A2 AUser Guide

Assessments to Action (A2A) Toolkit for the IFA: Guidelines for Users
(Version 1 Gas)
Assessments to Action (A2A) Toolkit for the IFA: Guidelines for Users

(Version 1 Gas)
Developed by: Institute for Industrial Productivity, and ICF Marbek 16 June 2011
Contents
1 2 Purpose of Guideline ........................................................................................... 1 Introduction ......................................................................................................... 2 2.1 2.2 2.3 Context and Scope of IIP A2A Toolkit ........................................................... 2 Assessment Methodology ............................................................................ 4 Description of Toolkit Modules ..................................................................... 4 Energy Use & Technical Best Practice Assessment (Excel File: A2A TA) . 4
2.3.1
2.3.2 Generic Measure Library (Excel File: A2A Generic) and Ammonia Measure Library (Excel File: A2A Ammonia) ....................................................................... 5 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.4 2.5 2.6 3 Energy Management System Assessment (Excel File: A2A MA) ............. 5 Productivity Improvement Assessment (Excel File: A2A PIA) .................. 5 Report Card and Opportunity Identification (Excel File: A2A RCOI) .......... 5 EE&M Plan Checklist (Excel File: A2A Checklist and Action Plan) ............ 6 EE&M Action Plan Template (Excel File: A2A Checklist and Action Plan) . 6
Managing and Updating Toolkit..................................................................... 6 Structure of Guideline ................................................................................... 6 Common Elements in Tools.......................................................................... 8
Energy Use Performance and Technical Best Practices Assessment .................. 9 3.1 Description ................................................................................................... 9 Objective.................................................................................................. 9 Variables Collected ................................................................................. 10 Layout of the Tool .................................................................................. 10 Flow of Information Between Tools ....................................................... 14 Using the Tool ........................................................................................ 14
3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.2
Accuracy, Detail and Making Assumptions ................................................. 20 Average equipment capacities and operating hours ............................... 20 Energy Balance ...................................................................................... 21
3.2.1 3.2.2
3.3 3.4 4
Technical Best Practices Assessment ........................................................ 23 Ammonia Sub-Sector Specific Assessment ................................................ 23
Technical Measure Library ................................................................................. 24 4.1 Description ................................................................................................. 24 Objective................................................................................................ 24 Variables Collected ................................................................................. 24 Layout of Tool ........................................................................................ 25 Flow of information Between the Tools ................................................. 28 Using the Tool ........................................................................................ 28
4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 5
Management Best Practices Assessment ......................................................... 30 5.1 Description ................................................................................................. 30 Objective................................................................................................ 30 Variables collected ................................................................................. 30 Layout .................................................................................................... 30 Flow of Information Between Tools ....................................................... 32 Using the Tool ........................................................................................ 32
5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.2 6
Accuracy, Detail and Making Assumptions ................................................. 33
Productivity Improvement Assessment ............................................................. 34 6.1 Description ................................................................................................. 34 Objective................................................................................................ 34 Variables collected ................................................................................. 34 Layout .................................................................................................... 34 Flow of information Between Tools ....................................................... 35 Using the Tool ........................................................................................ 35
6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 7
Report Card and Opportunity Identification ........................................................ 37 7.1 Description ................................................................................................. 37 Objective................................................................................................ 37 Variables collected ................................................................................. 37
7.1.1 7.1.2
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7.1.3 7.1.4 7.1.5 8
Layout .................................................................................................... 37 Flow of information Between Tools ....................................................... 40 Using the Tool ........................................................................................ 40
Energy Efficiency and Management (EE&M) Plan and Action Plan .................... 46 8.1 Description ................................................................................................. 46 Objective................................................................................................ 46 Variables collected ................................................................................. 46 Layout .................................................................................................... 46 Flow of Information Between Tools ....................................................... 47 Using the toolkit module ........................................................................ 48
8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.2 9 10 11
Accuracy, Detail and Making Assumptions ................................................. 51
Glossary ............................................................................................................. 52 Abbreviations ................................................................................................. 55 Appendices .................................................................................................... 56 Report Card checklist and Completed Report Card ....................... 56 A2A Energy Use and Technical Best Practice Assessment .......... 58 A2A Energy Management System Assessment ........................... 59 A2A Productivity Improvement Assessment Template................. 60 A2A Checklist and Action Plan Template ...................................... 61
Appendix A Appendix B Appendix C Appendix D Appendix E
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Table of Exhibits
Exhibit 1: Continuous improvement process. .............................................................. 2 Exhibit 2: Tools in the toolkit and results to be achieved ............................................. 3 Exhibit 3: Sequential use of tools ................................................................................ 6 Exhibit 4: Example of first few tabs in Excel tools....................................................... 8 Exhibit 5: Tool 1 in the sequence ................................................................................ 9 Exhibit 6: Technical best practice assessment index table ........................................ 10 Exhibit 7: Tools in the toolkit and results to be achieved ........................................... 13 Exhibit 8: Example of Technical Assessment Purchased fuel questions ................... 15 Exhibit 9: Example of Technical Assessment Sold and self-generated fuel questions16 Exhibit 10: Example of Technical Assessment Sold and self-generated fuel questions ................................................................................................................................. 16 Exhibit 11: Example of Technical Assessment feedstock questions ......................... 17 Exhibit 12: Example of Technical Assessment equipment features questions (first question group) ......................................................................................................... 17 Exhibit 13: Example of Technical Assessment drop down menu .............................. 17 Exhibit 14: Example of Technical Assessment section not applicable box ............ 18 Exhibit 15: Example of Technical Assessment general questions (second question group) ....................................................................................................................... 19 Exhibit 16: Example of Additional Opportunities boxes ............................................. 20 Exhibit 17: Portion of the energy balance tables ....................................................... 21 Exhibit 18: Ammonia sub-sector specific data table .................................................. 23 Exhibit 19: Tool 2 in the sequence ............................................................................ 24 Exhibit 20: Example of Measure Library tab .............................................................. 26 Exhibit 21: Measure Library Index Tab ...................................................................... 29 Exhibit 22: Tool 3 in the sequence ............................................................................ 30 Exhibit 23: Management Best Practice Assessment index table .............................. 31 Exhibit 24: Example of Management Assessment drop down menu ........................ 32 Exhibit 25: Example of Management Assessment button selection ......................... 32
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Exhibit 26: Tool 4 in the sequence ............................................................................ 34 Exhibit 27: Productivity Improvement Assessment index table................................. 35 Exhibit 28: Example of Productivity Improvement Assessment multiple option selection ................................................................................................................... 36 Exhibit 29: Tool 5 in the sequence ............................................................................ 37 Exhibit 30: Report and Opportunity Identification index table .................................... 38 Exhibit 31: Report Card Edit Links screen ............................................................. 41 Exhibit 32: Report card macro button on Tab RC 2 ................................................... 42 Exhibit 33: Report card opportunities table to be completed manually ...................... 42 Exhibit 34: Report card opportunities table to be completed manually ...................... 43 Exhibit 35: Report Card plant information to be checked .......................................... 44 Exhibit 36: Report Card product information and energy use per unit of production . 44 Exhibit 37: Report Card pie charts ............................................................................. 44 Exhibit 38: Converting to PDF (step 2) ...................................................................... 45 Exhibit 39: Converting to PDF (steps 3 and 4) ........................................................... 45 Exhibit 40: Tool 6 in the sequence ............................................................................ 46 Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan index table.......................................................................................................................... 47 Exhibit 42: Example of EE&M Plan Checklist ............................................................ 48 Exhibit 43: Example EE&M Action Plan template...................................................... 50
Purpose of Guideline
This guideline provides guidance for a user on how to use the Institute of Industrial Productivitys ammonia sector Assessments to Action (A2A) toolkit. The user using the toolkit and this guideline needs to be: Experienced in on-site energy efficiency auditing. Familiar with industrial manufacturing processes, specifically ammonia manufacturing. Familiar with industrial technologies, energy management best practices, and ISO 50001. Proficient in using MS Excel.
This guideline does not provide guidance in how to conduct an audit, or explanations of industrial processes, technologies, best practices and the use of MS Excel. The outline of the toolkit is described in Sections 2.1 and 2.3, while the structure of the manual is described in 2.5. Data obtained from plants are considered to be confidential and a confidentiality agreement can be signed with the company. An example confidentiality agreement template is included in the toolkit and needs to be completed by the company and the company using the A2A toolkit to conduct an assessment.
Introduction
2.1 Context and Scope of IIP A2A Toolkit

The Institute for Industrial Productivity (IIP) retained ICF Marbek, a Canadian consulting firm, to develop an energy performance assessment and continuous improvement toolkit. The toolkit provides a standardized methodology for industrial energy performance assessments, and engaging companies to implement a continuous improvement process to reduce energy use and improve energy management. The toolkit is to be used by trained users during on-site assessments in a consultative process to assist a company in implementing a continuous energy efficiency improvement plan. This version of the toolkit was developed specifically for the ammonia manufacturing sector. The toolkit addresses the assessment, opportunity identification and planning stages of the continuous improvement process, as illustrated in Exhibit 1.
Exhibit 1: Continuous improvement process.
Commitment by Factory
Assess Energy Performance & Establish Indicators
A2A Toolkit
Implement EE&M Action Plan
Identify Opportunities & Define EE&M Plan Develop EE&M Action Plan
Additional Support
The actual implementation of both the energy efficiency and energy management (EE&M) plan and the action plan may require additional resources and support. This support may include, for example, financial support to implement opportunities, training and capacity building in energy management, and technical expertise to undertake detailed economic and feasibility studies. This support can be resourced either internally from within a company, or an external organizations, such as service providers or financial institutions. The assessment tools included in the toolkit are appropriate as a first-order, high-level assessment to identify and prioritize energy efficiency opportunities. The results from the assessments will assist in short and long term strategic planning to implement the opportunities, and to identify follow-up actions. More detailed energy audits, and feasibility studies may be required for some of the opportunities that are identified with the toolkit. 2
Exhibit 2 illustrates the tools in the toolkit and how it correlates with the continuous improvement process, and the results to be achieved. The tools and the use of the tools are described in detail in the guideline, and examples are provided throughout the guideline to illustrate the use of the toolkit.
Exhibit 2: Tools in the toolkit and results to be achieved
Continuous Improvement Process

Obtain Commitment
Toolkit
Results
Company committed to energy management and allocating necessary resources to energy management Understand current energy use, productivity and energy performance. Derive performance indicators for continuous improvement.
Technical Assessment (Includes Energy Use Performance and Technical Best Practices Assessment) Measure Library (incl. Ammonia Specific) Management Assessment (Includes Technical Management Best Practices Assessment) Productivity Improvement Assessment
Assess Performance and Establish Indicators
Identify Opportunities and Define EE&M Plan Scope Develop Action Plan to Implement EE&M Plan
Report Card and Opportunities Identification EE&M Plan Checklist
Definition and understanding of the opportunities to improve energy performance. A defined scope for the EE&M Plan. Action plan to guide development and implementation of EE&M Plan.
EE&M Action Plan Template
Implement Action Plan
Training and Capacity Building of Trainers and Auditors

The development of the toolkit included a comprehensive review by international experts, and was pilot tested at Chinese factories to ensure ease of use and practical applicability. IIP will manage updating and maintaining the toolkit, and will most likely develop new versions tailored to other industrial sectors. IIP will retain intellectual property of the toolkit and licence it to users and companies without any cost to the users or company.
2.2 Assessment Methodology

The toolkit is based on an assessment approach that includes: Determining the overall plant energy intensity, or energy use per unit production (for example, GJ/ton ammonia). In this version of the tool the energy intensity is not calculated at a more detailed level, such as process step, but determined by evaluating energy use in the plant against the main product only. Determining the implementation of technical best practices (TBP). Identifying the technical best practices already implemented at a plant, reveals the technical best practices not yet implemented at the plant. This provides an opportunity to implement the applicable best practices that will reduce energy use. Determining the implementation of energy management best practices (MBP). Identifying the management best practices already implemented at a plant, reveals the management best practices not yet implemented at the plant. This provides an opportunity to implement the applicable best practices that will assist in reducing energy use.
This comprehensive approach helps an assessor to understand and explain a companys energy efficiency performance. For example, low implementation of MBPs and TBPs identify reasons for low energy intensity values, and highlights opportunities and management areas for improvement to improve energy intensity values. To assist companies in continuously improving their energy efficiency and energy management it is recommended to use the A2A Toolkit on a regulate basis, such as every second year, to track progress in improving energy efficiency and the implementation of best practices.
2.3 Description of Toolkit Modules

The seven modules in the toolkit are summarized in Exhibit 2 and described below. 2.3.1 Energy Use & Technical Best Practice Assessment (Excel File: A2A TA)
The technical assessment tool is used to collect data applicable to assess energy use performance and to determine the implementation of TBPs. Energy use performance includes generating an energy balance to determine energy use by each end use (such as, boilers, motors, and process cooling) and by energy source (such as electricity and natural gas). It also includes the calculation of the overall energy intensity of the plant in terms of energy use per unit production (for example GJ / ton ammonia).
Energy technical best practices are production system and efficiency measures that reduce energy use per unit of production. An example of a TBP is installing a heat recovery system on a process exhaust stream to pre heat a feed stream, resulting in reduced process energy use per unit of output. The TBP performance indicator is the total number of applicable TBPs that are implemented at a plant. All Energy technical best practices listed in this toolkit are commercialized, and exclude pilot-test or demonstration technologies. 2.3.2 Generic Measure Library (Excel File: A2A Generic) and Ammonia Measure Library (Excel File: A2A Ammonia)
The measure library provides information about each technical best practice. The technical best practices are grouped in two broad categories: Measures applicable to generic end uses. It refers to end uses that are not sector specific, such as: boilers and steam systems, motors, process cooling and refrigeration, and direct process heating in ovens, dryers, furnaces and kilns. Energy efficiency technical best practices applicable to these end uses are included in the Measure Library. Measures only applicable to the ammonia manufacturing sector. Energy efficiency technical best practices applicable to only the ammonia manufacturing sector are included in the Measure Library Ammonia Specific. Energy Management System Assessment (Excel File: A2A MA)
2.3.3
The energy management assessment tool is used to obtain information to assess the implementation of energy Management Best Practices (MPBs), illustrated by a high level of commitment, awareness, organization and acting in support of energy management. Numerous studies have shown that application of energy management practices is a critical success factor for sustained improvement in energy use performance in industrial facilities. 2.3.4 Productivity Improvement Assessment (Excel File: A2A PIA)
The productivity improvement assessment tool is used to obtain information to evaluate at a high-level the current awareness regarding productivity improvement. Integrating energy use performance with productivity improvement systems and strategies exposes the importance of energy efficiency, and optimize the use of resources. 2.3.5 Report Card and Opportunity Identification (Excel File: A2A RCOI)
The report card and opportunity identification tool is used to read the data from the assessment tools (described in the previous points above) and to generate the results and output exhibits.
The results and exhibits include the energy use profiles, TBPs and MBPs benchmarks, and prioritized opportunities. These opportunities include associated savings in terms of energy, cost and GHG emissions. 2.3.6 EE&M Plan Checklist (Excel File: A2A Checklist and Action Plan)
The energy efficiency and energy management (EE&M) plan checklist is used to determine the status of energy management system implementation. Elements that are not fully implemented are prioritized and then manually transferred to the action plan template, which is described in the next point. 2.3.7 EE&M Action Plan Template (Excel File: A2A Checklist and Action Plan)
The energy efficiency and management (EE&M) action plan template is contained in the same Excel workbook as the EE&M plan checklist. The action plan template is used to guide implementation of the opportunities and outstanding energy management system elements. The opportunities and elements are manually captured as action items, responsibilities are assigned, scheduled dates for completion are assigned and the completion of the actions is tracked.
2.4 Managing and Updating Toolkit

The toolkit will be managed by IIP. IIP will regularly update the toolkit and release revisions of the toolkit. This guide is for the user who will not have to make changes to the structure or methodology of the toolkit, and will only have to use the toolkit by populating it with data and information. IIP will provide training for users to use the A2A toolkit.
2.5 Structure of Guideline

Exhibit 3 illustrates the logical sequential flow of how the tools are used by a user.
Exhibit 3: Sequential use of tools
Energy Use Performance and Technical Best Practices Assessment
5
Report Card and Opportunity Identification
Technical Measure Library
4 3
Management Best Practices Assessment
EE&M Plan Checklist and Action Plan Template
Productivity Improvement Assessment
Tool 1: The technical best practices and energy use performance assessment is completed though an on-site assessment, using the Technical Assessment Excel workbook. The on-site assessment generally takes one to two days, depending on the complexity of the plant. To optimize the time during the onsite assessment a pre-site visit information request and site visit agenda are send to the plant well in advance of the site visit. Examples of the information request and agenda are included in the toolkit. Tool 2: The technical measure library (included in the Measure Library Excel workbook) and the ammonia specific measure library (included in the Measure Library Ammonia Specific Excel workbook) are used as supporting references for the technical best practices assessment conducted in Tool 1 above. The best practices are cross referenced in the Technical Assessment workbook. Tool 3: The energy management best practices assessment (which uses the Management Assessment Excel workbook) is generally completed first in a workshop setting with representatives from different levels in the organization and who is using the energy management system of the plant. Tool 4: Information is obtained regarding productivity improvement during the on-site assessment using the Productivity Improvement Excel workbook. Tool 5: Using the data, information and results from Tools 1, 2 and 3 the report card is generated and opportunities are identified, using the Report Card and OI (OI: Opportunity Identification) Excel workbook. Tool 6: The results from all the tools are used to manually develop both an energy efficiency and energy management plan and an action plan to ensure implementation of the actions. The EEM Plan Checklist and Action Plan Template Excel workbook is used to develop the plans in consultation with the plant. This development process is an iterative process and may require a number of meetings with the plant to complete the development of the plans.
Experience has shown that it is easier for a user to first be familiarized with the technical best practices and energy performance assessment, before building competence in energy management best practices assessment. The guideline follows this approach and will first discuss TBP and energy performance assessment, followed by the discussion on MBP assessment. Tools 4 and 5 are discussed in sequence as the last three sections of the guideline. Many guidelines exist to assist assessors in conducting an industrial energy assessment 1, and this A2A guideline assumes that the user already has the necessary skills (see Section 1).
Office of Industrial Productivity and Energy Assessment, 2001. (US). Modern Industrial Assessments: A Training Manual NRCan (Canada), 2007. Energy Savings Toolbox An Energy Audit Manual and Tool LBNL (US), 2010. Industrial Energy Audit Guidebook: Guidelines for conducting and Energy Audit in Industrial Facilities. EECA, 2007. Energy Audit Manual, New Zealand.
2.6 Common Elements in Tools

Each Excel workbook contains a similar structure and the first few pages in each workbook (see Exhibit 4) are: Revisions: This page tracks the revisions that are made in the workbook and is only to be managed by IIP. Index: This page contains an outline of the pages in the Excel workbook and provides descriptive names for each of the page tabs. Instructions: A summary of the instruction to use the tool is provided on this page.
Exhibit 4: Example of first few tabs in Excel tools
Exhibit 5: Tool 1 in the sequence
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4 3
3.1 Description
3.1.1 Objective
The purpose of the energy use performance assessment is to determine the profile of energy use by end use and energy source, and the overall plant energy intensity. The energy use profile is based on an energy balance, which is calculated using the actual annual purchased energy amounts and the estimated energy used by equipment in the facility. The energy intensity is an indication of the energy used per production unit. The energy use profile assists in identifying the end uses that use the largest amount of energy and guide prioritization of the opportunities. Implementing energy efficiency opportunities at the end uses that consume the most energy will result in the most significant energy and cost savings. The overall plant energy intensity is a key performance indicator for the plant and can be compared with the requirements national standards, and international best practice plants. The purpose of the technical best practice (TBPs) assessment is to determine which TBPs are implemented at the plant, and to develop benchmarks for the plant. The benchmarks highlights the areas where opportunities exist to implement TBPs, and indicate the potential that still exist to implement TBPs.
3.1.2
Variables Collected
The Energy Technical Assessment questionnaire collects information on energy purchased and the energy used by equipment in the plant. The questionnaire includes questions pertaining to the overall energy use, production, characteristics of the equipment, and the presence of energy efficiency measures. The Excel workbook includes the following sections: 3.1.3 Section A gathers general information regarding the facility production and procurement of energy. Section B is specifically related to generic equipment, such as cooling, heating and motive power. Section C outlines types of heating, ventilation and air conditioning systems specifically associated with occupancy comfort. Section D is an overview of system practices, other major energy consuming equipment, and the implementation of emerging technologies. Section E collects data on ammonia production practices only. Layout of the Tool
The following exhibit illustrates the layout of the Technical Best Practice Assessment tool as shown in the index tab.
Exhibit 6: Technical best practice assessment index table
The end uses referred to in the Index Table are: Process: Energy end uses applicable to the manufacturing processes and generic to different manufacturing plants.
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Comfort: Energy end uses that support the comfort of the employees, such as lighting, space heating and cooling, and air ventilation to maintain appropriate air quality for employees. Other: Energy end uses applicable to processes not covered by process and comfort end uses, and non-generic energy end uses specific to the processes in a specific manufacturing sector.
The questionnaire is categorized according to the categories described above. For each Section B to E, the equipment number, type, operating hours and fuel-type used (where applicable) is requested. The energy efficiency features of the equipment are also requested at the end of each section. Enter only operating equipment and do not include back-up equipment. The Excel workbook contains the following sheets: Revisions See section 2.6 Index See section 2.6 Instructions See section 2.6 TA 1 Plant information Enter general information about the plant and its operation. TA 2 Energy and Production Data In Section A.1, statistics on the company purchases of energy is collected. It is important to ONLY list energy used as fuel, and EXCLUDE energy used as feedstock in the production of ammonia. The lower heating value (LHV) is required to determine the fuel energy content to use in the Energy Balance tab. The source used for LHVs is the BEST Cement for China tool developed by Lawrence Berkeley National Laboratory. The LHV for some fuels may vary in energy content and can be overwritten if necessary. The quantity of fuel and its units are required, as well as the purchased cost. The cost per unit of fuel is summarized in the final column of the table in A.1, and used to provide a verification of reported data. In section A.2, itemize the possible types of non-purchased fuel and self-generated power. The fuel lower heating value (LHV) is not provided and must be entered. In Section A.3, provide the production data for the plant for the five most important products, listing the highest revenue generator first, followed by the others in descending order.
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In section A.4, provide the quantity and LHV of the fuels used as feedstock (raw material used in the production process). The feedstock fuel should be distinguished from that used as fuel. TA 3 Cooling and Heating Equipment In this section, the questionnaire requires characteristics of the following equipment: cooling/refrigerating equipment, ovens, dryers, kilns, furnaces and boilers. All equipment that provides cooling and heating for occupancy comfort should NOT be listed in this section but in sections C.1 and C.2. For each equipment type, it is possible to give up to four capacities. Each capacity represents a size range; however it is the average value of that size range which must be entered. See section 3.2 for more detail on average capacities. The features questions should be left blank if the plant has no equipment in the given category. TA 4 Compression Heating Equipment All equipment related to compression is characterized in this section. This includes compressors for pneumatic equipment and compression systems for process gas or air systems. For each equipment type, it is possible to give up to four capacities. Each capacity represents a size range; however it is the average value of that size range which must be entered. See section 3.2 for more detail on average capacities. The features questions should be left blank if the plant has no equipment in the given category. TA 5 Motor Related The parameters of motive power equipment are summarized in this section, including fans, pumps, motors and conveyors. See section 3.2 for accuracy and assumptions. TA 6 Onsite Transport This section requires the characteristics of the vehicles used on-site for production related purposes, such as forklifts and cranes and excludes vehicles used off-site or delivery fleets.
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TA 7 Comfort-Lighting For all lighting fixtures, their characteristics are entered in this section. See section 3.2 for accuracy and assumptions. The number of lamps refers to both standard and high efficient types (i.e. if there are 10 metal halide lamps, all of which are high efficiency, 10 should be entered in both columns). The classification of lamps as energy efficient is at the discretion of the user. However the following table can be used as a rough guideline for that allocation
Exhibit 7: Tools in the toolkit and results to be achieved
Type Fluorescent CFL's Metal Halide High Pressure Sodium Incandescent
Standard T17, T12 Mercury Vapour
Energy Efficient T5, T8 All All other All
All
TA 8 Comfort-HVAC and Air System Equipment providing heating and cooling for occupancy comfort, is entered in this section with details on characteristics. The ventilation data entered in the third table refers only to the motor power. If there is heating of make-up air, the heating capacity should be entered in the second table (non-packaged HVAC equipment). TA 9 Other & System Practice All equipment that does not fit into the other categories and is not specifically related to ammonia production is outlined in this section, e.g. scrubbers, miscellaneous machines. Up to five pieces of these types of equipment can be entered, as it is expected that most equipment will be captured in the other sections.
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TA 10 Ammonia Production In this section, all ammonia manufacturing specific equipment with characteristics that do not fit into other sections is summarized here e.g. cryogenic purifier. More details are in section 3.4. TA 11 Energy Balance In this tab, the energy balance of the purchased energy and the energy used by the reported equipment is determined (see section 3.2.2 for details on the calculation of energy balance) TA 12 Conversion In this tab, conversions used in the calculations are provided for reference purposes only. 3.1.4 Flow of Information Between Tools
The responses from this questionnaire are used to: Calculate the energy balance and portion of energy used by each end use and energy source. Calculate the technical best practice scores in the Report Card and Opportunity Identification tool (see section 7), where a score for each TBP category is determined. Evaluate the opportunities available to a facility to implement improved TBP practices (see section 7). Develop an Energy Efficiency and Management Plan using the checklist and template tools (see section 8.2). Using the Tool
3.1.5
The equipment related tabs (TA 3 to TA 10) are divided into two groups of questions, followed by a table where additional opportunities can be entered. Section A: First Question group: Purchased Energy The first part of this group of questions requires details on the purchased energy at your facility including the quantity (with fixed units) and cost. The cost per unit is provided to verify the data, by checking that this is a reasonable value.
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The lower heating value of the fuel (LHV) is provided as reference, but may be overwritten to customize it for the fuel type. The first selections are common energy types and drop down menus provide additional fuel-type selections.
Exhibit 8: Example of Technical Assessment Purchased fuel questions
The quantity of steam purchased can also be entered here, provided that the steam temperature (in degree Kelvin) and pressure (in bar) are available. The LHV (or enthalpy) of the steam can be calculated by linking to the water97_V13 file (as described below) or by entering the known LHV of the steam. Section A: Link to water tables for steam enthalpy calculation The energy content or enthalpy of steam can be calculated by linking the technical assessment to the water97_V13 add-in. This is done as follows: Copy the water97_V13.xla file to the appropriate directory Add the water97_V13 file (provided) to Excel Add-ins Select Edit links in Excel and change the source link for the water97_V13 file if necessary Select Open source from the Edit links pop-up menu above. Select Enable macros in the technical assessment
Section A: Second Question group: Sold and self-generated Energy The second part of this section is the documentation of sold fuel from the facility, including self-generated electricity and steam generated on-site.
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Exhibit 9: Example of Technical Assessment Sold and self-generated fuel questions
Section A: Third Question group: Production Data This section is the production summary of the products in the facility. In the first table, list the products produced beginning with the most important. Specifics on the output, sales and energy consumption may be listed in the table.
Exhibit 10: Example of Technical Assessment Sold and self-generated fuel questions
Section A: Fourth Question group: Purchased Energy for Feedstock This section is a summary of the fuel used as feedstock in the plant. The total quantity of feedstock and fuel for three main types of fuel are provided at the end of the table for verification. 16
Exhibit 11: Example of Technical Assessment feedstock questions
Sections B, C, D and E are structured in the same format and are described generally below. Sections B to E: First Question Group Equipment Information The first question group requires detailed equipment data as shown in the following exhibit.
Exhibit 12: Example of Technical Assessment equipment features questions (first question group)
This section of the questionnaire is completed by: Filling in the blank white cells where a response is required. Selecting from the drop down menu where available as shown below:
Exhibit 13: Example of Technical Assessment drop down menu
Indicating that a section is not applicable by selecting the I do not have this equipment box at the beginning of most sections:
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Exhibit 14: Example of Technical Assessment section not applicable box
Some grey cells have an autofill, and do not require user input (i.e. the Annual Energy Use column in Exhibit 12). Therefore it is important to fill out the questionnaire in order. For each piece of equipment that is entered, all information in that row pertaining to the equipment is required (eg. fuel type, operating hours, efficiency rating) to avoid subsequent calculation errors (such as energy balance and best practice scores). Please take special note of the following specific examples: If there is no equipment meeting criteria requested for the featured equipment in the plant, enter 0 in these cells (e.g. If there are 15 fluorescent lamps, and none are high efficient, enter 15 for number of (fluorescent) lamps, and enter 0 for number of efficient lamps). The number of high efficiency equipment must not exceed the number of equipment for each capacity range. For example: in Exhibit 12, there are ten 2kW pumps. The sum of high efficiency motors and premium efficiency motors must be ten or less in this capacity range. If there is an option for high efficiency as well as premium efficiency as is the case in Exhibit 12 for pumps, you can consider a piece of equipment as high or premium efficiency, but not both. Recording equipment as high or premium efficiency is left to the discretion of the user. In some cases, guidelines are given in the manual for the given measure. In general, it is unlikely that old equipment (greater than 10 to 15 years, depending on the type of equipment) can be considered high efficiency NTF (Not Technically Feasible) should be entered if the measure is not applicable for the given piece of equipment. For large counts of equipment, where it is difficult to provide and exact number of equipment (eg number of motors or light fixtures), a best estimate can be provided. The following can be used to provide this estimate: Review of line drawings and determine capacity. Equipment count lists available from maintenance staff / operators.
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Name plate capacity of equipment with multiple motors can be grouped into one piece of equipment. Estimate equipment count/capacity rating/efficiency rating during walkthrough audits and consult with staff on count/ratings of equipment Boilers require special attention, due to a large number of features that can be applied: As explained in 3.1.3, it is possible to give up to four capacities, each capacity representing a size range. However, in the case of boilers, it is recommendable to only group boilers if there are more boilers than the number of lines provided. If grouping is required, they should be grouped not only by size, but also according to boiler type and economizer type (as entered in cells G35 to H38 in TA 3). For example, if the plant has two 15 MW boilers, one with a standard economizer and the other with a condensing economizer, these two boilers should be entered on separate lines, despite being the same size).
Sections B to E: Second Question Group Features Questions The second question group refers to the entire system of a given end-use. I.e. in the exhibit below the questions refer to all pumps, fans, etc.
Exhibit 15: Example of Technical Assessment general questions (second question group)
Drop-down menu selections for equipment features have responses with the following implications: No Implementation implies that the measure is applicable but not implemented. Partially Adopted implies that the measure has been considered and introduced but is not fully adopted.
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Fully Adopted implies that the measure has been fully adopted in the plant, with controls and verification in place where applicable. Not Technically Feasible implies that the measure is not an option due to technical limitations. Enter NTF for measures with this qualification.
Sections B to E: Additional Opportunities The bottom section of each tab allows the user to record any additional opportunities he/she noticed but werent covered in the first two question groups.
Exhibit 16: Example of Additional Opportunities boxes
All sections B to E need to be reviewed, and those that are applicable to be filled in with equipment type, characteristics, number, and hours of operation. For the Technical Assessment, verify that for all applicable sections B to E, the equipment feature questions at the end of each section are ALL be answered, including all features questions in Section D (TA 9); input either the level of implementation or NTF (not technically feasible). In sections where the equipment is not installed in the plant, these can be omitted by indicating inapplicable sections in the boxes provided at the beginning of each section. It is anticipated that completing the questionnaire during an on-site assessment requires one to two days, depending on the complexity of the plant, the availability of the data, and verification of the energy balance (see section 3.2).
3.2 Accuracy, Detail and Making Assumptions

This questionnaire requires that ALL applicable sections to be filled in using one of the responses available in the menus with all fuels purchased accounted for by the equipment using it. 3.2.1 Average equipment capacities and operating hours
There may be numerous pieces of equipment under each type, and it is recommended to categorize this by size. Up to six ranges of equipment sizes can be entered, by providing weighted average equipment capacity values and average hours of operation for each range.
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For example, if there are 25 motors ranging in size from 0.3 to 0.5 kW, operating between 500 to 6000 hours per year, the average range of equipment capacity would be: Average range [kw] = (motor power [kw]) x (motor hours of operation [h]) hours of operation [h]])
The hours of operation entry would be the average hours for all the motors in that range. 3.2.2 Energy Balance
The following exhibit shows the energy balance tables, however most of the enduses and some of the energy types were hidden for this example.
Exhibit 17: Portion of the energy balance tables
The fuel purchased is balanced against the fuel used by each of the equipment in the plant, by each fuel types categorized as follows: Electricity, Natural, Gas, Steam, Fuel Oil No.2, Fuel Oil No.6, Gasoline, Propane, Other (fuel that does not fit into the previous categories).
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The energy content of the purchased fuels is determined by summing the energy content of each fuel type. The sold energy is the summation of the energy content of the sold fuels. For sold energy products such as steam, the energy value of the steam is allocated to the type of fuel used to generate the steam, with an adjustment applied to account for the conversion of fuel to steam. This adjustment is assumed to be 0.9, which is typical of boilers and reformer conversion. Self-generated energy is the total steam and electricity generated on-site. Net-imported energy is the net purchased energy minus self-generated energy The energy used by fuel type is determined by summing the energy use per equipment end-use for that fuel type. The adjustment factor is the ratio of net imported fuel to utilized fuel for each fuel, and should always be less than one because of the following assumptions: Equipment is assumed to be 100% efficient. The hours of operation are applied directly to operating time without adjustment for load factors applied to equipment. Equipment capacity is assumed to be the rated capacity. If the adjustment factor is much greater than one, the following should be reviewed to address this: Review quantity of purchased energy (may be too high). Review the hours of operation of equipment using the fuel with the discrepant adjustment factor. Review the capacity rating of equipment using the fuel with the discrepant adjustment factor. Review the quantity of equipment using the fuel with the discrepant adjustment factor. Review the firing time and efficiency of equipment where this is reported, such as for boilers and ovens. Investigate whether all equipment using this fuel have been accounted for.
When the adjustment factor is close to one, then all purchased energy is being accounted for by all reported equipment. If the adjustment factor for steam as a fuel is much greater or less than one, review the following:
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That the source of the steam has been correctly identified in TA2 That the fuel used as steam has not been generated using another source fuel accounted for elsewhere (e. g. natural gas generated steam) and therefore added twice in the energy balance
3.3 Technical Best Practices Assessment

As discussed in section 3.1.3, each tab of the Energy Technical Assessment questionnaire presents best practices (energy efficiency measures) associated with each major equipment end-use. For each of these sections, a rating of the adoption level of these practices is required to be entered in the questionnaire (section 3.1.5). The score of best practices per end use is the ratio of the applied best practices to the total applicable best practices. The results of this evaluation is to provide a report of how many of the applicable technical best practices have been implemented and outline the opportunities available to the facility (section 7).
3.4 Ammonia Sub-Sector Specific Assessment

The ammonia subsector energy use and best practice assessment is presented in section E of the Energy Technical Assessment questionnaire. It is possible to list equipment associated with ammonia specific processes that do not fit in the other tabs of the questionnaire. Up to five such types of equipment can be detailed, in order of energy use. It is expected that most equipment will be captured in tabs B.1 to C.2. The ammonia specific table is shown in the exhibit below.
Exhibit 18: Ammonia sub-sector specific data table
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5
4 3
4.1 Description
4.1.1 Objective
The purpose of the Technical Measure Library is to catalogue energy efficient technical best practice measures in a standard format. This library lists new technology, improvements in existing technology and operational and maintenance best practices that improve energy efficiency and/or energy intensity. Each of these measures is cross-referenced in the Energy Technical Assessment in each of the questions on the equipment features. They form the basis of technical best practice assessment (see section 3.3). There are two measure libraries, the Generic Technology Measures Library that can apply to all industries, and the Ammonia Specific Technology Measure Library that applies to ammonia manufacturing sector only. 4.1.2 Variables Collected
The library organizes energy efficiency technical best practices by end use and several process levels. Each energy savings measure is entered in a separate tab with its associated parameters, providing the energy savings, the fuel type saved, and a detailed description of the measure along with the reference sources of information.
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4.1.3
Layout of Tool
There are two types of tabs in the Excel spreadsheet of this toolkit module: Index This is a summary of all the energy efficient measures in the library. It lists the following for each measure: Tab number, Measure Description, a breakdown of applicable plant level to which this measure is applied (Plant Region, Plant Area, System, End Use, Other grouping), the applicable Industry (typically all for this generic library), percent savings for each fuel type (natural gas, electricity, refined petroleum products, other fuel), and finally, the measure life. For more information on navigating through the Measure Library using the Index tab see section 4.1.5. Tabs 1 to 144 Each tab in this library has the same format. It is a repository of the details of each energy efficiency measure.
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Exhibit 20: Example of Measure Library tab
The measure information provided includes: Profile type: each measure is classified as either technology, operating, behavioural or maintenance. Relative implementation cost: each measure is rated as high, medium or low to indicate the relative cost of implementation:
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High there would be significant investment to implement the measure. A detailed economic feasibility study would generally be required. Most measures in this category would involve the replacement of large equipment, or large retrofit projects. Medium may involve inexpensive equipment replacement or retrofits. An economic feasibility study is generally advisable. Low little or no capital cost would be required. Often involves behavioural changes and only a rudimentary economic assessment may be needed. Relative implementation difficulty: each measure is rated as high, medium or low to indicate the relative difficulty of implementation: High the implementation of the measure involves complex change to the plant. The measure may involve redesign, and a detailed engineering feasibility assessment would be required. Medium may involve small equipment replacement or simple retrofits. A less extensive technical feasibility assessment is usually required. Low relatively easy to implement the opportunities and most often involves maintenance related opportunities and/or behavioural changes. Technical feasibility studies are generally not required. Level (1 to 5): further describe each measure based on which part of the plant and which category of equipment the measure is relevant to. This allows the user to filter the measure list on the Index tab by a variety of criteria. Energy type: five energy types are listed: natural gas, electricity, refined petroleum products, and other. Measure savings are shown for each fuel type. As illustrated in Exhibit 20 (boiler economizer), some measures show savings for more than one energy type. This indicates that there are multiple energy source options for the given end-use; the savings will be calculated for the energy source selected in the Technical Assessment, not all of the energy sources listed in the library. For the measures which may save other types of energy than those listed, the fuel type is entered in the Other fuel line. Savings percentage: the amount of energy that would be saved for that particular fuel type. The savings is given as a percentage of the end-use consumption (not the total plant energy use). Savings are dependent on site specific conditions and the savings indicated in the measure library provides only typical values, or ranges of savings for implementation of a specific measure, as guidance. These values are reported in literature or obtained from industrial experts. Savings are provided per opportunity and are not additive. Furthermore, interactive effects will reduce the total potential savings if more than one opportunity is implemented. Description: explanation of the measure, and the means by which the measure saves energy.
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4.1.4
Reference Sources: the source of the savings percentage and measure life. Flow of information Between the Tools
The measures from this library are used to: Supporting references to assist in populating the Energy Technical Assessment (see section 3.3). Populate the opportunities available to a facility to implement improved TBP practices (see section 7). Using the Tool
4.1.5
This toolkit module can be used to cross reference the energy efficiency measures in the technical assessment or the opportunities listed in the report card. Each measure listed in the technical best practice assessment has a number in column L, which corresponds to the measure number in the Measure Library. Note: do not change the Measure Number or the tab numbers, as these are used to link to other toolkit modules. The Index tab can be used to easily navigate the library. The first column contains the Tab Numbers (measure number) which can be clicked to view that particular tab. Filters are set up to show the measures by groups, or to sort measures as desired: click the down-arrow on any of the column headings to view the filter options. For example, as shown in Exhibit 20, to view only the measures related to pumps, click the filter arrow in the Level 4 Enduse column, un-check Select All then check the box beside Pumps and click Ok.
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Exhibit 21: Measure Library Index Tab
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5
4 3
5.1 Description
5.1.1 Objective
The purpose of the energy management assessment questionnaire is to evaluate the implementation of energy management best practices in an organization. This sets the context for taking steps to improve Energy Management at both the corporate and facility level with the additional support provided by the Energy Efficiency and Management Plan and Action Plan tool (see section 8.2). 5.1.2 Variables collected
The questionnaire organizes management best practices into a set of seven categoriescommitment, planning, organization, project development, financing, measurement and reporting, communicationeach of which implies roles, responsibilities, procedures and competencies. The management best practice analysis is applied at two levels: corporate level and plant level. Additional information on the quality systems in the plant is also gathered, which will tie into the productivity improvement system assessment (see section 0). 5.1.3 Layout
The following exhibit illustrates the layout of the Management Best Practice Assessment tool as shown in the index tab.
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Exhibit 23: Management Best Practice Assessment index table
There are seven tabs in the Excel spreadsheet of this toolkit module: Revisions See section 2.6 Index See section 2.6 Instructions See section 2.6 MA 1 Contact information Enter general information about the plant and its operation. MA 2 Corporate improvement Obtain general information about the operation of the company. MA 3 Corporate survey Energy Management best practices at the corporate level. The information collected in this tab will disclose the level of importance or priority that is given to energy management and energy conservation by assessing the energy management systems in place at a corporate level. MA 4 Plant survey Energy Management best practices at the plant/facility level. The information collected in this tab is another indication of the companys commitment to energy management, but in this case by assessing the energy management systems in place a plant level. 31
5.1.4
Flow of Information Between Tools
The responses from this questionnaire are used to: Calculate the management best practice scores in the Report Card and Opportunity Identification tool (see section 7), where a score for each MBP category is determined. Evaluate the opportunities available to a facility to implement improved MBP practices (see section 7). Develop an Energy Efficiency and Management Plan and Action Plan using the checklist and template tool (see section 8.2). Using the Tool
5.1.5
This section of the questionnaire is completed by: Filling in the blank white cells where a response is required. Selecting from the drop down menu where available as shown in Exhibit 24.
Exhibit 24: Example of Management Assessment drop down menu
Selection from the buttons provided.
Exhibit 25: Example of Management Assessment button selection
Drop down menu selections for equipment features have responses with the following implications Yes response implies that the measure is fully implemented.
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A Partially response implies that the measure has been considered or introduced but is not fully adopted. A No response implies that the measure is not considered or adopted.
All sections are required to be filled out for this questionnaire. It is anticipated that completing the questionnaire takes 45-60 minutes.

This questionnaire requires that ALL sections to be filled in using one of the responses available in the menus. No assumptions need to be made for this toolkit element.
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5
6
4 3
6.1 Description
6.1.1 Objective
The purpose of the Productivity Improvement Assessment questionnaire is to evaluate the implementation and awareness of continuous improvement practices in an organization. This sets the context for taking steps to improve productivity with the additional support provided by the Energy Efficiency and Management Plan and Action Plan checklist and template tool (see section 8.2). 6.1.2 Variables collected
The questionnaire organizes productivity improvement practices by sustainability actions and the methods/tools used to achieve continuous improvement. Additional information on the management systems in the plant is gathered under the Energy Management Assessment (see section 5). 6.1.3 Layout
The following exhibit illustrates the layout of the Productivity Improvement Assessment tool as shown in the index tab.
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Exhibit 27: Productivity Improvement Assessment index table
There are four tabs in the Excel spreadsheet of this toolkit module: Revisions See section 2.6 Index See section 2.6 PI 1 Plant information Enter general information about the plant. PI 2 Productivity improvement Enter more detailed information about the company and plant. This section includes company presence within the country or worldwide, production quantities, and questions related to productivity and profitability. 6.1.4 Flow of information Between Tools
The responses from this questionnaire are used to: Define an Energy Efficiency and Management Plan and Action Plan using the checklist and template tool (see section 8.2). Using the Tool
6.1.5
This section of the questionnaire is completed by: Filling in the blank white cells where a response is required. Selecting from the drop down menu where available. Selection from the buttons provided. Selecting (by clicking) from the list of options given (questions 2.2.2 to 2.2.4). Note: more than one option can be selected in these questions as shown below.
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Exhibit 28: Example of Productivity Improvement Assessment multiple option selection
All sections are required to be filled out for this questionnaire. It is anticipated that completing the questionnaire takes 20-30 minutes.
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5
4 3
7.1 Description
7.1.1 Objective
The Report Card and Opportunity Identification tool imports data from the assessment tools, performs calculations to analyse and summarize the data, and presents the results by means of graphs, charts and tables. The result is a report card which displays a breakdown of energy consumed, technical and best practice scores, and a summary of prioritized energy management opportunities and their potential savings. 7.1.2 Variables collected
All variables are automatically imported from the Technical Assessment and Management Assessment tools, and the measure library. There is no requirement to gather and enter data for this tool. 7.1.3 Layout
The following exhibit illustrates the layout of the Report Card and Opportunity Identification tool as shown in the index tab.
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Exhibit 30: Report and Opportunity Identification index table
There are five tabs in the Report Card and Opportunity Identification tool: Revisions See section 2.6 Index See section 2.6 RC 1 Report card This is the final summary of the plants energy use and energy saving opportunities. It is populated automatically, importing data from the subsequent tabs. A completed report card is presented in Appendix A. RC 2 Technical Energy Management Opportunities The opportunities are listed in order, starting with the highest priority. The priority is determined based on the energy consumed and the opportunity to implement technical best practices in the facility. For example, if an end-use consumes a large amount of energy, and scores poorly on the best practices (that is, the opportunity to implement energy efficiencies is high, compared to all available energy efficiency opportunities in the plant), it will be given a high priority because there is a large potential for energy savings. The designation of high, medium and low priority are based on a threshold defined by a function of the proportion of energy use and opportunity ratio.
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RC 3 Energy Management (EM) Opportunities The opportunities are listed in order, grouped by categories. Categories are shown in columns, starting (on the left) with the highest priority. The priority is determined based on the best practice score for each category (the category with the lowest score is given the highest priority). RC 4 Technical Energy Management Calculation Summary This tab is a summary of the calculations from the subsequent tabs, as well as an imported summary of energy use from the Technical Assessment tool (Energy Balance tab). RC 5 Reference Data A summary is provided of greenhouse gas emissions factors for the various energy types and the reference source of the factor. RC 6 Best Practice Calcs (Management) This is where calculations are performed to determine the Management Best Practices score. The scores are determined in the following manner: Maximum score = 2 for all questions Achieved score = 0 if the question is answered no, 1 if the question is answered partially and 2 if the question is answered yes
A score is calculated for each category of questions. RC 7 Best Practice Calcs (Technical) This is where calculations are performed to determine the Technical Best Practices score for each end-use. The scores for each end-use are determined in the following manner: Features intermediate score: Maximum score = 1 if there is equipment in that end-use, and if high efficiency equipment in that end-use is feasible. Otherwise the score is 0 Achieved score = the number of high efficiency equipment / the total number of equipment that could feasibly be high efficiency
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Practices intermediate score: Maximum score = 1 if the measure is technically feasible or 0 if the measure is not Achieved score = 0 if the question is answered no implementation, 0.5 if the question is answered partial adopted or 1 if the question is answered fully adopted
A combined score is calculated by dividing the sum of the achieved scores by the sum of the maximum scores. 7.1.4 Flow of information Between Tools
This toolkit imports data and finally summarizes the data in a concise and coherent plant report card. The answers from the Technical Assessment and Management Assessments tools are imported into RC 6 and RC 7 tabs where the scores are calculated. The energy use for each end-use is imported from the Technical Assessment. The tool calculates best practices scores and uses them together with energy use by end use to determine energy savings potential for each end-use, and to prioritize the opportunities. The report card (RC 1) displays these results in the form of charts and tables. Using the Tool
7.1.5
The Report Card module functions automatically, however a series of steps must be followed to correctly link the toolkit, and subsequently to ensure that the data is correct, and presentable. Instructions for generating the Report Card: Review the Technical and Management Assessments to ensure that the data contained is valid for analysis. Verify that the Technical and Management Assessments are saved with the correct name (following an established naming convention). If not, change the file name. Close the Technical and Management Assessments, and open the Report Card template file (A2A RCOI). If the Excel default is to disable macros, a security warning will appear, followed by an options button. Click the button and enable the macros.
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Save the file with the appropriate name (following an established naming convention). Link the Report Card to the appropriate Technical and Management Assessments, and open the files. The following exhibit shows the Edit Links screen where the subsequent steps are performed.
Exhibit 31: Report Card Edit Links screen
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Data
Edit Links
Select A2A MA from the list of sources Click the Change Source button Select the Management Assessment file and press Ok Click the Open Source, then go back to the Report Card Screen Select A2A TA from the list of sources Click the Change Source button Select the Technical Assessment file and press Ok Click the Open Source button, then go back to the Report Card screen Select A2A Ammonia Library from the list of sources Click Update values Select A2A Generic Library from the list of sources Click Update values Keep the Technical Assessment file (A2A TA) open for subsequent steps. The other files can be closed
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Run the macro on the tab RC 2 by pressing the button as shown in the following exhibit. The macro should take a few seconds to run. It imports the relevant opportunities to the tables in RC 2 and the relevant management opportunities to the tables in RC 3. The macro also resets the maximum potential energy savings values (if they have been inputted).
Exhibit 32: Report card macro button on Tab RC 2
After running the macro, the report card is created. However, there are some additional steps and/or checks to ensure the report is complete and presentable. These steps are outlined in detail below. In addition, a more concise checklist is provided in Appendix A. Tab RC 2 The technical opportunities are grouped by end-use. The end-uses are listed in order from highest potential opportunity to the lowest. The following exhibit shows the first end-use group after running the macro. There are two things to do/check on this tab after running the macro: 1. The column with maximum savings is left blank, and must be filled in manually for each opportunity (in the example below, the first three savings have been entered, and three more remain to be entered). Note that the savings is given in the description. Sometimes this savings is given as a range; in that case, enter the maximum savings in the range. NOTE: for the ammonia savings, the entry must be in energy units per ton of ammonia production (eg. 0.4 GJ/t_NH3). Where savings are provided in percent of energy use, convert this to energy units per ton of ammonia, based on the energy consumption per unit of ammonia production (eg. 11.7 GJ/t_NH3) and measure savings is 4% of energy use, then enter 0.47 GJ/t_NH3 (0.04*11.7 GJ/t_NH3). 2. Check that the text is not cut off by the grid; increase the appropriate row height if necessary.
Exhibit 33: Report card opportunities table to be completed manually
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Tab RC 3 The management opportunities are shown in tables in tab RC 3 as shown in the following exhibit. The opportunities are grouped into categories and ordered by those categories starting with the highest potential opportunity for improvement in the left column, and decreasing to the right. There is no additional data to enter on this tab, but it should be checked to ensure that no text is cut off by the grid (increase row height if necessary).
Exhibit 34: Report card opportunities table to be completed manually
Tab RC 1. The report card does not require any additional data inputs, but several checks and possible aesthetic adjustments will need to be performed: 1. Check over the report card for missing information. There are some cells to check in particular that will be blank or show errors if the assessment tools were not filled out properly: o Plant information, user information and date should be shown at the top of the sheet:
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Exhibit 35: Report Card plant information to be checked
Below the pie charts, product should be shown, followed by energy use per (main) unit of production. If div#/0! is shown, the product quantity was not entered in table A.3 of the Technical Best Practices Assessment tool.
Exhibit 36: Report Card product information and energy use per unit of production
Check the energy intensity number and ensure that the units are suitable (GJ/t_NH3), and that only one decimal or no decimals are shown. 2. Check the leader lines on the pie charts; they may need adjusting if there are several small pie chart portions close to each other.
Exhibit 37: Report Card pie charts
3. Check that the graph axes are not cut off
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PDFs
The results are recommended be presented in PDF format. There are three tabs (RC 1, RC 2 and RC 3) from the Report Card and Opportunity Identification tool be converted to PDF format; these PDFs can then be included in summary reports for the participating company. To make the PDFs using MS Excel 2007, ensure that the add-in for this version of Excel is installed and follow the steps below. For older versions of Excel, ensure you have the appropriate printer drivers installed to save the file as a PDF. 1. Select tab RC 1. 2. From the Save as menu, select PDF or XPS
Exhibit 38: Converting to PDF (step 2)
3. Under Save as type, select PDF

Exhibit 39: Converting to PDF (steps 3 and 4)
4. Click the options button. Under Publish what, choose Active sheets and press ok 5. Click the Publish button to create the PDF. 6. Repeat these steps for tabs RC 2 and RC 3. Alternatively, select RC 1, and then press the Ctrl button on the keyboard while selecting RC 2 and RC 3 simultaneously and carry out the steps above. All three tabs will be printed into one document.
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Energy Efficiency and Management (EE&M) Plan and Action Plan
5
6
4 3
8.1 Description
8.1.1 Objective
The purpose of the Energy Efficiency and Management plan checklist and Action Plan template is to assist an organization in developing an Energy Management Plan, and setting priority and defining responsibility and a timeline for carrying out activities to achieve and sustain energy efficiency improvement while considering productivity improvement aspects. 8.1.2 Variables collected
The questionnaire lists elements to consider when developing and implementing both an energy management plan and an action plan. The identified opportunities resulting from using the previously discussed tools, are to be included in the development of the plans. The plans are developed in consultation and collaboration with the plant, and may require a number of meetings to be developed and completed. 8.1.3 Layout
The following exhibit illustrates the layout of the Energy Efficiency and Management Plan and Action Plan tool as shown in the index tab.
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Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan index table
There are four tabs in the Excel spreadsheet of this toolkit module: AP 1 Plant Information Enter general information about the plant and its operation. AP 2 Outline of EE&M Plan An outline of the elements of the Energy Efficiency and Management Plan. AP 3 EE&M Plan Checklist This tab contains checklist of elements of an Energy Management and Continuous Improvement Plan with a section to set the priority of the actions. Descriptions of each element are also provided. AP 4 EE&M Action Plan This tab is a blank template to assist in developing actions to implement the EE&M Plan. The EE&M Action Plan includes a timeframe, responsibilities, and budget for each action. Actions are developed from the actions identified in the EE&M Plan checklist. 8.1.4 Flow of Information Between Tools
The results of the Report Card and Opportunities Identification tool are used to complete the EE&M Plan checklist. The prioritized elements of the EE&M Plan Checklist are used to prepare an action plan to implement the opportunities, using the EE&M Action Plan template.
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8.1.5
Using the toolkit module
EE&M Plan Checklist The following exhibit shows a partially filled in EE&M plan checklist.
Exhibit 42: Example of EE&M Plan Checklist
The EE&M Plan Checklist section of the questionnaire is completed by: Filling in the blank white cells where a response is required. Selecting from the menu where available.
Drop-down menu selections for energy management (EM) elements have responses with the following implications: Yes response implies that the element is fully implemented. A Partially response implies that the element has been considered or introduced but is not fully adopted. A No response implies that the element is not considered or adopted.
All questions are required to be filled out. It is anticipated that completing the checklist takes 45-60 minutes.
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EE&M Action Plan The EE&M Action Plan is completed with input from both the EE&M Plan Checklist and the Report Card and Opportunity Identification tools. The high priority elements defined in the EE&M Plan Checklist, followed by the medium and low priority elements, are manually transferred to the Action Plan (tab AP 4). The energy management elements are captured in the first eight action item categories, which corresponds with the EE&M Plan Checklist: 1. Policy 2. Planning 3. Organization and Accountability 4. Financing 5. Project Management 6. Monitoring 7. Reporting and Communication 8. Training and Capacity Building The ninth and last action item category is for the technical best practices opportunities. Here the technical best practices opportunities identified in the Report Card and Opportunity Identifications (RCOI) are manually transferred. The RCOI list the opportunities by end uses, and include the cost savings, relative implementation cost and relative implementation difficulty. All these elements are manually copied by the user from the RCOI to the Action Plan together with the applicable library reference and description (see the example provided below in Exhibit 37). The user needs to prioritize the list by arranging the opportunities by each end use starting with the opportunity that has the largest energy savings first, followed sequentially with the opportunities with lower energy savings and ending with the opportunity with the smallest energy savings. The user highlights in yellow the four opportunities that has the largest energy savings. Once the EE&M Action Plan template is completed, it is recommended that the prioritized actions are reviewed, and discussed with senior management. Responsibility can then be assigned to personnel who will ensure that the action is carried out, as well as a scheduled date for the completed action. This task is accomplished working in consultation with the enterprise. This action plan allows entry of the status of updates to be carried out after monthly, semi-annual or scheduled review. The action plan is a working document and needs to be revised and updated in a collaborative effort between the user and the enterprise.
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Exhibit 43: Example EE&M Action Plan template.
Energy Efficiency and Management (EE&M) Action Plan Template

The following Energy Efficiency and Management (EE&M) Action Plan template is to assist your enterprise in developing actions to implement the EE&M Plan. The EE&M Action Plan includes a timeframe, responsibilities, and budget for each action. Actions are developed from the actions identified in the EE&M Plan checklist. EE&M Element Action Item (from EE&M Plan Checklist) Responsibility Assigned to
Do
Time Frame Scheduled Status or Actions/ Date Date Comments Completed

Do Check Act
Plan 5 Project Management Parameters to be considered in identifying Energy management project opportunities can include fuel substitution and use of renewable energy. Implementation of Identified Opportunities (Including Technical Best Practices and Productivity Improvement)
Relative Implementation Difficulty 1
Maximum Potential Energy Relative 2 Savings3,4 Implementation Cost [TCE]
Maximum Potential Energy Cost Savings4
Responsibility Assigned to:
Scheduled Date
Status or Actions/ Date Completed Comments
Ammonia Production
High emissivity coating of radiant section refractory: 2 5% reformer heating energy savings
Low
Medium
451
465,988
Modify steam turbine drivers to improve efficiency: 0 - 9.5 GH/t_NH3 energy savings
Medium
Medium
10,654
11,012,533
Library Reference #
Library Description
AM-54
AM-34
High emissivity coating of the refractory surfaces in the radiant section of the primary reformer reduces the radiant heat reabsorbed by the combustion flame and flue gases. This increases the radiant section efficiency and reduces the reformer bridgewall temperature. Less fuel is thus required to achieve a given reformer process outlet temperature. Fuel savings of 25% have been demonstrated. Steam turbine drivers can be modified with updated designs for rotors and stationary parts to increase horsepower rating while reducing the water rate and saving energy.
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This questionnaire requires that ALL sections to be filled in using one of the responses available in the menus. No assumptions need to be made for this toolkit element.
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9
5S
Glossary
A program of 'industrial housekeeping', the 5S's are 5 Japanese words which help to guide organizations to increased levels of cleanliness, organization, & efficiency. Category (plant information) Grouping category provided when the enterprise was registered to obtain their business license from the government Code of region Regional code provided by the National Bureau of Statistics End use The final application or final use to which energy is applied, such as motors, boilers, and air compressors. Energy intensity The energy use per unit of product produced is referred to as the energy intensity. In this assessment energy intensity is determined by evaluating energy use against the main product only. Energy management system A set of interrelated or interacting elements to establish an energy policy and energy objectives, and processes and procedures to achieve those objectives. (Draft ISO 50001) Energy use profile The percentage breakdown, by fuel type, of energy use for a generic plant in a given sub-sector. Energy source Refers to the sources of energy, such as, electricity, natural gas and oil.
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High Efficiency Equipment Equipment that by design and function consumes less energy than conventional equipment for the same function. This equipment can be specified by its design for efficient use of energy and in some cases, identified by a national efficiency rating or label. JIT Just in Time: a strategy that exposes waste, makes continuous improvement a reality, and relies on total employee involvement. It concentrates on delivering what the customer wants, when they want it, in the quantity they want. The key elements of JIT are flow, pull, standard work (with standard in-process inventories), and takt time (takt time is a calculated value: available production time / customer demand). Kaizan Blitz Kaizan in lean terminology means 'continuous, incremental improvement' implying everyone applying small (low impact & low cost) improvements each and every day. Applied in this manner, kaizen can have the same effect as large, costly, infrequent changes. A Kaizan Blitz refers to improvement workshops. Kanban Designates a pull production means of communicating need or service. Originally developed as a means to communicate between operations in different locations, it was intended to communicate a change in demand or supply. In application, it is generally used to trigger the movement of material to or through a process. Management best practice Management Best Practices address the people aspect in reducing energy use. In an industrial organization, management best practice is illustrated by a high level of commitment, awareness, organization and action in support of energy efficiency. An example of energy management best practices is having a policy and plan to manage energy. Registered date / capital The date and the city for which the plant registered to get its business operation license (official establishment date) Replacement measure/technology An energy efficiency measure/technology that can be installed to replace a less efficient piece of equipment. Replacement measures are applied on an incremental cost basis, as they are normally implemented once the existing piece of equipment has reached the end of its useful life and would have to be replaced any way.
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Retrofit measure/technology An energy efficiency measure/technology that can be used to upgrade an existing piece of equipment, as opposed to replacing it. Retrofit measures are applied on a full cost basis and may be implemented immediately. Six sigma Refers to six standard deviations from mean. Six sigma methodology provides the techniques and tools to improve the capability and reduce the defects in any process. Standardized work instructions Specific instructions that allow processes to be completed in a consistent, timely, and repeatable manner. By implementing SWIs employees will increase production, improve quality, and enjoy a safer, predictable working environment. Technical best practice A set of energy efficiency measures that represent the most advanced technology available. TPM Total Productive Maintenance: preventative maintenance carried out by all employees. It is equipment maintenance performed on a company wide basis. Value stream mapping Identification of all the specific activities occurring along a value stream for a product or product family. This is part of creating a lean enterprise. The output should be a list of action items to be done to improve the process.
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10 Abbreviations
A2A: Assessments to action A2A MA: Energy management assessment tool of the A2A Toolkit A2A PIA: Productivity improvement assessment tool of the A2A Toolkit A2A RCOI: Report card and opportunity identification tool of the A2A Toolkit A2A TA: Technical assessment tool of the A2A Toolkit EE&M: Energy efficiency and management EM: Energy management h: hours HVAC: Heating, ventilation and air conditioning kW: kilowatts IIP: Institute for Industrial Productivity ISO 50001: Energy Management of the International Organization for Standardization LHV: Lower heating value MBP: Management best practices MW: megawatts NPV: Net present value NTF: Not technical feasible RPP: Refined petroleum products SME: Small and medium enterprises TBP: Technical best practices TCE: Tons coal equivalent TPM: Total product maintenance
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11 Appendices
Appendix A

Report Card checklist and Completed Report Card
Linking and running macro Review the Technical and Management Assessments to ensure that the data contained is valid for analysis. For the Technical Assessment, verify that for all applicable sections B to E, the equipment feature questions at the end of each section are ALL be answered including all features questions in Section D (TA 9); input either the level of implementation or NTF (not technically feasible). Verify that the Technical and Management Assessments are saved with the correct name (following an established naming convention). If not, change the file name. Close the Technical and Management Assessments, and open the Report Card template file (A2A RCOI). If the Excel default is to disable macros, a security warning will appear, followed by an options button. Click the button and enable the macros. Save the file with the appropriate name (following an established naming convention). Link the Report Card to the appropriate Technical and Management Assessments, and open the files. The following exhibit shows the Edit Links screen where the subsequent steps are performed. 1. Data Edit Links 2. Select A2A MA from the list of sources 3. Click the Change Source button 4. Select the Management Assessment file and press Ok 5. Click the Open Source, then go back to the Report Card Screen 6. Select A2A TA from the list of sources 7. Click the Change Source button 8. Select the Technical Assessment file and press Ok 9. Click the Open Source button, then go back to the Report Card screen 10. Select A2A Ammonia Library from the list of sources 11. Click Update values 12. Select A2A Generic Library from the list of sources 13. Click Update values 14. Keep the Technical Assessment file (A2A TA) open for subsequent steps. The other files can be closed Run the macro on the tab RC 2 by pressing the button as shown in the following exhibit. The macro should take a few seconds to run. It imports the relevant opportunities to the tables in RC 2 and the relevant management opportunities to the tables in RC 3. The macro also resets the maximum potential energy savings values (if they have been inputted).
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Checklist after running macro Tab RC 2 All savings are filled in (manually) Text is not cut off by grid
Tab RC 3 Text is not cut off by grid
Tab RC 1 No missing information (blank cells where there should be information provided) Energy use per unit of production: not div#/0!, has suitable units, set to one decimal or no decimal places Pie chart labels are legible and appropriately situated (i.e. not overlapping with other labels) Pie chart leader lines are appropriately situated (i.e. do not cover labels, are a suitable length, etc) Graph axes and axis titles are not cut off
Creating a PDF (using Excel 2007 or higher) 1. Select tab RC 1. 2. From the Save as menu, select PDF or XPS 3. Under Save as type, select PDF 4. Click the options button. Under Publish what, choose Active sheets and press ok 5. Click the Publish button to create the PDF. 6. Repeat these steps for tabs RC 2 and RC 3. Alternatively, select RC 1, and then press the Ctrl button on the keyboard while selecting RC 2 and RC 3 simultaneously and carry out the steps above. All three tabs will be printed into one document.
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Appendix B
A2A Energy Use and Technical Best Practice Assessment
58
A2A Toolkit Energy and Technical Best Practice Assessment
Industrial Energy Use and Technical Best Practice Assessment

TO DO: STEP 1 - Please complete the contact information requested on this page. STEP 2 - Review instruction sheet and complete the questions on the next pages. Confidential Plant Information
Location Organization Name Registration Date Name of Legal Person Address Code of Region Phone number Energy conservation Manager (primary) Phone number E-mail address Name of Auditor Auditor's Organization / Company Name Title of Auditor Date of Audit Evaluation year (for purchased & utilized energy) Industry Category Registrated Capital Contact Phone Number Post Code Fax Number Energy conservation Manager (secondary) Phone number E-mail address
Auditor Information
Direct Telephone Number Fax Number E-mail address
2009
The survey questionnaire is the ownership of IIP and ICF Marbek. Any use of the survey by another party requires to be granted permission by IIP or ICF Marbek prior to use.
IIP / ICF Marbek
TA 1
Page 1 of 28
This section includes energy used at your facility:- the purchased, self generated and sold energy products. A.1. PURCHASED ENERGY (exclude energy purchased for use as raw material feedstock in ammonia production)
What sources of purchased energy do you presently use at your facility? Please indicate all types of purchased energy sources, quantities used and purchase totals (including taxes). Fuel Type Electricity Natural Gas Gasoline Diesel Oil (transport) LPG Fuel Oil type (select) Fuel Oil type (select) Gas type (select) Gas type (select) Gas type (select) Biomass type (select) 0.03897 0.04311 0.04269 0.05023 0.00090 LHV* GJ per [kg or m3] Quantity 2009 2008 kWh m3 ton (metric) ton (metric) ton (metric) ton (metric) ton (metric) m3 m3 m3 ton (metric) ton (metric) ton (metric) ton (metric) ton (metric) Units 2009 Cost ($) 2008 $ Cost/unit (current year) per
Biomass type (select) Other Fuel (select) Other Fuel (select)

Steam quantity Steam Temp [k] Steam Pressure[bar]
483 K 22 bar
*LHV's can be overwritten for coal or other fuels which may vary in energy content
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A.2. NON-PURCHASED FUEL and SELF-GENERATION of ELECTRICITY

Only purchased fuel used. Go to A.2.2-----> No co-generation at this facility. Go to A.2.3----> No energy products sold at this facility. Go to A.3
If the following are applicable, please indicate the type, quantity and units of each fuel used in your facility. LHV* Fuel Type GJ per 2009 [kg or m3] A.2.1 Non-Purchased Fuel
NON-RENEWABLE (eg. coke, oven gas, still gas), BIOMASS (eg.hog fuel, pulping liquor) or RENEWABLE FUEL (eg. wind, geothermal, solar)
Quantity 2008
Units [ton or k m3]
A.2.2 Co-generation Energy Form
Electricity
Steam Steam Temp [k] Steam Pressure[bar]
0.00090
kWh ton (metric)
483 K 22 bar
0.00090 kWh ton (metric)
A.2.3 Sold Energy Products
Electricity Steam Quantity Steam Source fuel Steam Temp [k] Steam Pressure[bar] Coke Biomass
483 K 22 bar
0.02846 ton (metric) ton (metric)
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A.3. PRODUCTION and PLANT DATA

What are the main products produced at your facility, and what is the annual volume? Please list the most important products first and the reported annual energy consumption in GJ. Units [please provide] 2009 Quantity 2008 Annual Energy Consumption (all fuel and feedstock) [GJ] 2009 2008 Energy Consumption (all fuel and feedstock) [GJ per unit of product] 2009 2008
Product Description
2009 Industrial Output ($) Sales Revenue ($) Actual Comprehensive energy consumption Equivalent (GJ) Specific industrial output energy Actual consumption (GJ/$) Equivalent Energy Consumption cost ($) Share of energy consumption cost (%)
2008
% Change
A.4 FEEDSTOCK FUEL

What type and quantity of feedstock do you presently use at your facility? Fuel Type LHV* GJ per [kg or m3] Quantity 2009 2008 m3 Units Total fuel and feedstock 2009 2008
Natural Gas 0.03897 *LHV's can be overwritten for coal or other fuels which may vary in energy content
IIP / ICF Marbek
TA 2
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B.1 COOLING and HEATING SYSTEMS This section includes Cooling and Heating equipment (excluding HVAC) at your facility. This includes refrigeration compressors, ovens/dryers/kilns/furnaces and boilers.
I do not have this equipment--------> Go to Section B-2 What are the energy sources and features of your equipment? Exclude HVAC related equipment Please indicate the features that are not technically feasible. Equipment Nameplate Capacity enter average value of up to four ranges Total number of equipment in each Capacity Range Energy Source [nat.gas / elec. / etc] Number of high efficiency equipment [enter number or NTF*] Average Age of Equipment [years] Annual Operating Time [hrs] Annual Energy Use [GJ]
Total: 0.0E+00 -
Units [ kW / MW]
COOLING / REFRIGERATION COMPRESSORS
BOILERS
Total: 0.0E+00 -
OVENS / DRYERS / KILNS / FURNACES
Total: 0.0E+00 -
* NTF = Not technically Feasible
IIP / ICF Marbek
TA 3
Page 5 of 28
What are some other features of the Heating Equipment? Please respond to the following questions. Number with Boiler type Air-fuel ratio Number with Number with Economizer Number with High [closed/open Average Load controlled by blowdown heat preheated maketype efficiency burners water/fire [% of flue gas recovery up air [standard / [enter number or tube Maximum] monitoring [enter number [enter number or condensing / NTF*] Condensing [enter number or NTF*] NTF*] NTF*] Direct Contact] or NTF*] BOILERS
Equipment Nameplate Capacity
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TA 3
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A2A Toolkit Energy and Technical Best Practice Assessment Are the following features included in your respective systems? Features B.1.1 B.1.2 B.1.3 B.1.4 B.1.5 B.1.6 B.1.7 B.1.8 B.1.9 B.1.10 B.1.11 COOLING / REFRIGERATION COMPRESSORS Smart demand-based defrost controls The cooling / refrigeration distribution system has been assessed and modified to ensure an optimum, efficient distribution system More than 90% of insulation of cooling rooms, doors and refrigeration system is in good The system includes floating head pressure control The refrigeration / cooling system is controlled by an advanced integrated control system, or multiple compressors are controlled by optimal sequencing/integrated control system. Doorways to cooling rooms and openings to cooling/refrigeration tunnels are covered to minimize loss of cool air. VSDs are installed on chiller compressors or chilled water distribution system to manage cooling loads that fluctuate. The chilled water set temperature is increased to its maximum feasible temperature and/or the condenser cooling water is decreased to its optimal temperature. Condenser pressure is reduced to its minimum feasible pressure. Cooling water from cooling tower is used instead of chiller when outside temperature is Equipment is included in regularly scheduled preventative maintenance program Rating
IIP / ICF Marbek
TA 3
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A2A Toolkit Energy and Technical Best Practice Assessment Are the following features included in your respective systems? Features BOILERS B.1.12 B.1.13 B.1.14 B.1.15 B.1.16 B.1.17 B.1.18 B.1.19 B.1.20 B.1.21 B.1.22 B.1.23 B.1.24 B.1.25 B.1.26 B.1.27 B.1.28 B.1.29 Automated blowdown control Makeup water is preheated with heat recovered from other heat sources Boiler load assessment was conducted when boiler was installed to ensure it is optimum size. For multiple boilers load management study was conducted to define optimum load management strategy. At least 90% of insulation is in good condition Advanced/Automated boiler controls (e.g. linkage less control) Boiler water treatment to remove impurities Deaerator vent losses are minimized through regular inspection or automation Condensate is returned to the boiler where it is technically feasible Steam trap surveys completed within past 2 years and faulty traps were repaired Boilers are included in regularly scheduled preventative maintenance program OVENS / DRYERS / KILNS / FURNACES Heat from the flue gas is recovered and used At least 90% of insulation is in good condition Systems have advanced heating/process controls Infrared or radiant heating is used instead of convection heating Air curtains or other methods are used at the inlet/outlet of the oven/dryer to minimise loss of hot air. Adjust air-fuel ratio to optimize combustion efficiency Equipment is included in regularly scheduled preventative maintenance program and includes combustion efficiency testing. Rating
Rating
IIP / ICF Marbek
TA 3
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A2A Toolkit Energy and Technical Best Practice Assessment Additional Opportunities Identified (Describe) COOLING / REFRIGERATION COMPRESSORS
BOILERS
IIP / ICF Marbek
TA 3
Page 9 of 28
B.2 COMPRESSION SYSTEMS This section includes Compression Systems at your facility. This includes air compressors used for pneumatic equipment and air/gas compressors used for process.
I do not have this equipment--------> What are the energy sources and features of your equipment? Please indicate the features that are not technically feasible. Equipment Nameplate Capacity
[enter average value of up to four ranges]
Go to Section B-3
Units [ kW / MW]
Total number of equipment in each Capacity Range
Energy Source [nat.gas / elec. / etc]
Number of high efficiency equipment

[enter number or NTF*]
Average Age of Equipment [years]
Annual Operating Time [hrs]
Annual Energy Use [GJ]

Total: 0.0E+00 -
AIR COMPRESSORS FOR PNEUMATIC EQUIPMENT
AIR OR GAS COMPRESSORS FOR PROCESS
Total: 0.0E+00 -
IIP / ICF Marbek
TA 4
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A2A Toolkit Energy and Technical Best Practice Assessment Are the following features included in your respective systems? Features B.2.1 B.2.2 B.2.3 B.2.4 B.2.5 B.2.6 Equipment is included in regularly scheduled preventative maintenance program B.2.7 B.2.8 B.2.9 B.2.10 B.2.11 B.2.12 B.2.14 B.2.15 B.2.16 B.2.17 B.2.18 B.2.19 B.2.20 B.2.21 Synchronous belts are used. Replace compressed air use with mechanical or electrical methods (such as sweeping waste from floors instead of blowing it with compressed air) The size of the air compressors were assessed to ensure it matches the minimum load required. Outside air (or coolest available air) is used as make up air. For air cooled compressors, a heat recovery system is installed Synchronous belts are used. AIR OR GAS COMPRESSORS FOR PROCESS Compression ratio is annually evaluated and optimized Internal parts of centrifugal compressors have been retrofit to improve efficiency Compressors are properly sized Volume pockets are adjusted for optimum performance Cylinder clearance is set at a minimum For air cooled compressors, a heat recovery system is installed Equipment is included in regularly scheduled preventative maintenance program Air leak and condensate trap survey and repairs are conducted on a regularly scheduled basis Air pressure is annually assessed to ensure minimum supply air pressure in lines. The compressed air distribution system was assessed and modified to ensure an optimum, efficient distribution system Sufficiently sized compressed air receiver tanks are used to minimize load fluctuations AIR COMPRESSORS FOR PNEUMATIC EQUIPMENT Energy efficient air dryers are used Multiple compressors are controlled by optimal sequencing/integrated control system Rating
Rating
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TA 4
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Additional Opportunities Identified (Describe) AIR COMPRESSORS FOR PNEUMATIC EQUIPMENT
AIR OR GAS COMPRESSORS FOR PROCESS
IIP / ICF Marbek
TA 4
Page 12 of 28
B.3 MOTORS, PUMPS, FANS and CONVEYORS This section includes motors and motor-related equipment (fans, pumps, conveyors) at your facility.
Please indicate the inventory of Motors, Conveyors, Pumps and Fans and their features? If you do not have a list of this inventory, please provide your best estimate. Exclude equipment related to HVAC. Number of Average Rated Annual Capacity Range Total number of Number with VFDs Number of Class Average Age Motors with Number of Class equipment in / ASDs 2 Motors 1 Motors Operating Synchronous [kW] of Equipment each Capacity [enter number or [enter number [enter number Time (enter average Belts [years] value of up to six Range NTF] or NTF*] or NTF*] [hrs] [enter number or
ranges) NTF*]

Total: 0.0E+00
PUMPS
0.0 0.0 0.0 0.0 0.0 0.0
FANS
0.0 0.0 0.0 0.0 0.0 0.0
OTHER MOTORS (including those for conveyors)

0.0 0.0 0.0 0.0 0.0 0.0 * NTF = Not technically Feasible
IIP / ICF Marbek
TA 5
Page 13 of 28
Conveyor Number Type of system Synchronous belts enter [pneumatic / used? characteristics of mechanical] [yes/No/NTF*] up to 5 systems 1 2 3 4 5
Drive details Average Age [direct couple of Equipment drive / ASD / [years] etc]
Are the following features included in your pump/fan/conveyor/motor systems? Features Where feasible piping are replaced with low-friction networks (e.g. minimum restrictions, minimum B.3.1 bends, etc) Where feasible ducts are replaced with low-friction networks (e.g. minimum restrictions, minimum B.3.2 bends, etc) Pump sizes are assessed to ensure it is correctly sized, and impellers are trimmed where necessary. B.3.3 B.3.4 B.3.5 B.3.6 B.3.7 Fan sizes are assessed to ensure it is correctly sized, IGVs installed and/or impellers are trimmed where necessary. Have implemented a program / procedures to turn equipment off when not in use - preferably automated. Pumps, fans and motors are include in scheduled preventative maintenance program. Program to replace old motors with high/premium efficiency motors and includes an assessment to ensure motors are correctly sized.
Rating
Motive Equipment Opportunities Identified (Describe) Pumps/Fans/Other motors/Conveyors
IIP / ICF Marbek
TA 5
Page 14 of 28
B.4 ONSITE TRANSPORT EQUIPMENT This section includes onsite transport vehicles used at your facility.
I do not have this equipment--------> Go to Section C-1 Please list the onsite transport equipment used at your facility. Please indicate the features that are not technically feasible. Average Equipment Rating (incl. Number of high Annual Energy Category or Type of Annual Number of Energy Source efficiency auxiliary equipment) Use [GJ] vehicle Operating vehicles of [nat.gas / diesel / equipment [eg. excavator, Time Units this type etc] Total: 0.0E+00 Rated Capacity [enter number or truck, forklift] [hrs] [kW / MW] NTF*]
Are the following features included in your onsite transport equipment systems? Features B.4.1 B.4.2 B.4.3 B.4.4 Alternative fuelled vehicles or hybrid technology adopted to reduce energy consumption Minimal idling Preventative vehicle maintenance program High Efficiency Battery Chargers for forklift type vehicles Transport Equipment Opportunities Identified (Describe) Rating
IIP / ICF Marbek
TA 6
Page 15 of 28
C.1 LIGHTING This section includes lighting system features in the entire facility
What lighting is present at the facility? Type of Lighting Fluorescent and CFL's Metal Halide High Pressure Sodium Average Rated Capacity [Watts] Total Number of Lamps Number of Lamps that are Energy Efficient Annual Operating Time [hrs] Annual Energy Use [GJ]
Total: 0.0E+00 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Incandescent and Other
Does your lighting system include the following? Features C.1.1 C.1.2 C.1.3 C.1.4 C.1.5 On/off timer settings Occupancy sensors High-efficiency ballasts for lighting Control of lighting system according to zones or production areas Lighting (auditing) survey completed Rating
Location [interior / exterior / both] Latest system design change [MM / YY]
IIP / ICF Marbek
TA 7
Page 16 of 28
A2A Toolkit Energy and Technical Best Practice Assessment Lighting System Energy Efficiency Opportunities Identified (Describe) Control:
Equipment / Technology:
Other:
IIP / ICF Marbek
TA 7
Page 17 of 28
C.2 HEATING, VENTILATION and AIR CONDITIONING (HVAC) This section includes all HVAC equipment in the facility, including that used in offices and the plant.
Please list any HVAC equipment (equipment with the highest energy-use). I do not have this equipment Categories / Types of Equipment
[eg. radiant heaters/ convection heaters / chillers / window air conditioning]
Number of Energy Source equipment [nat.gas / elec / in of this etc] type
Avg Unit Heating Capacity Rated Capacity Units [ kW / MW]
Avg Unit Cooling Capacity Rated Capacity
Number of high efficiency Average equipment Equipment [enter number Units Age or NTF*] [cooling ton
/ kW / HP]
[years]

Total: 0.0E+00
Does your plant contain any /all equipment below for ventilation? I do not have this equipment Process equipment description
Energy Source [nat.gas / elec / etc]
Total Motor Power Units Rated [ kW / Capacity MW]
Average Equipment Age [years]

Total: 0.0E+00
Air make-up system(s) Air exhaust system(s)
IIP / ICF Marbek
TA 8
Page 18 of 28
A2A Toolkit Energy and Technical Best Practice Assessment Does your HVAC system include the following? Features C.2.1 Heat pumps for cooling/heating C.2.2 Automated plant HVAC control system C.2.3 Different heating and cooling set points for seasonal and daily fluctuations C.2.4 C.2.5 C.2.6 C.2.7 C.2.8 C.2.9 C.2.10 C.2.11 C.2.12 C.2.13 C.2.14 C.2.15 C.2.16 Set back temperatures when facility is not occupied, e.g. during weekends Recover heat from exhaust flow Recover heat from process or exhaust gas to heat make-up air Premium efficiency motors on fans System uses free cooling System uses variable speed fans An assessment was made to install solar walls to heat ventilation air Destratification fans are used to reduce air stratification in large areas. Radiant heaters are used in areas close to loading dock doors and where convection heating is not required Loading docks are well insulated, sealed and managed to minimise loss of heated/cooled air Within last 3 years an assessment was conducted to determine ventilation requirements and ventilation system was optimised. System uses demand-controlled ventilation The HVAC system is included in scheduled preventative maintenance program. Rating
IIP / ICF Marbek
TA 8
Page 19 of 28
A2A Toolkit Energy and Technical Best Practice Assessment HVAC Opportunities Identified (Describe) HVAC
Other Heating Equipment
Air Make-up and Exhaust Other
IIP / ICF Marbek
TA 8
Page 20 of 28
D.1 OTHER PROCESS EQUIPMENT This section includes other major energy consuming equipment, control systems and other emerging technology implemented or under consideration.
I do not have this equipment--------> Go to Section D-2 below List other major energy-consuming equipment (top five only)present at your plant by type. Exclude equipment related to HVAC. Energy Source [nat.gas / elec / etc] Avg Rated Capacity Units Power [kW / MW] Annual Operating Time [hrs]
Equipment Category / Type (eg. Stamping machines, grinders)
Total:
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TA 9
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D.2 GENERAL FACILITY PRACTICES

Please indicate if your facility practices include any of the following? Features D.2.1 Interval and sub- metering system on various plant areas or processes using electricity and processes using natural gas if applicable. D.2.2 Electricity demand management control system D.2.3 Power factor correction capacitors (enter power factor below) What is the power factor for your facility? (enter value <1) D.2.4 High efficiency dry-type transformers D.2.5 Overall integrated plant control system D.2.6 Heat exchanger maintenance and repair is D.2.7 carried out regularly Heat exchanger optimization completed periodically For facilities purchasing steam D.2.8 Steam trap surveys completed within past 2 years and faulty traps repaired D.2.9 Condensate is recovered for additional energy value, where technically feasible Rating
D.3 EMERGING TECHNOLOGY

Are there any other emerging technologies you are considering or you have implemented in your facility? Technology [implemented / under consideration]
Other Notes or Remarks
IIP / ICF Marbek
TA 9
Page 22 of 28
AMMONIA PRODUCTION This section includes all equipment related directly to Ammonia production that does not fit into the previous categories. E.1 AMMONIA PROCESS EQUIPMENT CAPACITY
What are the respective capacities of Ammonia-specific production equipment that is not captured in any of the other sections ? I do not have this equipment Description of industryspecific equipment Process Step [pre treatment, synthesis, etc] Number of equipment in Rated Capacity Range Energy Source [nat.gas / elec / etc] Average Rated Capacity Units [ kW / MW] Annual Operating Time [hrs] Annual Energy Use [GJ]
Total: 0.0E+00
IIP / ICF Marbek
TA 10
Page 23 of 28
E.2 AMMONIA PROCESS PRACTICES - General

Please indicate if your facility practices include any of the following? Features E.2.1 E.2.2 E.2.3 E.2.4 E.2.5 E.2.6 E.2.7 E.2.8 E.2.9 Installation of Gas Turbine to drive process air compression, using hot exhaust gases Isothermal CO converter with built in heat exchanger Axial-radial flow converter to improve conversion efficiency and reduce pressure drop Improved catalysts in Shift Process Improved Design for Shift Converter Gas Distributor and Collector Hydrogen separation and recovery from synthesis gases Enhanced CO2 removal solvents Pressure Swing Adsorption for product purification Improved Ammonia synthesis catalysts Rating
E.2.10 Flash of CO2 Solvent with Ejectors or Mechanical Recompression E.2.11 High Efficiency Packings and Internals for CO2 Removal Columns E.2.12 Waste Heat Recovery from Lean Solvent E.2.13 2 Stage Stripping for CO2 Removal Solvent in the process E.2.14 CO2 Removal Condensate Reboiler installed E.2.15 Recovery and Recycle of Flashed gases E.2.16 Supplemental reboiler to heat CO2 removal condensate E.2.17 Compressor Seal Gas Leakoff Recovery E.2.18 High Conversion Synthesis Reactor (indirect cooling) to remove reaction heat E.2.19 Low-Pressure difference synthesis reactor E.2.20 Waste heat recovery from compressor synthesis gas E.2.21 Synthesis Gas Molecular Sieve Dryer and Direct Synthesis Converter Feed in process E.2.22 Optimized Loop Recycle Flow E.2.23 Warm Ammonia Delivery to Consumers E.2.24 Advanced Process Control to optimize Ammonia synthesis process E.2.25 Improved steam turbine design to improve efficiency E.2.26 Retrofit of Gas Turbine for improved Efficiency E.2.27 Optimized Refrigeration Levels E.2.28 Optimized Control of Refrigeration Inerts
IIP / ICF Marbek
TA 10
Page 24 of 28
E.3 AMMONIA PROCESS PRACTICES - Natural Gas

This type of fuel is NOT used --> This is the last page of the survey Features E.3.1 E.3.2 E.3.3 E.3.4 E.3.5 E.3.6 E.3.7 E.3.8 E.3.9 Adiabatic pre-reformer to reduce primary reformer duty Waste heat recovery from reformer using heat exchanger reactor Waste Heat Recovery from reformer flue Gas Improved insulation of reformer furnace Modified reformer operating Pressure Lower reformer steam-carbon ratio to reduce primary reformer heat demand Optimized shift reformer duty balance between primary and secondary reformer Waste Heat to preheat fuel gas High Pressure water power recovery turbine to drive absorbent liquid pump Rating Please indicate if your facility practices include any of the following?
E.3.10 Improved catalysts in reforming process E.3.11 Saturation of feed gas with recycle process condensate to allow export of steam Increase mixed feed preheat temperature, convection modifications to optimize process energy use in process E.3.12 E.3.13 Reformer tubes are made of micro alloys with minimum permitted wall thickness E.3.14 Improved arch seals at primary reformer that reduce leakage while permitting thermal movement of tubes Improved secondary reformer burner design to optimize reform reaction equilibrium at exit. E.3.15 E.3.16 E.3.17 E.3.18 E.3.19 Optimize (reduce) secondary reformer catalyst volume/ redesigned collector Recycle of hydrogen to primary reformer improves catalyst performance Radian section of primary reformer refractory has high emissivity coating Isobaric ammonia manufacturing
E.3.20 Expansion of fuel gas for power recovery Other Notes or Remarks
This is the last page of this survey. Thank you very much for your time and assistance.
IIP / ICF Marbek
TA 10
Page 25 of 28
Energy Balance Equipment energy-reported GJ/yr

1 Electricity Cooling / Refrigeration Boilers Ovens / Dryers / Kilns / Furnaces Pneumatic Compressors Air or Gas Compressors Fans, Motors, Pumps Heavy Transport HVAC and Air System System & Other Process Ammonia production Lighting Total energy/year 2 Natural Gas 3 Diesel 4 Fuel Oil 5 Gasoline 6 Propane 8 Biomass / Other fuel 7 Steam -
Energy Balance
Electricity Purchased Energy (GJ/yr) Sold Energy* (GJ/yr) Net Purchased Energy (GJ/yr) Self Generated Energy (GJ/yr) Net Imported Energy (GJ/yr) Adjustment Factor Equipment / Purchased ratio Natural Gas Diesel Fuel Oil Gasoline Propane Other fuels Steam -
* Energy content of sold steam is converted back to the fuel used to generate steam with an adjustment factor for efficiency of conversion (see TA2)
Equipment energy-adjusted GJ/yr

Cooling / Refrigeration Boilers Ovens / Dryers / Kilns / Furnaces Pneumatic Compressors Air or Gas Compressors Fans, Motors, Pumps Heavy Transport HVAC and Air System System & Other Process Ammonia production Lighting Total energy/year Electricity Natural Gas Diesel Fuel Oil Gasoline Propane Other fuels Steam -
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TA 11
Page 26 of 28
Year of Evaluation Energy Share By End Use

All Energy Cooling / Refrigeration Boilers Ovens / Dryers / Kilns / Furnaces Pneumatic Compressors Air or Gas Compressors Fans, Motors, Pumps Heavy Transport HVAC and Air System System & Other Process Ammonia production Lighting Total
2009
GJ/year #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A % of Total #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A Steam energy by end use GJ/year % of Total #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A -
Energy Share By End Use
Purchased Energy By Fuel Type

Annual Net Purchased Energy [GJ] Annual Purchased Energy Cost [$]
Electricity Natural Gas Diesel Fuel Oil Gasoline Propane Other fuels Steam Total
GJ #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A -
Cost ($) -
Annual Purchased Energy Cost [$]

Natural Gas Other fuels Electricity Gasoline Propane Fuel Oil Steam Diesel 0%
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TA 11
Page 27 of 28
Conversion Tables (Multiplication Factors)

Energy1,2 GJ kWh kVA TCE kgCE BTU kCal MMBTU GJ 1 0.0036 0.0036 29.3 0.0293 1.05506E-06 4.19E-06 1.05506 Weight1 ton (metric) ton [short] ton [long] kg lbs lb kg 1000 907 1,016 1 0.454 0.454 Volume1 gallon ft3 L m3 L 3.785 28.317 1 1000 Power Units1 BHP HP BTU/hr MMBTU/hr Cooling Ton Boiler HP kW MW kW 0.746 0.7355 0.000293 293.0711 3.517 9.8095 1 1000 Energy1,2 GJ kWh kVA TCE kgCE BTU kCal MMBTU TCE 0.034129693 0.000122867 0.000122867 1 0.001 3.60087E-08 1.42867E-07 0.036008874
References 1. www.engineeringtoolbox.com 2. LBNL BEST tool
IIP / ICF Marbek
TA 12
Page 28 of 28
Appendix C
A2A Energy Management System Assessment
59
A2A Toolkit Energy Management System Assessment
Institute for Industrial Productivity

Energy Management System Assessment
TO DO: STEP 1 - Please complete the contact information requested on this page. STEP 2 - Review instructions sheet and complete the questions on the next pages. Confidential Plant Information
Plant Name Company Name Sub-sector (choose from menu) Plant Address: Street and number City Province Postal code Plant Telephone Number Plant Contact Info Name Title (Position) E-mail Address Telephone Number
Auditor Information
Name of Auditor Title of Auditor Auditor's Organization / Company Name Direct Telephone Number E-mail address Date of Audit
IIP / ICF Marbek
Page 1 of 10
MA 1
1.0 Corporate Information

1.1 Has the company adopted quality/environmental management systems (such as ISO 9001, ISO 14000)? 1.2 Has the company calculated the GHG footprint of the plant, company or both? 1.3 Has the company adopted a carbon management plan? If no, does the company intend to develop a carbon management plan? 1.4 1.5 Has the plant adopted any elements of a nationally recognised Energy Management standard? % 1.6 1.7 What percentage of the companys total operating costs in the latest fiscal year was represented by
purchased energy costs?
What percentage of the plants total operating costs in the latest fiscal year was represented by purchased energy costs? 1.8 What is the companys current annual operating cost reduction target? [%/year] 1.9 What is the plants current annual operating cost reduction target? [%/year] What is the companys desired return on investment on a capital project designed to improve energy use performance and reduce energy operating costs? (Can be expressed in terms of simple payback, NPV or IRR) 1.11 Does the company have a plan to phase out old equipment over a specific period of time? 1.10
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MA 2
2.1 Corporate Energy Management Policy and Planning

The company has a documented corporate energy management policy: which defines long-term strategic energy management commitments and objectives; 2.1.1 which specifies responsibilities and sets targets for controlling energy use and cost; 2.1.2 The company has a documented energy management planning process which annually: sets targets for controlling energy use and cost; 2.1.3
2.1.4 2.1.5 2.1.6
Yes Yes
No No
Partially Partially
Yes Yes Yes Yes
No No No No
Partially Partially Partially Partially
defines actions to reduce energy costs and achieve the energy performance targets; integrates the energy use and cost reduction targets and actions with annual corporate production and cost objectives; defines a policy and guidelines on energy performance measurement and verification.
2.2 Corporate Financing of Energy Management

2.2.1
2.2.2 2.2.3
The company treats energy management as a key financial variable of every capital project and its contribution is clearly determined. The company has formalized procedures which enable capital and operating financial allocations for energy management projects to: have the same level of authority and importance as other corporate capital and operating financial allocations. be assessed using similar methods and processes as other plant capital and operating financial allocations.
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
The company requires the business case development of all energy management projects to include an assessment 2.2.4 of energy cost avoidance, maintenance cost reduction, productivity improvements and reduced environmental compliance costs. The company requires energy management investments to be assessed using a life-cycle cost analysis methodology 2.2.5 that converts estimated savings and cost data into a cash-flow and integrates that cash-flow with other decisionmaking metrics. (Continue on page below)
Yes
No
Partially
Yes
No
Partially
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Page 3 of 10
MA 3
2.3 Corporate Organization and Accountability

2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6
The company has assigned accountability to a designated senior manager to implement the corporate energy management policy and meet the energy use performance targets. The company regularly (at least once within a two year period) conducts corporate and plant energy use benchmarking using key performance indicators. The companys energy management policy and/or internal technical standards specify energy management measurement and verification requirements. Internal auditing is conducted of the corporate energy management policy, planning and activities as a formalized part of existing audit systems and protocols. External auditing is deployed to check the companys energy management system, which includes reviewing data base accuracy and verifying measurement system accuracy. The company complies with local, regional and national laws and regulations applying to energy and environment, meeting energy conservation design code and energy standards for upgrades, project expansion and construction.
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
2.4 Corporate Communications

2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6
The corporate energy management policy or strategy is communicated externally , for example it is posted on the company web-site. The corporate energy management policy or strategy is communicated internally to plants, for example it is posted on communication boards in the plant(s). Energy use key performance indicators are communicated externally , for example it is posted on the company web site. Energy use key performance indicators are communicated internally , for example it is posted on communication boards in plant(s). Energy costs and cost management are communicated in the companys annual report along with a management discussion of energy impacts on the business. Energy costs and cost management are communicated to the plant(s) on a quarterly basis (or more frequent). (Continue on page below)
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
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MA 3
2.5 Corporate Level Recognition of Achievements

2.5.1 2.5.2 2.5.3 Compensation system (such as salary adjustments, bonuses, titles) tied in with achievements on projects. Internal company recognition: Recognition system in place with awards for exceptional projects and teams. External recognition: Government and third party recognition (eg. trade magazines, international organizations) sought for project successes and achievements.
Yes Yes Yes No No No Partially Partially Partially
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MA 3
3.1 PLANT LEVEL ENERGY MANAGEMENT - Planning

The plant develops an annual operational business plan which includes energy performance targets, key energy
3.1.1 use performance indicators, specification of management and other staff responsibilities / accountabilities and a
Yes No Partially
plan to implement specific projects/actions.

3.1.2 Departments in the plant participate in the planning process and adhere to the plan.
Yes Yes No No Partially Partially
The plant has a formalized production planning process that links annual production and cost objectives to weekly
3.1.3 and daily production schedules. This production planning links the energy use performance targets and
performance improvement actions to the production plan. Energy use performance improvements are defined and scheduled as actions in the annual business plan and 3.1.4 prioritized in the plant project planning process. A full technical energy assessment that includes energy management system performance benchmarking is 3.1.5 conducted by energy professionals at least every 5 years.
Yes
No
Partially
Yes
No
Partially
3.2 PLANT LEVEL ENERGY MANAGEMENT - Organization and Accountability

3.2.1 The plant has a formal organizational, reporting and responsibility structure (with an Organizational Chart)
Yes No Partially
identifying energy management accountabilities at all management, supervisory and operator levels. The plant has a designated senior energy manager assigned responsibility and accountability to implement the 3.2.2 energy management component of the annual plant business plan. The designated senior energy manager has energy performance targets defined in his/her annual Personal Performance Appraisals. The plant has an energy committee led by the senior energy manager and other personnel (e.g., technical & 3.2.4 operations personnel). Plant employees, groups and teams are aware of energy performance targets and commitment to energy use 3.2.5 performance improving actions as stated in the plant annual operational business plan. The plant has systems and resources in place to adequately meet the energy performance reporting requirements 3.2.6 in the business plan. (Continue on page below)
3.2.3
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
IIP / ICF Marbek
Page 6 of 10
MA 4
3.3 PLANT LEVEL ENERGY MANAGEMENT - Monitoring

The plant maintains an active energy procurement plan that reviews energy bills, reviews energy consumption data and assesses tariff structure. The plant operates an Energy Management Information System that comprises: Sensors and instruments to collect energy use data, including energy meters (electricity, gas, oil, steam) and 3.3.2 other utility meters directly associated with energy use (heat flow, cooling flow, compressed air flow), temperature, pressure and flow; Data acquisition systems (e.g., the energy meters are usually connected to a monitoring and control system 3.3.3 such as a Programmable Logic Controller, Supervisory Control and Data Acquisition or Distributed Control System); An energy use database that includes time-series data storage;
3.3.1 3.3.4 3.3.5
Yes No Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
3.3.6 3.3.7 3.3.8 3.3.9 3.3.10 3.3.11 3.3.12
Software tools which typically integrate directly with the control/monitoring system and database to analyze energy use against key energy use performance indicators. Energy consumption is measured on a basis that can be easily related to an operational unit; measured per physical unit of product; identified for each operational area; both real-time and periodic; can be correlated to production; can be correlated to weather.
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes Yes
No No
Partially Partially
The difference between actual and targeted energy consumption is tracked at the plant and production process levels and causes of increased or decreased consumption are assessed. All energy metrics (e.g., real time energy data, synchronized real time production data and reports) can be 3.3.13 accessed from a desk top computer by approved personnel. (Continue on page below)
Yes
No
Partially
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Page 7 of 10
MA 4
3.4 PLANT LEVEL ENERGY MANAGEMENT - Reporting and Communication

3.4.1
3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7
The plant uses a consistent communications and reporting protocol to channel key performance indicator results and relevant energy use information to business units and staff. The plant regularly reports on energy use performance relative to targets and budgets (e.g., annual, quarterly and monthly) to those with accountability (teams or individuals) at the corporate and plant levels (e.g., operations and technical managers). Key energy use performance indicator results are communicated to all employees on a regular basis. The plant uses a variety of tools as part of an ongoing energy awareness campaign to display performance, ideas, etc. Energy saving and other energy management ideas are solicited from employees during general team, subcommittee or employee meetings. Energy management project costs and progress are reported to plant technical and operations management. Energy management project costs and progress are reported to corporate management.
(Continue on page below)
Yes
No
Partially
Yes
No
Partially
Yes Yes
No No
Partially Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
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Page 8 of 10
MA 4
3.5 PLANT LEVEL ENERGY MANAGEMENT - Project Management

Identification of Opportunities The plant typically considers the scope of energy management project opportunities to include: Energy efficiency and conservation. 3.5.1 Peak load and demand management. 3.5.2
3.5.3 3.5.4 3.5.5 3.5.6 3.5.7
Yes Yes Yes Yes Yes Yes
No No No No No No
Partially Partially Partially Partially Partially Partially
Utility bill management. Fuel substitution and/or use of renewable energy sources. On-site power generation. Improved energy management information systems.
The plant uses the following means to identify energy management project opportunities: A Suggestion Plan administered by the energy manager or other senior staff. Energy audits, assessments and studies. 3.5.8
3.5.9 3.5.10 3.5.11 3.5.12
Yes Yes Yes Yes Yes Yes Yes
No No No No No No No
Partially Partially Partially Partially Partially Partially Partially
Internal and external benchmarking, and detailed analysis of production process and infrastructure consumption patterns. Routine maintenance activities.
The plants continuous improvement management system. Existing metering, additional sub-metering if required, and energy management information system. Energy management best practices are identified by regularly monitoring trade journals, internal databases and 3.5.14 by networking with other facilities. Best practices are shared throughout the plant and developed into projects. Project Implementation
3.5.15 The plant has implemented a procedure to manage the implementation of energy management projects. 3.5.16
Yes Yes
No No
Partially Partially
3.5.17 3.5.18 3.5.19
The plant has designated a project manager or sub-committee to oversee the implementation of energy management projects as ratified by upper management. Project Measurement and Verification Project measurement and verification plans are normally carried out as part of the project design for all energy performance improvement projects requiring capital allocations. The costs of conducting a project measurement and verification plan and implementation are normally included in the cost analysis of the project. The measurement and verification plan requires establishment of energy performance baselines and a formal reporting process of actual versus baseline performance.
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
(Continue on page below)
IIP / ICF Marbek
Page 9 of 10
MA 4
3.6 PLANT LEVEL ENERGY MANAGEMENT - Training and Capacity Development

3.6.1 The budget for staff training to support energy management is included in the annual plant budget. 3.6.2 3.6.3
The approved staff training plan for energy management is incorporated into the annual employee training schedule. The staff training plan for energy management includes both management and technical training competencies.
Yes Yes
No No
Partially Partially
3.6.4 Energy use and energy management is included in orientation training for new personnel.
Senior plant staff and teams accountable for energy use and cost performance targets, are trained to:
3.6.5 3.6.6 3.6.7 3.6.8 3.6.9
Conduct energy management planning as a key part of the business planning processes. Prepare and submit a financial business case evaluation of energy performance improvement projects, in terms relevant to the financial criteria of the corporate project approval process. Scope, budget and manage pre-feasibility and investment grade studies. Designated plant employees (usually from Energy Team sub-committees) and managers are trained to oversee and manage the identification and implementation of energy management projects. Designated plant personnel are trained to manage energy data and information.
Yes Yes Yes Yes Yes
No No No No No
Partially Partially Partially Partially Partially
3.7 PLANT LEVEL ENERGY MANAGEMENT - Recognition of Achievements

Compensation system (such as salary adjustments, bonuses, titles) tied in with achievements on projects and performance improvement Internal company recognition: Senior staff acknowledge accomplishments and project successes through a recognition 3.7.2 system. 3.7.1
This is the last page of this survey. Thank you for your time and assistance.
IIP / ICF Marbek
Page 10 of 10
MA 4
Appendix D
A2A Productivity Improvement Assessment Template
60
A2A Toolkit Productivity Improvement Assessment
Institute for Industrial Productivity

Productivity Improvement Review
TO DO: STEP 1 - Please complete the contact information requested on this page. STEP 2 - Please complete the questions on the next page.
Confidential Plant Information

Auditor Information
Name of Auditor Title of Auditor Auditor's Organization / Company Name Direct Telephone Number E-mail address Date of Audit
IIP / ICF Marbek
Page 1 of 3
PI 1 - Plant Information
A2A Toolkit Productivity Improvement Assessment Section 1: About the Plant and the Company 1.1 1.1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.3 1.3.1 1.3.2 1.4 Company Ownership Type of company ownership? Company Presence (International or in-country) Years of company operation Number of years the specific factory has been operating Number of factories currently operating Number of employees: Total in company Total in the target factory Products and Output Annual revenue / total income: Across all of the company's plants In the target plant Factors Impacting Profitability Response Response
Response
What does the company consider to be the corporate and business factors that will impact profitability over the next two year period? (Please indicate the top 5 factors and rank from 1 to 5 from the list below) 1.4.1 Operational efficiency 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.4.10 Importance of new technology to improve production and productivity New product development People development Strength of your brand Competitiveness of product Environmental compliance costs Customer loyalty Effectiveness of the supply chain Other (please describe):
IIP / ICF Marbek
Page 2 of 3
Productivity Improvement
A2A Toolkit Productivity Improvement Assessment Section 2: Sustainability and Productivity 2.1 Sustainability 2.1.1 Does the company set targets to improve sustainability? If yes, what is the annual target percentage improvement for: 2.1.2 Energy use 2.1.3 Total carbon emissions 2.1.4 Water use 2.1.5 Waste water discharge Does the company measure environmental sustainability of its 2.1.6 operations? If yes, what techniques are used? 2.1.7 Certification of performance (e.g., ISO 14001) 2.1.8 Tracking improvement (e.g., energy audits) 2.1.9 Reporting (e.g., corporate sustainability reporting) 2.2 Continuous and Productivity Improvement Response
Countinuous Improvement thinking and practices are a systematic approach on how to identify and eliminate waste while focusing on adding value to internal and external customers. To what extent is your organization engaged in the adoption of Continuous Improvement thinking 2.2.1 and practices? (Choose from the dropdown list below)
Cost reduction and increased profit Waste reduction Customer value Improve competitiveness Reduce number of staff Corporate directive Six sigma Kaizan Blitz 5S Kanban JIT TPM Value Stream Mapping Standardized Work Instructions
If you indicated that the company has begun implementing continuous 2.2.2 improvement, please indicate the reasons for implementing this approach by selecting from the list to the right.
2.2.3 What kind of continuous improvement tools/processes are used?
2.2.4
What kind of support is available for personnel development?
Development/Implementation of tools and techniques Management training Employee training Events and activities to identify waste reduction opportunities
IIP / ICF Marbek
Page 3 of 3
Productivity Improvement
Appendix E
A2A Checklist and Action Plan Template
61
A2A Toolkit Checklist and Action Plan
Energy Efficiency and Management Plan

TO DO: STEP 1 - Please complete the contact information requested on this page. STEP 2 - Complete the questions on the following tabs as per instructions on each page Confidential Plant Information
Auditor Information
Name of Auditor Title of Auditor Auditor's Organization / Company Name Direct Telephone Number E-mail address Date of Audit The survey questionnaire is the ownership of IIP and ICF Marbek. Any use of the survey by another party requires to be granted permission by IIP or ICF Marbek prior to use. IIP / ICF Marbek AP 1 Page 1 of 9
Outline of Energy Efficiency and Management Plan

EE&M Plan: Table of Content
1 2 3 4 5 6 7 8 9 10 Policy Planning Organization and Accountability Financing Project Management Monitoring Reporting and Communication Training and Capacity Building Implementation of Identified Opportunities Other Elements
IIP / ICF Marbek
AP 2
Page 2 of 9
Energy Efficiency and Management (EE&M) Plan Checklist

Management best practice is illustrated by a high level of commitment, awareness, organization and action in support of energy management. This checklist will assist in developing a new Energy Management (EM) Plan or reviewing an existing Energy Management Plan. The checklist comprises of Yes/No/Partially questions, where "partially" refers to element that are less than 80% implemented. Once each question has been answered, assign a priority to those requiring attention. The items requiring attention should be included in the Energy Management Action Plan to ensure the items will be addressed and implemented. Energy Management Element 1
1.1
Status
(Y/N/Partially)
Details
Priority
(high/med/low)
Policy
Does the EM Plan include a documented corporate energy policy? Effective energy management begins with senior management issuing a company energy policy that is documented, communicated and understood within the organization. The policy needs to include long-term strategic energy management commitments and objectives. Energy targets are set and performance is linked to the objectives of the organization. There is commitment to ensure the availability of information and resources to carry out the actions and a commitment to comply with legal and other requirements. The company's EM Plan and policy is reviewed annually with commitment from senior management, and evaluated to ensure continuous improvement, with regular updates to reflect changing needs and priorities. There are guidelines and procedures in place to establish the scope and boundary of energy management activities.
1.2
1.3
Does the policy: - define energy management targets and objectives, - specify responsibility, and - set targets for controlling energy use and costs? Does the EM Plan include a process for an annual review, evaluation, and update of the policy and the EM Plan?
2
2.1
Planning
Does the EM Plan commit to providing the necessary resources to carry out the energy management planning activities? Does the EM Plan include: - methodology and criteria to develop the plant's energy profile and energy baseline? - the plant's energy baseline and energy profile? Finances and human resources are allocated to support planning of energy management.
2.2
An energy profile is developed by measuring and analyzing energy use, identifying areas of significant energy use and prioritizing opportunities for improvement of energy performance. An energy baseline establishes the initial energy profile considering a data period suitable to the organization's energy use. Adjustments are made to the baseline if major process, operational or system changes have been affected. Energy performance indicators determine energy performance and assist in evaluating progress towards targets and objectives. Establish, implement and maintain energy management action plans that include designation of responsibility, timeframe to achieve targets and methodology to verify energy performance. An Energy Management Information System (EMIS) provides the necessary data and information for the actions identified from the EM Plan review and included in the EM Action Plan. The data and information provided by the EMIS allows management to take action to improve energy performance, change policy, change targets or allocate resources.
2.4 2.5
Does the EM Plan define energy performance indicators to evaluate progress? Is there an action plan in the EM Plan to implement the EM Plan activities? Does the EM Plan include a process to develop, review and, if necessary, modify an Energy Management Information System (EMIS)?
2.6
IIP / ICF Marbek
AP 3
Page 3 of 9
3
3.1
Organization and Accountability

Does the EM Plan identify a designated manager responsible for implementing corporate energy policy and assign authority and accountability to achieve energy performance targets? Does the EM Plan contain a list of key personnel of the energy team and/or energy leader assigned to oversee and implement energy management activity? A designated energy manager ensures that energy policy is implemented and energy performance targets are met. Energy performance objectives can be tied to performance assessment of the designated energy manager. The team leader defines and communicates responsibilities and authority, reporting to top management on energy performance and improvements. An energy committee, led by a senior manager, establishes an energy management information system, maintains it and implements it in accordance with company policy. The team is aware of the organizational commitment to energy management and the targets. Appointed members by the management are assigned sufficient responsibility, authority and provided with required skills and training. Internal audits of policy, planning and activities are carried out regularly. External audits are used to check the energy management system, and accuracies, with activities such as benchmarking.
3.2
3.3
Does the EM Plan identify the procedures and actions to: - audit energy management policy and systems, - conduct data analysis, and - verify data accuracy?
4
4.1
Financing
Does the EM Plan include procedures to ensure energy performance is a criteria in capital project evaluation? Does the EM Plan include procedures for developing a business case for projects that integrates energy management prior to project approval? Establish procedures to treat energy management performance as a variable of every capital project and assign it the same level of authority and importance as other corporate capital and operating financial allocations. Business case development of energy management projects need to also include nonenergy benefits. For example the business case needs to assess: cost avoidance, maintenance cost reduction, productivity improvements, and reduced environmental costs. The procedures to assess the business case of energy management projects should use methods consistent with assessing other projects. Energy management investments are assessed using life-cycle cost analysis, integrating estimated savings into a cash flow that is linked to decision-making metrics. The energy profile is assessed and updated over the project operating lifetime. Suppliers are informed that purchasing is evaluated on the basis of energy efficiency. Consider the following when purchasing energy: energy quantity, availability and capacity, variation over specified time, billing parameters and cost, environmental impact and renewable energy sources.
4.2
4.3
Does the EM Plan address energy performance as part of the plant's procurement activities?
4.4
Does the EM Plan identify criteria to be considered when energy (fuel) is purchased, which includes the fuel impact on energy management?
IIP / ICF Marbek
AP 3
Page 4 of 9
5
5.1
Project Management
Does the EM Plan identify the procedures to enable the identification of energy management projects? Energy management project opportunities can be identified by (among others): an administered suggestion plan, energy audits and assessment studies, benchmarking of production process, and routine maintenance activity. Parameters to be considered in identifying opportunities can include (for example): energy reduction opportunities, peak load reduction, utility bill management, and fuel substitution. A designated project manager or sub-committee oversees the implementation of energy management projects. Project measurement and verification are part of the project design, with costs included in the project budget, and a plan to establish energy performance baselines and reporting of deviation from the baseline. Monitoring of trade journals, databases and networking with other facilities can identify energy management best practices, which can be shared throughout the facility and developed into projects. An Energy Management Information System should provide data that is accurate and repeatable. Equipment used in data collection should be calibrated regularly. Key elements of energy performance to be supported by the EMIS include: defining plant's energy profile, identifying significant energy uses, measuring energy reduction impacts of projects, and evaluating effectiveness of energy plans in achieving objectives and targets. Operations using significant energy should form the basis of establishing and setting criteria for effective operation and maintenance, with appropriate communication of operational protocols provided to operating personnel. Energy use can be correlated to other metrics (such as an operational unit, or production) to provide energy performance indicators. The indicators are used to measure, record and evaluate differences between actual and targeted energy consumption, and inform actions to improve performance. When developing performance indicators it is important to also consider non-production influences, such as weather and seasonal fluctuations of temperature. Procedures need to include corrective and preventative actions with the aim to minimize non-conformance. These actions may include (for example): review, root-cause analysis, determining the need for action, defining the actions and reviewing their effectiveness. Establishing and maintaining records demonstrates conformity and provides historical and organizational knowledge.
5.2
Does the EM Plan identify how human and financial resources are allocated to oversee management and implementation of energy management projects?
5.3
Does the EM Plan include a process to review and identify energy management best practices and project opportunities?
6
6.1
Monitoring
Does the EM Plan define an Energy Management Information System (EMIS) that enables the collection, management, interpretation and use of all necessary energy data and information.
6.2
Does the EM Plan define criteria of how operations associated with significant energy use are identified and how the energy use of these operations are tracked? Does the EM Plan define how to relate energy use data to production/operational units, and what performance metrics to be used to track differences between targeted and actual energy consumption?
6.3
6.4
Does the EM Plan define a procedure to deal with nonconforming energy performance and the implementation of corrective and preventative actions to address nonconformance?
IIP / ICF Marbek
AP 3
Page 5 of 9
7
7.1
Reporting and Communication

Does the EM Plan include a method and frequency of communicating corporate energy management policy and key energy management performance indicators to all employees? Does the EM Plan identify the energy performance metrics to be communicated internally and/or externally? Effective communication is maintained by regular reporting on, not only corporate policy, but energy use performance relative to targets set in the energy policy. Communication is aimed at those accountable for energy management as well as all employees. The procedure should be appropriate to the size of the plant. If a plant decides to report energy management and its performance to customers and stakeholders, the annual report or the company website can be a good venue. A variety of tools can be used to display energy costs, results and progress as part of an internal energy awareness campaign, such as internal boards, team meetings, and newsletters. Ensure that a process is in place to encourage personnel to make proposals for energy management improvements. General team, sub-committee or employee meetings can be used to solicit ideas from staff who are knowledgeable with the day to day facility operations. Establish, implement and maintain a procedure to communicate the organizations energy performance, appropriate to the size of the organization.
7.2
7.3
Does the EM Plan provide a process to regularly solicit energy management savings opportunities from employees?
7.4
Does the EM Plan identify a method to report costs and progress on energy management to staff at technical, facility and corporate levels?
8
8.1
Training and Capacity Building

Does the EM Plan contain a procedure to evaluate the training needs to carry out energy management activity? Identify training needs associated with control of significant energy systems, operation of energy management information systems. Ensure designated personnel are provided access to adequate training to manage energy data, information and oversee identification and implementation of energy management projects. The facility budget needs to include a budget for staff training (both technical and management competencies) to support energy management. It is important to develop and maintain awareness of the importance of personnel roles and responsibilities in energy management, as well as the benefits and significance of energy use and consequences of non-conformity. Designate staff and energy managers to ensure energy management training and capacity needs are identified and addressed through training and capacity building. Establish a recognition and/or award system for exceptional projects or energy performances improvements. Individual compensation systems can also be included, tied in with achievements on projects and performance improvements.
8.2
Does the EM Plan address how and when employees will be trained, to oversee and carry out energy management activity, and does it allocated sufficient budget for the training and capacity building? Does the EM Plan identify and designate senior staff responsible for overseeing energy management training and capacity building? Does the EM Plan describe a procedure to evaluate and provide recognition to personnel contributing to key achievements in energy performance improvements?
8.3
8.4
IIP / ICF Marbek
AP 3
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9
9.1
Implementation of Identified Opportunities

Does the organization identify and prioritize energy savings opportunities and review at established and regular intervals? Has the organization prioritized the energy performance improvement opportunities to be assessed, and/or carried out? Does the organization identify and prioritize productivity improvement opportunities and review at established and regular intervals? Has the organization prioritized productivity improvement opportunities to be assessed, and/or carried out? Regularly review audits results, employee suggestion plans, review of industry best practices and other review processes to identify relevant energy performance improvement opportunities, along with expected savings. A business plan should be prepared for each identified opportunity, with, at minimum, investment cost, payback, energy savings. Establish a budget, plan, and resources to carry out prioritized opportunities. Regularly review audits results, employee suggestion plans, review of industry best practices and other review processes to identify relevant productivity improvement opportunities, along with expected waste reduction. A business plan should be prepared for each identified opportunity, with, at minimum, investment cost, payback, waste reduction, productivity improvement benefits. Establish a budget, plan, and resources to carry out prioritized opportunities.
9.2
9.3
9.4
10 Other Elements
10.1 Does company policy and practices confirm to relevant laws, regulations and agreed rules? Are energy management and productivity improvement practices and systems documented (electronically or in writing) with references made to relevant procedures? Are non-conformances to energy management and productivity improvement systems managed, with cause analysis and corrective action deployed? The policy statement should indicate that relevant laws, regulations, permit requirements and other agreed upon rules are satisfied, and the organization should ensure that all practices conform to them. Define the energy management and continuous improvement systems, their operation and ensure its availability to all users. The documents should indicate who is responsible for them and how and where each is managed. Analyze non-conformance occurrences, and ensure that corrective measures are taken to prevent reoccurrences.
10.2
10.3
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AP 3
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Energy Efficiency and Management (EE&M) Action Plan Template

The following Energy Efficiency and Management (EE&M) Action Plan template is to assist your enterprise in developing actions to implement the EE&M Plan. The EE&M Action Plan includes a timeframe, responsibilities, and budget for each action. Actions are developed from the actions identified in the EE&M Plan checklist. Energy Efficiency Action Item (from EE&M Plan Checklist) and Management Element
Plan 1 Policy
Responsibility Assigned to
Time Frame Scheduled Status or Actions/Comments Date Date Completed

Do Check Act
Do
Planning
Organization and Accountability
Financing
Project Management
Monitoring
Reporting and Communication
Training and Capacity Building
Implementation of Identified Opportunities (Including Technical Best Practices and Productivity Improvement)1.
Maximum Potential Maximum Potential Energy Savings2,3 Energy Cost Savings3 [GJ]
Relative Implementation Cost4
Relative Implementation Difficulty5
Responsibility Assigned to:
Scheduled Date
Status or Actions/Comments Date Completed
Marbek / IIP
AP 4
Page 8 of 9
The potential savings presented are an estimate of maximum savings per individual opportunity and are not additive. Interactive effects will reduce the total potential savings if more than one opportunity is implemented. General practices for implementation of energy efficiency opportunities: a) Sequence of implementation i) Optimize the demand and output of equipment as a first step (eg. fix air leaks) ii) Properly size the supply equipment and, if possible, upgrade to more efficient equipment, at the same time. b) If the equipment demand is low, then consider optimization of the equipment characteristics, such as efficiency. If demand is fluctuating, consider implementing measures to meet the fluctuating demand, such as variable speed drives or other controls. c) When implementing control equipment to optimize energy use (such as VSDs or advanced control), consider the effects on the power factor of the facility.
Notes: 1. The opportunities are listed by end use, starting the the highest priority end-use as listed in the report card. Within each end use, the opportunities are listed by 1) highest cost savings, 2) lowest relative implementation cost 3) lowest implementation difficulty. The top three potential energy cost savings opportunities are highlighted. 2.The opportunities are based on both the energy consumed and the technical best practices for your facility. Please note that the values shown are approximations and are based on site conditions. 3.Energy savings are maximum values based on all energy consumed by each end use and does not consider equipment that is already efficient. More detailed analysis is required to determine precise energy and cost savings. 4. Relative Implementation Cost: High: Implementation cost is very high, and a detailed economic feasibility analysis (based on a detailed process design) is required to justify and estimate the cost. Medium: Cost is relatively average, and usually requires a first-order economic feasibility analysis to justify and estimate the cost. Low: Limited to no cost involved to implement the opportunity. Generally referred to as "low hanging fruit. 5. Relative Implementation Difficulty: High: Replacement of existing, large equipment / process units, or complex modification to the process, which requires external expertise to design and implement. Requires a detailed technical and economic feasibility assessment and detailed process design prior to implementation. Medium: Replacement of existing, small/medium size equipment / process units, or relative minor modification to the process, which can often be design and implemented by in-house expertise. Retrofit of equipment that require a moderate effort to implement. Generally requires only a first order technical and economic feasibility assessment and minor process design prior to implementation. Low: Process modifications, equipment replacements and retrofits that are relatively easy to implement. Most oftern can be integrated with maintenance activities and include operational and behaviorual changes. A high level economic and technical feasibility analysis may be required in some instances.
Marbek / IIP
AP 4
Page 9 of 9

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Assessments to Action (A2A) Toolkit for the IFA: Guidelines for Users

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.2

4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 5

5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.2 6

Accuracy, Detail and Making Assumptions ................................................. 33

6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 7

7.1.3 7.1.4 7.1.5 8

8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.2 9 10 11

Accuracy, Detail and Making Assumptions ................................................. 51

Appendix A Appendix B Appendix C Appendix D Appendix E

2.1 Context and Scope of IIP A2A Toolkit

Assess Energy Performance & Establish Indicators

Implement EE&M Action Plan

Continuous Improvement Process

Assess Performance and Establish Indicators

Report Card and Opportunities Identification EE&M Plan Checklist

EE&M Action Plan Template

Implement Action Plan

Training and Capacity Building of Trainers and Auditors

2.2 Assessment Methodology

2.3 Description of Toolkit Modules

2.4 Managing and Updating Toolkit

2.5 Structure of Guideline

Energy Use Performance and Technical Best Practices Assessment

Technical Measure Library

EE&M Plan Checklist and Action Plan Template

Productivity Improvement Assessment

2.6 Common Elements in Tools

Exhibit 4: Example of first few tabs in Excel tools

Energy Use Performance and Technical Best Practices Assessment

Exhibit 5: Tool 1 in the sequence

Energy Use Performance and Technical Best Practices Assessment

Technical Measure Library

EE&M Plan Checklist and Action Plan Template

Productivity Improvement Assessment

Exhibit 7: Tools in the toolkit and results to be achieved

Type Fluorescent CFL's Metal Halide High Pressure Sodium Incandescent

Standard T17, T12 Mercury Vapour

Energy Efficient T5, T8 All All other All

Exhibit 9: Example of Technical Assessment Sold and self-generated fuel questions

Exhibit 11: Example of Technical Assessment feedstock questions

Exhibit 13: Example of Technical Assessment drop down menu

Exhibit 14: Example of Technical Assessment section not applicable box

3.2 Accuracy, Detail and Making Assumptions

3.3 Technical Best Practices Assessment

3.4 Ammonia Sub-Sector Specific Assessment

Technical Measure Library

Exhibit 19: Tool 2 in the sequence

Energy Use Performance and Technical Best Practices Assessment

Technical Measure Library

EE&M Plan Checklist and Action Plan Template

Productivity Improvement Assessment

Exhibit 20: Example of Measure Library tab

Exhibit 21: Measure Library Index Tab

Management Best Practices Assessment

Exhibit 22: Tool 3 in the sequence

Energy Use Performance and Technical Best Practices Assessment

Technical Measure Library

EE&M Plan Checklist and Action Plan Template

Productivity Improvement Assessment

Exhibit 23: Management Best Practice Assessment index table

Flow of Information Between Tools