A2A User Guideline - IfA V1

Assessments to Action (A2A)
Toolkit for the IFA:

Guidelines for Users
(Version 1)
Assessments to Action (A2A)

Toolkit for the IFA:
Guidelines for Users
(Version 1)
Developed by:
Institute for Industrial Productivity, and
ICF Marbek
16 June 2011
Contents
1
Purpose of Guideline ............................................................................................. 1
Introduction ............................................................................................................ 2
2.1
Context and Scope of IIP A2A Toolkit ............................................................ 2
2.2
Assessment Methodology .............................................................................. 4
2.3
Description of Toolkit Modules ....................................................................... 4
2.3.1
TA)
Energy Use and Technical Best Practice Assessment (Excel File: A2A
4
2.3.2 Generic Measure Library (Excel File: A2A Generic) and Ammonia
Measure Library (Excel File: A2A Ammonia)......................................................... 5
2.3.3
Energy Management System Assessment (Excel File: A2A MA) ............. 5
2.3.4
Productivity Improvement Assessment (Excel File: A2A PIA) ................... 5
2.3.5
Report Card and Opportunity Identification (Excel File: A2A RCOI) ......... 5
2.3.6
EE&M Plan Checklist (Excel File: A2A Checklist and Action Plan) ........... 6
2.3.7
EE&M Action Plan Template (Excel File: A2A Checklist and Action Plan) 6
2.4
Managing and Updating Toolkit...................................................................... 6
2.5
Structure of Guideline..................................................................................... 6
2.6
Common Elements in Tools ........................................................................... 8
Energy Use Performance and Technical Best Practices Assessment .................. 9

3.1
Description ..................................................................................................... 9
3.1.1
Objective.................................................................................................... 9
3.1.2
Variables Collected.................................................................................... 9
3.1.3
Layout of the Tool .................................................................................... 10
3.1.4
Flow of Information Between Tools ......................................................... 14
3.1.5
Using the Tool ......................................................................................... 14
3.2
Accuracy, Detail and Making Assumptions .................................................. 20
3.2.1
Average equipment capacities and operating hours ............................... 20
3.2.2
Energy Balance ....................................................................................... 20
3.3
Technical Best Practices Assessment ......................................................... 22
3.4
4
Technical Measure Library .................................................................................. 24

4.1
Objective.................................................................................................. 24
4.1.2
Variables Collected.................................................................................. 24
4.1.3
Layout of Tool .......................................................................................... 25
4.1.4
Flow of information Between the Tools ................................................... 27
4.1.5
Using the Tool ......................................................................................... 28
Management Best Practices Assessment ........................................................... 29

Description ................................................................................................... 29
5.1.1
Objective.................................................................................................. 29
5.1.2
Variables collected .................................................................................. 29
5.1.3
Layout ...................................................................................................... 29
5.1.4
5.1.5
Using the Tool ......................................................................................... 31
5.2
Productivity Improvement Assessment ............................................................... 33

6.1
Description ................................................................................................... 24
4.1.1
5.1
Ammonia Sub-Sector Specific Assessment ................................................. 22
Description ................................................................................................... 33
6.1.1
Objective.................................................................................................. 33
6.1.2
6.1.3
Layout ...................................................................................................... 33
6.1.4
Flow of information Between Tools ......................................................... 34
6.1.5
Using the Tool ......................................................................................... 34
Report Card and Opportunity Identification ......................................................... 35

7.1
Description ................................................................................................... 35
7.1.1
Objective.................................................................................................. 35
7.1.2
7.1.3
Layout ...................................................................................................... 35
7.1.4
Flow of information Between Tools ......................................................... 38
ii
7.1.5
8
Using the Tool ......................................................................................... 38
Energy Efficiency and Management (EE&M) Plan and Action Plan .................... 44
8.1
8.1.1
Objective.................................................................................................. 44
8.1.2
8.1.3
Layout ...................................................................................................... 44
8.1.4
8.1.5
Using the toolkit module .......................................................................... 46
8.2
9
Description ................................................................................................... 44
Glossary .............................................................................................................. 50
10
Abbreviations ................................................................................................... 53
11
Appendices ...................................................................................................... 54
Appendix A
Report Card checklist and Completed Report Card ....................... 54
Appendix B
A2A Energy Use and Technical Best Practice Assessment .......... 56
Appendix C
A2A Energy Management System Assessment ............................ 57
Appendix D
A2A Productivity Improvement Assessment Template .................. 58
Appendix E
A2A Checklist and Action Plan Template ...................................... 59
iii
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 .................... 14
Exhibit 9: Example of Technical Assessment Sold and self-generated fuel questions15
Exhibit 10: Example of Technical Assessment Sold and self-generated fuel questions
.................................................................................................................................... 16
Exhibit 11: Example of Technical Assessment feedstock questions .......................... 16
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 .............. 17
Exhibit 15: Example of Technical Assessment general questions (second question
group) ......................................................................................................................... 19
Exhibit 16: Example of Additional Opportunities boxes .............................................. 19
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 ....................................................................... 28
Exhibit 23: Management Best Practice Assessment index table ................................ 30
Exhibit 24: Example of Management Assessment drop down menu .......................... 31
Exhibit 25: Example of Management Assessment button selection ........................... 31
iv
Exhibit 27: Productivity Improvement Assessment index table .................................. 33

Exhibit 28: Example of Productivity Improvement Assessment multiple option
selection ..................................................................................................................... 34
Exhibit 30: Report and Opportunity Identification index table ..................................... 36
Exhibit 31: Report Card Edit Links screen................................................................ 39
Exhibit 32: Report card macro button on Tab RC 2 .................................................... 40
Exhibit 33: Report card opportunities table to be completed manually ....................... 40
Exhibit 34: Report card opportunities table to be completed manually ....................... 41
Exhibit 35: Report Card plant information to be checked ........................................... 42
Exhibit 36: Report Card product information and energy use per unit of production .. 42
Exhibit 37: Report Card pie charts .............................................................................. 42
Exhibit 38: Converting to PDF (step 2) ....................................................................... 43
Exhibit 39: Converting to PDF (steps 3 and 4) ........................................................... 43
Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan index
table ............................................................................................................................ 45
Exhibit 42: Example of EE&M Plan Checklist ............................................................. 46
Exhibit 43: Example EE&M Action Plan template. ...................................................... 48
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
Identify
Opportunities
& Define
EE&M Plan
Implement
EE&M
Action Plan
Additional
Support
A2A Toolkit
Develop
EE&M
Action Plan
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.
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
Toolkit
Obtain Commitment
Technical Assessment
(Includes Energy Use Performance
and Technical Best Practices
Assessment)
Assess Performance
and Establish
Indicators
Measure Library (incl. Ammonia

Specific)
Management Assessment
(Includes Technical Management Best
Practices Assessment)
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.
Productivity Improvement
Assessment
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
EE&M Action Plan Template
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.
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 and 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.
2.3.3
Energy Management System Assessment (Excel File: A2A MA)
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
EE&M Plan
Checklist and
Action Plan
Template
Technical
Measure Library
4
Management
Best Practices
Assessment
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 assessment1, 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
Energy Use Performance and Technical Best Practices Assessment
Exhibit 5: Tool 1 in the sequence
Energy Use
Performance and
Technical Best
Practices
Assessment
5
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template
Technical
Measure Library
4
Management
Best Practices
Assessment
Productivity
Improvement
Assessment
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:
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.
3.1.3
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.
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.
10
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.
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
11
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.
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
12
Exhibit 7: Tools in the toolkit and results to be achieved
Type
Standard
Energy
Efficient
Fluorescent
T17, T12
T5, T8
CFL's
All
Metal Halide
High Pressure
Sodium
Mercury Vapour
Incandescent
All
All other
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.
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)
13
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).
3.1.5
Using the Tool
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.
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.
14
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.
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.
15
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.
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.
16
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:
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:
17
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.
Name plate capacity of equipment with multiple motors can be grouped into
one piece of equipment.
Estimate equipment count/capacity rating/efficiency rating during walk-through
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.
18
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.
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,
19
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.
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 end-uses
and some of the energy types were hidden for this example.
20
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).
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.
21
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:
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
22
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
23
Technical Measure Library
Energy Use
Performance and
Technical Best
Practices
Assessment
5
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template
Technical
Measure Library
4
Management
Best Practices
Assessment
Productivity
Improvement
Assessment
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.
24
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.
25
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:
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.
26
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.
Reference Sources: the source of the savings percentage and measure life.
4.1.4
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
27
4.1.5
Using the Tool
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.
Exhibit 21: Measure Library Index Tab
28
Management Best Practices Assessment
Energy Use
Performance and
Technical Best
Practices
Assessment
5
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template
Technical
Measure Library
4
Management
Best Practices
Assessment
Productivity
Improvement
Assessment
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.
29
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
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.
30
5.1.4

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
Develop an Energy Efficiency and Management Plan and Action Plan using
the checklist and template tool (see section 8.2).
5.1.5
Using the Tool

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.
A Partially response implies that the measure has been considered or
A No response implies that the measure is not considered or adopted.
31
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.
32
Productivity Improvement Assessment
Energy Use
Performance and
Technical Best
Practices
Assessment
5
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template
Technical
Measure Library
4
Management
Best Practices
Assessment
Productivity
Improvement
Assessment
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.
Exhibit 27: Productivity Improvement Assessment index table
33
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

Define an Energy Efficiency and Management Plan and Action Plan using the
checklist and template tool (see section 8.2).
6.1.5
Using the Tool

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.
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.
34
Report Card and Opportunity Identification
Energy Use
Performance and
Technical Best
Practices
Assessment
5
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template
Technical
Measure Library
4
Management
Best Practices
Assessment
Productivity
Improvement
Assessment
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.
35
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.
36
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
Practices intermediate score:
37
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.
7.1.5
Using the Tool
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.
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.
38
Exhibit 31: Report Card Edit Links screen
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
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
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).
39
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:
I. 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).
II. 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
40
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:
i. 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:
41
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.
ii. 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
iii. Check that the graph axes are not cut off
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
42
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.
I.
II.
Select tab RC 1.
From the Save as menu, select PDF or XPS
Exhibit 38: Converting to PDF (step 2)
III.
Under Save as type, select PDF
Exhibit 39: Converting to PDF (steps 3 and 4)
IV.
V.
VI.
Click the options button. Under Publish what, choose Active sheets
and press ok
Click the Publish button to create the PDF.
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.
43
Energy Efficiency and Management (EE&M) Plan and Action Plan
Energy Use
Performance and
Technical Best
Practices
Assessment
5
Report Card and
Opportunity
Identification
EE&M Plan
Checklist and
Action Plan
Template
Technical
Measure Library
4
Management
Best Practices
Assessment
Productivity
Improvement
Assessment
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.
44
Exhibit 41: Energy Efficiency and Management Plan (EE&M) and Action Plan index table
There are three tabs in the Excel spreadsheet of this toolkit module:
AP 1
Plant Information
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
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.
45
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:

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
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.
46
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.
2.
3.
4.
5.
6.
7.
8.
Policy
Planning
Organization and Accountability
Financing
Project Management
Monitoring
Reporting and Communication
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.
47
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
Plan
5
Do
Time Frame
Scheduled
Status or Actions/
Date
Date
Comments
Completed
Do
Check
Act
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)
Ammonia
Production
Library
Reference #
AM-54
AM-34
Relative
Implementation
1
Difficulty
Maximum
Relative
Potential Energy
Implementation Cost2
Savings3,4
[TCE]
Maximum
Potential
Energy Cost
Savings4
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
Responsibility
Assigned to:
Scheduled
Date
Status or
Actions/
Date Completed Comments
Library Description
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.
48

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.
49
Glossary
5S
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.
50
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, tin 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.
51
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.
52
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
53
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.
i. Data Edit Links
ii. Select A2A MA from the list of sources
iii. Click the Change Source button
iv. Select the Management Assessment file and press Ok
v. Click the Open Source, then go back to the Report Card Screen
vi. Select A2A TA from the list of sources
vii. Click the Change Source button
viii. Select the Technical Assessment file and press Ok
ix. Click the Open Source button, then go back to the Report Card screen
x. Select A2A Ammonia Library from the list of sources
xi. Click Update values
xii. Select A2A Generic Library from the list of sources
xiii. Click Update values
xiv. 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).
54
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)
Select tab RC 1.
From the Save as menu, select PDF or XPS
Under Save as type, select PDF
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.
1.
2.
3.
4.
55
Appendix B
A2A Energy Use and Technical Best Practice Assessment
56
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
Industry
Category
Registrated Capital
Contact Phone Number
Post Code
Fax Number
Energy conservation Manager
(secondary)
Phone number
E-mail address
Energy conservation Manager (primary)

Phone number
E-mail address
Auditor Information
Name of Auditor
Auditor's Organization /
Company Name
Title of Auditor
Date of Audit
Evaluation year (for purchased &
utilized energy)
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
A2A Toolkit
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).
LHV*
GJ per
[kg or m3]
Fuel Type
Quantity
2009
2008
2009
Electricity
Natural Gas
kWh
0.03897
m3
Gasoline
0.04311
ton (metric)
Diesel Oil (transport)
0.04269
ton (metric)
LPG
0.05023
ton (metric)
Fuel Oil type (select)
ton (metric)
Fuel Oil type (select)
ton (metric)
Gas type (select)
m3
Gas type (select)
m3
Gas type (select)
m3
Biomass type (select)
ton (metric)
Biomass type (select)
ton (metric)
Other Fuel (select)
ton (metric)
Other Fuel (select)
ton (metric)
Steam quantity
0.00090
ton (metric)
Steam Temp [k]
483 K
Steam Pressure[bar]
22 bar
Cost ($)
Units
Cost/unit (current year)

2008
per
*LHV's can be overwritten for coal or other fuels which may vary in energy content
IIP / ICF Marbek
TA 2
Page 2 of 28
A2A Toolkit
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
Quantity
2008
Units
[ton or k m3]
NON-RENEWABLE (eg. coke, oven gas, still gas),

BIOMASS (eg.hog fuel, pulping liquor) or
RENEWABLE FUEL (eg. wind, geothermal, solar)
A.2.2 Co-generation Energy Form
Electricity
kWh
Steam
0.00090
ton (metric)
483 K
22 bar
Steam Temp [k]

Steam Pressure[bar]
A.2.3 Sold Energy Products
Electricity
kWh
Steam Quantity
0.00090
ton (metric)
Steam Source fuel

Steam Temp [k]
Steam Pressure[bar]
Coke
Biomass
IIP / ICF Marbek
483 K
22 bar
ton (metric)
ton (metric)
0.02846
TA 2
Page 3 of 28
A2A Toolkit
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.
Product Description
Annual Energy Consumption (all fuel

and feedstock)
[GJ]
2009
2008
Quantity
Units
[please provide]
2009
2008
2009
Energy Consumption (all fuel and

feedstock) [GJ per unit of product]
2009
2008
2008
% Change
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 (%)
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
Natural Gas
0.03897
*LHV's can be overwritten for coal or other fuels which may vary in energy content
IIP / ICF Marbek
Total fuel and feedstock

Units
2008
m3
TA 2
2009
2008
Page 4 of 28
A2A Toolkit
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
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*]
COOLING / REFRIGERATION COMPRESSORS
Average Age of
Equipment
[years]
Annual
Operating
Time
[hrs]
Annual Energy
Use
[GJ]
Total: 0.0E+00
-
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
A2A Toolkit
What are some other features of the Heating Equipment? Please respond to the following questions.
Equipment
Nameplate Capacity
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
IIP / ICF Marbek
TA 3
Page 6 of 28
A2A Toolkit
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
IIP / ICF Marbek

Smart demand-based defrost controls
Rating
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
TA 3
Page 7 of 28
Appendix E
A2A Checklist and Action Plan Template
59
A2A Toolkit
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
Rating
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
B.1.23
Heat from the flue gas is recovered and used
B.1.24
At least 90% of insulation is in good condition
B.1.25
Systems have advanced heating/process controls
B.1.26
Infrared or radiant heating is used instead of convection heating
B.1.27
Air curtains or other methods are used at the inlet/outlet of the oven/dryer to minimise
loss of hot air.
B.1.28
Adjust air-fuel ratio to optimize combustion efficiency
B.1.29
Equipment is included in regularly scheduled preventative maintenance program and

includes combustion efficiency testing.
IIP / ICF Marbek
TA 3
Rating
Page 8 of 28
A2A Toolkit
Additional Opportunities Identified (Describe)
BOILERS
IIP / ICF Marbek
TA 3
Page 9 of 28
A2A Toolkit
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.
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]
Units
[ kW / MW]
Total number
of equipment
in each
Capacity
Range
Energy Source
[nat.gas / elec. /
etc]
Go to Section B-3
Number of high
efficiency
equipment
[enter number or
NTF*]
AIR COMPRESSORS FOR PNEUMATIC EQUIPMENT
Average Age of
Equipment
[years]
Annual
Operating
Time
[hrs]
Annual Energy
Use
[GJ]
Total: 0.0E+00
-
AIR OR GAS COMPRESSORS FOR PROCESS
Total: 0.0E+00
-
IIP / ICF Marbek
TA 4
Page 10 of 28
A2A Toolkit
Features
B.2.1

Energy efficient air dryers are used
Multiple compressors are controlled by optimal sequencing/integrated control system
Rating
B.2.2
B.2.3
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
B.2.4
B.2.5
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.
B.2.6
B.2.7
B.2.8
B.2.9
B.2.10
B.2.11
B.2.12
B.2.14
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.
Compression ratio is annually evaluated and optimized
Rating
Internal parts of centrifugal compressors have been retrofit to improve efficiency

B.2.15
B.2.16
B.2.17
B.2.18
B.2.19
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
B.2.20
B.2.21
IIP / ICF Marbek
Synchronous belts are used.
TA 4
Page 11 of 28
A2A Toolkit
Additional Opportunities Identified (Describe)

IIP / ICF Marbek
TA 4
Page 12 of 28
A2A Toolkit
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)
Annual
Energy Use
[GJ]
NTF*]
PUMPS
Total: 0.0E+00
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
IIP / ICF Marbek
TA 5
Page 13 of 28
A2A Toolkit
Conveyor
Number
Type of system Synchronous belts
enter
[pneumatic /
used?
characteristics of mechanical]
[yes/No/NTF*]
up to 5 systems
Drive details
Average Age
[direct couple
of Equipment
drive / ASD /
[years]
etc]
1
2
3
4
5
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
Rating
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.
Motive Equipment Opportunities Identified (Describe)

Pumps/Fans/Other motors/Conveyors
IIP / ICF Marbek
TA 5
Page 14 of 28
A2A Toolkit
B.4 ONSITE TRANSPORT EQUIPMENT

This section includes onsite transport vehicles used at your facility.
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
Rating
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)
IIP / ICF Marbek
TA 6
Page 15 of 28
A2A Toolkit
C.1 LIGHTING
This section includes lighting system features in the entire facility
What lighting is present at the facility?
Type of Lighting
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
Fluorescent and
CFL's
0
0
0
0
Metal Halide
0
0
High Pressure
Sodium
0
0
0
0
Incandescent and
Other
0
0
0
Does your lighting system include the following?

Features
C.1.1
C.1.2
C.1.3
C.1.4
C.1.5
IIP / ICF Marbek
Rating
Location
[interior / exterior /
both]
Latest system design

change
[MM / YY]
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
TA 7
Page 16 of 28
A2A Toolkit
Lighting System Energy Efficiency Opportunities Identified (Describe)
Control:
Equipment / Technology:
Other:
IIP / ICF Marbek
TA 7
Page 17 of 28
A2A Toolkit
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
Number of
Energy Source
equipment
[nat.gas / elec /
in of this
etc]
type
[eg. radiant heaters/

convection heaters /
chillers / window air
conditioning]
Avg Unit Heating

Capacity
Units
[ kW /
MW]
Rated
Capacity
Number of
high efficiency
Average
equipment
Equipment
[enter number
Units
Age
or NTF*]
[cooling ton
Avg Unit Cooling

Capacity
Rated
Capacity
[years]
/ kW / HP]
Annual
Operating
Time
[hrs]
Annual
Energy Use
[GJ]
Total: 0.0E+00
Does your plant contain any /all equipment below for ventilation?
Process equipment description
Energy Source
[nat.gas / elec / etc]
Total Motor Power

Units
Rated
[ kW /
Capacity
MW]
Average
Equipment
Age
[years]
Annual
Operating
Time
[hrs]
Annual
Energy Use
[GJ]
Air make-up system(s)
Air exhaust system(s)
Total: 0.0E+00
IIP / ICF Marbek
TA 8
Page 18 of 28
A2A Toolkit
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
Set back temperatures when facility is not occupied, e.g. during weekends
C.2.5
C.2.6
C.2.7
C.2.8
C.2.9
C.2.10
C.2.11
C.2.12
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
C.2.13
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.
C.2.14
C.2.15
C.2.16
IIP / ICF Marbek
Rating
System uses demand-controlled ventilation

The HVAC system is included in scheduled preventative maintenance
program.
TA 8
Page 19 of 28
A2A Toolkit
HVAC Opportunities Identified (Describe)
HVAC
Other Heating Equipment
Air Make-up and Exhaust

Other
IIP / ICF Marbek
TA 8
Page 20 of 28
A2A Toolkit
D.1 OTHER PROCESS EQUIPMENT

This section includes other major energy consuming equipment, control systems and other emerging
technology implemented or under consideration.
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.
Equipment Category / Type

(eg. Stamping machines, grinders)
Energy Source
IIP / ICF Marbek
Avg Rated Capacity

Units
Power
[kW /
MW]
Annual
Operating
Time
[hrs]
Annual Energy
Use
[GJ]
Total:
TA 9
Page 21 of 28
A2A Toolkit
D.2 GENERAL FACILITY PRACTICES

Please indicate if your facility practices include any of the following?
Features
Rating
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
carried
out regularly
D.2.7 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
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
A2A Toolkit
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 ?
Description of industryspecific equipment
Process Step
[pre treatment, synthesis,
etc]
Number of
equipment in
Rated Capacity
Range
Energy Source
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
A2A Toolkit
E.2 AMMONIA PROCESS PRACTICES - General

Features
Rating
E.2.1
Installation of Gas Turbine to drive process air compression, using hot exhaust gases
E.2.2
E.2.3
E.2.4
Isothermal CO converter with built in heat exchanger
E.2.5
Improved Design for Shift Converter Gas Distributor and Collector
E.2.6
Hydrogen separation and recovery from synthesis gases
E.2.7
Enhanced CO2 removal solvents
E.2.8
Pressure Swing Adsorption for product purification
E.2.9
Improved Ammonia synthesis catalysts
Axial-radial flow converter to improve conversion efficiency and reduce pressure drop
Improved catalysts in Shift Process
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
A2A Toolkit
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
Adiabatic pre-reformer to reduce primary reformer duty
E.3.2
Waste heat recovery from reformer using heat exchanger reactor
E.3.3
Waste Heat Recovery from reformer flue Gas
E.3.4
Improved insulation of reformer furnace
E.3.5
Modified reformer operating Pressure
E.3.6
Lower reformer steam-carbon ratio to reduce primary reformer heat demand
E.3.7
Optimized shift reformer duty balance between primary and secondary reformer
E.3.8
Waste Heat to preheat fuel gas
E.3.9
High Pressure water power recovery turbine to drive absorbent liquid pump
Rating
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
A2A Toolkit
Energy Balance
Equipment energy-reported 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
8
Biomass /
Other fuel
-
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
Fuel Oil
Gasoline
Propane
Diesel
-
Other fuels
-
Gasoline
-
Propane
-
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

Boilers
Fans, Motors, Pumps
Heavy Transport
HVAC and Air System
Ammonia production
Lighting
Total energy/year
IIP / ICF Marbek
Electricity
-
Natural Gas
-
Diesel
-
Fuel Oil
-
TA 11
Other fuels
-
Steam
-
Page 26 of 28
A2A Toolkit
Year of Evaluation
Energy Share By End Use
All Energy
Boilers
Fans, Motors, Pumps
Heavy Transport
HVAC and Air System
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]
Electricity
Natural Gas
Diesel
Fuel Oil
Gasoline
Propane
Other fuels
Steam
Total
IIP / ICF Marbek
Annual Purchased
Energy Cost [$]
GJ
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Annual Purchased Energy Cost

[$]
Cost ($)
Natural
Other
Electricity
Gasoline
Propane
Fuel
Steam
Diesel
fuels
Oil
Gas
0%
TA 11
Page 27 of 28
A2A Toolkit
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
57
A2A Toolkit
Energy Management System Assessment
Institute for Industrial Productivity

TO DO:
STEP 2 - Review instructions sheet and complete the questions on the next pages.
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
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
Page 1 of 10
MA 1
A2A Toolkit
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
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]
1.7
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
IIP / ICF Marbek
Page 2 of 10
MA 2
A2A Toolkit
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
Yes
No
Partially
Yes
No
Partially
The company has a documented energy management planning process which annually:
sets targets for controlling energy use and cost;
2.1.3
Yes
No
Partially
defines actions to reduce energy costs and achieve the energy performance targets;
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
2.1.4
2.1.5
2.1.6
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.
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)
IIP / ICF Marbek
Page 3 of 10
MA 3
A2A Toolkit
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
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).
IIP / ICF Marbek
Page 4 of 10
MA 3
A2A Toolkit
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.
IIP / ICF Marbek
Page 5 of 10
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
MA 3
A2A Toolkit
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
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
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.
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.
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)
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.
3.2.3
IIP / ICF Marbek
Page 6 of 10
MA 4
A2A Toolkit
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
3.3.6
3.3.7
3.3.8
3.3.9
3.3.10
3.3.11
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.
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.
3.3.12
IIP / ICF Marbek
Page 7 of 10
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
MA 4
A2A Toolkit
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.
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
IIP / ICF Marbek
Page 8 of 10
MA 4
A2A Toolkit
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
Yes
No
Partially
Yes
No
Partially
3.5.3
Utility bill management.
Yes
No
Partially
3.5.4
Fuel substitution and/or use of renewable energy sources.
Yes
No
Partially
3.5.5
On-site power generation.
Yes
No
Partially
3.5.6
Improved energy management information systems.
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
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
3.5.7
3.5.9
3.5.10
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.
3.5.11
3.5.12
Project Implementation
3.5.15 The plant has implemented a procedure to manage the implementation of energy management projects.
3.5.16
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.
IIP / ICF Marbek
Page 9 of 10
MA 4
A2A Toolkit
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.
3.6.4 Energy use and energy management is included in orientation training for new personnel.
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
Yes
No
Partially
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.
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
58
A2A Toolkit
Institute for Industrial Productivity

Productivity Improvement Review
TO DO:
STEP 2 - Please complete the questions on the next page.

Plant Name
Company Name
Plant Address:
Street and number
City
Province
Postal code
Plant Contact Info
Name
Title (Position)
E-mail Address
Telephone Number
Auditor Information
Name of Auditor
Title of Auditor
Auditor's Organization /
Company Name
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
Page 1 of 3
PI 1 - Plant Information
A2A Toolkit
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
A2A Toolkit
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)
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?
IIP / ICF Marbek
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
Development/Implementation of tools and techniques

Management training
Employee training
Events and activities to identify waste reduction opportunities
Page 3 of 3
A2A Toolkit
Checklist and Action Plan
Energy Efficiency and Management Plan

TO DO:
STEP 2 - Complete the questions on the following tabs as per instructions on each page
Plant Name
Company Name
Plant Address:
Street and number
City
Province
Postal code
Plant Contact Info
Name
Title (Position)
E-mail Address
Telephone Number
Auditor Information
Name of Auditor
Title of Auditor
Auditor's Organization / Company
Name
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
A2A Toolkit
Outline of Energy Efficiency and Management Plan

EE&M Plan: Table of Content
1
Policy
Planning
Financing
Project Management
Monitoring
10
Other Elements
IIP / ICF Marbek
AP 2
Page 2 of 9
A2A Toolkit
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
Status
Details
Priority
(Y/N/Partially)
1
1.1
Does the EM Plan include a documented corporate energy

policy?
1.2
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?
1.3
2
2.1
2.2
2.4
2.5
2.6
(high/med/low)
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.
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.
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?
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.
Does the EM Plan include a process to develop, review and, if

necessary, modify an Energy Management Information
System (EMIS)?
IIP / ICF Marbek
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.
AP 3
Page 3 of 9
A2A Toolkit
3.1
Does the EM Plan identify a designated manager responsible

for implementing corporate energy policy and assign
authority and accountability to achieve energy performance
targets?
3.2
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?
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?
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.
Financing
4.1
Does the EM Plan include procedures to ensure energy

performance is a criteria in capital project evaluation?
4.2
Does the EM Plan include procedures for developing a

business case for projects that integrates energy
management prior to project approval?
4.3
Does the EM Plan address energy performance as part of the

plant's procurement activities?
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.
4.4
Does the EM Plan identify criteria to be considered when

energy (fuel) is purchased, which includes the fuel impact on
energy management?
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.
IIP / ICF Marbek
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.
AP 3
Page 4 of 9
A2A Toolkit
Project Management
5.1
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.
5.2
Does the EM Plan identify how human and financial resources

are allocated to oversee management and implementation of
energy management projects?
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.
5.3
Does the EM Plan include a process to review and identify

energy management best practices and project
opportunities?
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.
Monitoring
6.1
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.
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.
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?
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.
6.3
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?
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.
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?
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.
IIP / ICF Marbek
AP 3
Page 5 of 9
A2A Toolkit
7.1
Does the EM Plan include a method and frequency of

communicating corporate energy management policy and key
energy management performance indicators to all
employees?
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.
7.2
Does the EM Plan identify the energy performance metrics to

be communicated internally and/or externally?
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.
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?
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.
8.1
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.
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?
8.3
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?
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.
8.4
IIP / ICF Marbek
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.
AP 3
Page 6 of 9
A2A Toolkit
9.1
Does the organization identify and prioritize energy savings

opportunities and review at established and regular intervals?
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.
9.2
Has the organization prioritized the energy performance

improvement opportunities to be assessed, and/or carried
out?
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.
9.3
Does the organization identify and prioritize productivity

improvement opportunities and review at established and
regular intervals?
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.
9.4
Has the organization prioritized productivity improvement

opportunities to be assessed, and/or carried out?
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.
10 Other Elements
10.1
Does company policy and practices confirm to relevant laws,

regulations and agreed rules?
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.
10.2
Are energy management and productivity improvement

practices and systems documented (electronically or in
writing) with references made to relevant procedures?
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.
10.3
Are non-conformances to energy management and

productivity improvement systems managed, with cause
analysis and corrective action deployed?
Analyze non-conformance occurrences, and ensure that corrective measures are taken to
prevent reoccurrences.
IIP / ICF Marbek
AP 3
Page 7 of 9
A2A Toolkit
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
Responsibility
Assigned to
Plan
1
Policy
Planning
Financing
Project Management
Monitoring
Implementation of Identified Opportunities (Including Technical Best Practices

and Productivity Improvement)1.
Marbek / IIP
Do
Maximum Potential
Maximum Potential
Energy Savings2,3
Energy Cost Savings3
[GJ]
Relative
Implementation
Cost4
AP 4
Relative
Implementation
Difficulty5
Time Frame
Scheduled
Status or Actions/Comments
Date
Date
Completed
Do
Responsibility
Assigned to:
Scheduled
Date
Check
Act
Status or
Actions/Comments
Date Completed
Page 8 of 9
A2A Toolkit
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

A2A User Guideline - IfA V1

Diunggah oleh

Informasi Dokumen

Deskripsi Asli:

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

A2A User Guideline - IfA V1

Diunggah oleh

Hak Cipta:

Format Tersedia

Assessments to Action (A2A)

Toolkit for the IFA:

Assessments to Action (A2A)

Purpose of Guideline ............................................................................................. 1

Context and Scope of IIP A2A Toolkit ............................................................ 2

Assessment Methodology .............................................................................. 4

Description of Toolkit Modules ....................................................................... 4

Energy Management System Assessment (Excel File: A2A MA) ............. 5

Productivity Improvement Assessment (Excel File: A2A PIA) ................... 5

Managing and Updating Toolkit...................................................................... 6

Common Elements in Tools ........................................................................... 8

Energy Use Performance and Technical Best Practices Assessment .................. 9

Layout of the Tool .................................................................................... 10

Flow of Information Between Tools ......................................................... 14

Using the Tool ......................................................................................... 14

Accuracy, Detail and Making Assumptions .................................................. 20

Average equipment capacities and operating hours ............................... 20

Energy Balance ....................................................................................... 20

Technical Best Practices Assessment ......................................................... 22

Technical Measure Library .................................................................................. 24

Layout of Tool .......................................................................................... 25

Flow of information Between the Tools ................................................... 27

Using the Tool ......................................................................................... 28

Management Best Practices Assessment ........................................................... 29

Variables collected .................................................................................. 29

Flow of Information Between Tools ......................................................... 31

Using the Tool ......................................................................................... 31

Accuracy, Detail and Making Assumptions .................................................. 32

Productivity Improvement Assessment ............................................................... 33

Ammonia Sub-Sector Specific Assessment ................................................. 22

Variables collected .................................................................................. 33

Flow of information Between Tools ......................................................... 34

Using the Tool ......................................................................................... 34

Report Card and Opportunity Identification ......................................................... 35

Variables collected .................................................................................. 35

Flow of information Between Tools ......................................................... 38

Using the Tool ......................................................................................... 38

Variables collected .................................................................................. 44

Flow of Information Between Tools ......................................................... 45

Using the toolkit module .......................................................................... 46

Accuracy, Detail and Making Assumptions .................................................. 49

Report Card checklist and Completed Report Card ....................... 54

A2A Energy Use and Technical Best Practice Assessment .......... 56

A2A Energy Management System Assessment ............................ 57

A2A Productivity Improvement Assessment Template .................. 58

A2A Checklist and Action Plan Template ...................................... 59

Exhibit 27: Productivity Improvement Assessment index table .................................. 33

2.1 Context and Scope of IIP A2A Toolkit

Measure Library (incl. Ammonia

Report Card and Opportunities

EE&M Action Plan Template

Definition and understanding of the

Training and Capacity Building of Trainers and Auditors

2.2 Assessment Methodology

2.3 Description of Toolkit Modules

Generic Measure Library (Excel File: A2A Generic) and Ammonia

Energy Management System Assessment (Excel File: A2A MA)

Productivity Improvement Assessment (Excel File: A2A PIA)

The productivity improvement assessment tool is used to obtain information to

Report Card and Opportunity Identification (Excel File: A2A RCOI)

2.4 Managing and Updating Toolkit

2.5 Structure of Guideline

2.6 Common Elements in Tools