems that consume it, and provides a report that helps the user understand where the largest opportunities are for energy and cost savings. The Quick PEP tool should be the first step in identifying areas for potential savings at the plant. Once those areas have been identified, Quick PEP provides a broad list of potential next steps to begin realizing energy and cost savings.
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Decision Tools for Industry (CD-ROM) contains MotorMaster+, Pump System Assessment Tool, Steam System Tool Suite, 3EPlus, and the new AirMaster+ software packages, as well as MotorMaster+ training.
Emerging Technologies:
The following publications outline emerging technologies focusing on industrial facilities:
Combined Heat and Power (CHP) Systems: Combine on-site power generation with the recovery and use of waste heat for making steam, hot water, chilled water (absorption cooling), compressing air, regenerating desiccant dehumidifiers, or reducing steam pressure. Industrial facilities typically consume these waste heat products in their processes.
New Emerging Technologies: Publication highlighting commercially available and new emerging technologies applicable to the industrial sector to improve productivity, reduce energy consumption and to avoid carbon emissions.
Wireless Sensor Technology: Technology to provide real-time remote sensing and control applicable in hazardous environments with an added benefit of reduced maintenance costs.
Database Resources
Databases are available on ITP's BestPractices Web site. These databases allow users to review results of plant assessments and find a variety of additional tools. For example:
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The IAC Database contains the results of more than 9,000 assessments, including baseline consumption data and energy and cost savings by recommended measure.
Training
FEMP provides training to Federal industrial facilities on energy-efficient practices and strategies, as well as ITP BestPractices tools. For information on upcoming training opportunities, visit the FEMP training database. Presentations from training specific industrial assessments are also available:
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Compressed Air Basics: Presentation given as part of a May 2011 webinar on the basics of conducting compressed air assessments at industrial facilities.
On-site training is also often available during assessments. IFI teams train Federal energy managers how to use available software tools. Contact the IFI technical contact for additional information.
Related Links
The following related links provide additional information for Federal industrial facilities.
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Industrial Assessment Centers: AMO recently launched the Better Plants program in place of Save Energy Now. The Better Plants site: www.eere.energy.gov/manufacturing/tech_deployment/betterplants/.
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Save Energy Now: National ITP initiative to drive a 25% reduction in industrial energy intensity in 10 years.
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Water Efficiency: FEMP water efficiency program outlining key strategies and technologies to deploy water conservation measures at Federal facilities.
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American Council for an Energy-Efficient Economy (ACEEE): Nonprofit organization dedicated to advancing energy efficiency as a means of promoting economic prosperity, energy security, and environmental protection.
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Alliance to Save Energy: Nonprofit coalition dedicated to supporting energy efficiency as a cost-effective energy resource and advocating energy efficiency policies that minimize costs to society and individual consumers and that lessen greenhouse gas emissions and their impact on the global climate.
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Labs for the 21st Century: FEMP and Environmental Protection Agency (EPA) sponsored program that creates a voluntary partnership program dedicated to improving the environmental performance of U.S. laboratories.
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Rutgers University, Center for Advanced Energy Systems (CAES): Multidisciplinary center dedicated to the creation, development, and promotion of new technologies and practices in the field of energy systems.