ENERGY MANAGEMENT FUNDAMENTALS FOR INDUSTRIES

INTRODUCTION FOR ENERGY MANAGEMENT FUNDAMENTALS FOR INDUSTRIES

From the national perspective, the importance of energy conservation (EC) cannot be overemphasized. The benefits of energy conservation are significant to the nation’s economy and performance in the management of its environment. Improving energy efficiency will lead to significant cost-savings and thereby improving competitiveness. Energy conservation activities will also help to conserve the usage of the nation’s limited natural resources and at the same time reduce the negative environmental impacts. The implementation of energy efficiency (EE) programs will focus on energy-saving features in the industrial and commercial sectors. In this regard, EE features in buildings and establishing comprehensive energy management system will be encouraged. In addition, the industrial sector will be encouraged to implement EE measures including improvements in plant, equipment and processes.

COURSE OBJECTIVES

On successful completion of this course, the participant should be able to:

• • Understand the benefits and implications of EC and EE problem solving programs, and relate the concepts to the overall business mission and objectives.
  • Think about his/her organization as a collection of processes, with inputs that determine the output.
  • Use the concept of FEC and EE systems engineering problem solving to evaluate the capability of a process or organization.
  • Recognize the engineering problem solving model used to improve processes.
  • Recognize the organizational factors that are necessary groundwork for a successful engineering problem solving program.
  • Integrate the EE and EC systems engineering problem solving program effort with other process improvement initiatives.

COURSE CONTENTS

DAY 1

Transformer

• Introduction
• Guidelines on Equipment Energy Efficiency
• Types of Transformers
• Parts of Transformers
• Types of Transformer Losses
• Guidelines on Selection of Transformers
• Guidelines on Efficient Utilization of Transformers
• Target Standard Values
• Guidelines On Best Practice in Design and Operation of Power Transformers
• Operational Aspects
• Maintenance Aspects

Chillers

• Guidelines on System Design & Chiller Selection
• Cooling Load Estimates
• System Diversity and Operating Regimes
• Types of Chillers
• Chiller Selection Criteria
• Equipment (Chiller) Energy Efficiency Rating
• Guideline for Best Practice
• Guidelines for Operation and Monitoring
• Guidelines for Inspection and Maintenance
• Case study 1: Installation of automatic controllers to improve energy efficiency of chillers in a hotel
• Case study 2: Replacement with energy-efficient chillers

Cooling Towers

• Guidelines on System Design & Equipment (Cooling Tower) Selection
• System Diversity
• Types of Cooling Towers
• Cooling Tower Selection Criteria
• Equipment (Cooling Towers) Energy Efficiency Ratings
• Guidelines for Best Practices
• Guidelines for Operation and Monitoring
• Operation
• Monitoring
• Weekly Checklist
• Guideline for Inspection and Maintenance
• Recommended Inspection and Maintenance Schedule
• Case Study 1
• Case Study 2
• Suggested Methods of Energy Savings for Cooling Towers

 Motors

• Guideline on Equipment Energy Efficiency
• Motor selection
• High Efficiency Motor
• Efficiency Classification
• Efficiency Testing Requirements
• Energy and Cost-Saving Potential
• Cost Premium for High Efficiency Motors
• Savings in Running Cost
• Motor Sizing
• What to Consider When Selecting a Motor
• How to Estimate the Efficiency of Existing Motors
• Guideline for Best Practice
• Operation and Maintenance
• Proper Commissioning
• Maintenance Records
• Motor Set-up and Alignment
• Motor Cleaning
• Motor Lubrication and Bearing Maintenance
• Motor Condition Assessment
• Electrical Performance Assessment
• Switching Off When Not Needed
• Reducing Motor Loads
• Slowing Down Loads for Pumps and Fans
• Motor Repair
• Decision to Replace or Repair the Failed Motor
• Other Factors Affecting Choice between Replace and Repair
• Variable Speed Drives
• Best Practice Guides
• Case study on payback estimates on buying a new high efficiency motor (HEM) compared to repairing a standard motor
• Approximate frequency of motor inspection and testing
• Case study 1: Energy Savings by retrofitting