1. IIEG Spring Conference
Energy Treasure Hunts-Where to Find Those Treasures!
Bremer Energy Consulting Services, Inc.
Bruce Bremer
April 11, 2017

2. Agenda Energy Program Treasure Hunt Background Treasure Hunt Process
Summary
Q & A
Bremer Energy Consulting Services, Inc.

3. ENERGY STAR Guidelines for Energy Management
Similar Characteristics of a Quality Energy Management Program and a Treasure Hunt
Make Commitment
Assess Performance
Set Performance Goals
Create Action Plan
Implement Action Plan
Evaluate Progress
Recognize Achievements
ENERGY STAR Guidelines for Energy Management
Treasure Hunt Tool
Bremer Energy Consulting Services, Inc.
Bremer Energy Consulting Services, Inc.

4. Energy Program Organization
Needs to be a Horizontal Program
Not A Vertical Program
Environmental & Energy
Human Resources
Occupational Safety
EH&S
Accounting & Finance
Facility, Manufacturing Engineers
I/T
Maintenance
Production
Public Affairs
Quality
Bremer Energy Consulting Services, Inc.
Bremer Energy Consulting Services, Inc.

5. Energy Strategy Framework
CO2
Mgmt
Innovation New Technologies
Energy at the right value
(What Should I use)
Energy Culture
(Actively Practice Conservation)
Energy Efficiency
(Optimize our Equipment, Tools, and Systems)
Increasing Complexity
Bremer Energy Consulting Services, Inc.
Bremer Energy Consulting Services, Inc.

6. The Energy Culture “The 5 Rs” Refine, Reduce, Reuse, Recycle, Recover
Part of Day to Day Responsibility with Continuous Improvement-Technical Side and Program/Behavior Side
Bremer Energy Consulting Services, Inc.
Bremer Energy Consulting Services, Inc.

7. Methods to Evaluate Energy Performance
Focus during operating and non operating hours
Focus on improving day to day operations
Bremer Energy Consulting Services, Inc.

8. Energy Improvements: Where are They Initiated?
Focus Area for Treasure Hunt Activity: Low Cost or No Cost
Bremer Energy Consulting Services, Inc.

9. What is a Treasure Hunt? Go and See
Bremer Energy Consulting Services, Inc.

10. What is a Treasure Hunt?
Treasure Hunt is a Tool for Employees to Learn a Culture of Continuous Improvement to Reduce Energy, Water, Cost and Emissions
How is it Done?
On Site ~3 day event where Cross Functional Teams Go out and Identify Energy and Water Reduction Ideas during Production and Nonproduction times
Teams Identify, Analyze, Evaluate and Recommend Opportunities through Day to Day Operations
Bremer Energy Consulting Services, Inc.

11. Objectives Identify Energy Reduction Opportunities:
No- and low-cost energy savings
Learn Energy Culture:
Philosophies, methodologies, and benefits
Tie energy to production and continuous improvement
Make part of day to day activities
Emphasize that it is a tool in an energy program.
Bremer Energy Consulting Services, Inc.

12. Treasure Hunt Philosophies
Optimizing: Improving the operation and efficiency of existing equipment
Teamwork: Engaging and educating team members to identify energy reduction opportunities and energy program enhancements
Ownership: Involving employees to use their expertise and knowledge and create a sense of ownership
Repetition: Conducting regular schedule-two or more times per year-continuous improvement
Bremer Energy Consulting Services, Inc.
Bremer Energy Consulting Services, Inc.

13. Treasure Hunt Distinct Phases
Preparation: Organization’s leadership support - 6 weeks before the planned onsite event
Pre-Training: Meet team leaders to confirm roles & responsibilities, and agenda – 1 week before the onsite event
Three-day Onsite Event: Teams identify, quantify energy-saving opportunities, summarize and present the results to management - Onsite 3 day event
Follow-up: Schedule for pursuing the energy reduction opportunities – 1 to 4 weeks after the onsite event
Bremer Energy Consulting Services, Inc.

14. Preparation Gaining facility buy-in Creating Treasure Hunt agenda
Assembling teams and resources
Collecting and analyzing data
Developing opportunity detail sheets and energy calculators
Bremer Energy Consulting Services, Inc.

15. Treasure Hunt Agenda Day Activity Function Location -Pre-Treasure Hunt
-Team Leader Training
-Review agenda and event details
-Review teams and roles and responsibilities
-Review detail sheets
Teleconference
-Treasure Hunt Summary
-Observe Non Operational Mode
-Create Detail Sheets
-Summarize Findings
-Energy journey, Energy Treasure Hunt introduction, possible opportunities and detail sheet demonstration
-Identify ideas during non operational mode
-Enter opportunity into detail sheet
-Teams/group summarize findings
Host Facility
-Observe Startup
-Observe Operations
-Observe Lunch Break
-Identify equipment starting too early
-Identify operational energy opportunities
-Identify equipment to turn off during lunch (between shift if applicable)
-Teams/group summarize findings and pick top 3
-Finish Detail Sheets
-Finalize Summary Presentation
-Summary Presentation
-Complete detail sheets for remaining opportunities and refine top 3 opportunities
-Summarize total opportunities and practice presentation
-Highlight top 3 opportunities and next steps
-Post Treasure Hunt
-Follow up
-Implementation update
-Share opportunities
Bremer Energy Consulting Services, Inc.

16. Treasure Hunt Focus Areas
Lighting:
High Bay
Bldg
Office
Utilities:
Chiller System
Compressed Air
HVAC
Steam/Hot Water System
Process:
Assembly
Painting
Machining
Casting
Motors, Fans, & Pumps:
Supply Systems
Exhaust Systems
Other:
Special systems
Water
Maintenance & Ops:
PMs
Standards
Efficiency
Bremer Energy Consulting Services, Inc.

17. Treasure Hunt Teams Facilitator & Host Team 1 Technical Team 2
Utility Systems
-Team Leader
-Maintenance
-Engineering
-Procurement
-Other plant sites
Building Systems
-Team Leader
-Maintenance
-Engineering
-Other plant sites
Process Systems
-Team Leader
-Process
-Accounting
-Engineering
-Management
Bremer Energy Consulting Services, Inc.

18. Collect and Analyze Data
Bremer Energy Consulting Services, Inc.

19. Electricity Consumption By Process
Bremer Energy Consulting Services, Inc.

20. Weekend Utility Demand Profiles
Bremer Energy Consulting Services, Inc.

21. On Site Event Training of what to look for Go to the floor and see
Analyze findings
Calculate savings
Implementation concepts
Presentation of ideas
Bremer Energy Consulting Services, Inc.

22. Treasure Hunt Process? Identify Opportunities Analyze Scope
Evaluate Impact
Implement Opportunities
Bremer Energy Consulting Services, Inc.

23. Treasure Hunt Questions?
How do I take what I already have and make more efficient?
What are energy needs/profile during production mode?
Turn it off, or link to production, or reduce base load?
How can I cascade my energy usage?
How to level equipment operation vs. production needs?
Am I maintaining my equipment like I should?
Am I operating my equipment in the most efficient manner?
What equipment can we turn off at breaks or lunch?
Production Equipment Operation
Equipment on 100%
Cycle Equipment
Tie to production
Turn Off equipment
Bremer Energy Consulting Services, Inc.

24. Questions?
What time does the equipment need to start to meet production?
What time can we turn the equipment off after production?
What equipment can we turn off at breaks, lunch or between shifts?
What are the minimum and maximum set point requirements of the system or piece of equipment?
Is there wasted energy that can be recovered or reused?
What is the overall system requirement-operate1 piece of equipment at 80% instead of 2 at 40%?
Bremer Energy Consulting Services, Inc.

25. Examples
Bremer Energy Consulting Services, Inc.

26. Identify Opportunities- What to look for!
Facility Lighting
Cooling Towers and Chillers
Air Compressors
Central Air Supply and HVAC Systems
Boiler
Bremer Energy Consulting Services, Inc.

27. Compressed Air System
Bremer Energy Consulting Services, Inc.

28. TH Analysis & Calculations Tool
Bremer Energy Consulting Services, Inc.

29. Presentation of Findings
Teams build a case, supported by its calculations, to gain approval to move forward with implementation
Key Energy Treasure Hunt concepts: purpose, benefits, value
Teams and their focus areas
Top three opportunities by each team, with photos and details
List of all opportunities identified, cost and payback
Proposed next steps
Summary of requests or approvals needed from organization leadership
Bremer Energy Consulting Services, Inc.

30. Opportunity Summary
Bremer Energy Consulting Services, Inc.

31. Report Out-Top 3 Pre-Paint Hot Water Boiler
Reset hot water boiler temperature from 200F to 170F in the summer months. Parts coming in are warmer during summer and temperature at contact is required to be at least 140F.
Savings: $4,100/year
Implementation: $100
Payback Period: 0.1 years
Bremer Energy Consulting Services, Inc.

32. Other Opportunities Remove task lighting that is not needed
Solvent recovery-Best practice sharing from other sites
Film heat recovery opportunities-$7K heat availability- where to use heat?
Install additional flow meters-compressed air, gas and steam
Enhance corporate energy dash board
Involvement by process members and communication of energy opportunities
Combine chilled water systems together
Install economizer on boilers
Bremer Energy Consulting Services, Inc.

33. Energy Savings Savings = $756,449/Year Payback = 0.65 Years
9.5% of Annual Energy Spend
Behavior= 59% (<$1k)
Project=41%
Bremer Energy Consulting Services, Inc.

34. Next Steps: Plant/Corporate
Opportunities Implementation:
Evaluate and prioritize projects
Meet with operations, facility engineering and maintenance to schedule and implement
Meet periodically to evaluate progress
Communicate with all employees to summarize activity
Explore integration of treasure hunt tool with existing initiatives
Develop schedule for plant internal treasure hunt
Train the trainer approach
Bremer Energy Consulting Services, Inc.

35. Follow Up
Bremer Energy Consulting Services, Inc.

36. Requirement From Host Plant
Information: Plant operating standards, previous years energy consumption and cost, building and process equipment (large equipment only) specifications
Resources: 3 teams of 3 to 5 members per cross functional team, 3 day activity, production and non production work schedule, Management support and buy in
Plant Access: Ability to review process and facility equipment operation during production and non production time
Bremer Energy Consulting Services, Inc.

37. Conclusion
Train the trainer activity to identify opportunities but also learn the Treasure Hunt culture
Management buy in and involvement
Use both internal/external knowledge and skill
Always ask questions: Why? Why? Why? How to improve?
Share best practices and ideas
Best ideas are still just ideas unless implemented
Continuous improvement philosophy
Make Treasure Hunt philosophies part of day to day activities
Bremer Energy Consulting Services, Inc.

38. Past Treasure Hunts: Overall Summary
40 TH: industrial, manufacturing, universities & commercial
Size from 100K to 3,000K square feet
Annual energy spend from $350K to $28,000K
Savings of 3-16% of annual energy spend <1 year payback
Companies such as Navistar, Alcoa, Honda, Siemens, John Deere, 3M, Volvo, Plastipak, Intertape, and many more
Bremer Energy Consulting Services, Inc.

39. Only Use What you Need, When you Need it, In the Amount Needed!
Just In Time Energy!
Thank You!
Bruce Bremer
(859)
Bremer Energy Consulting Services, Inc.