October 2013 Vol. XVII, No. 12
- Call for nominations for the CIPEC Leadership Awards - new deadline
- Employee awareness campaign accounts for nearly 25 percent energy savings at KI
- CIPEC webinar highlights the value of motor management
- Groupe Leclerc takes holistic view on resource savings
- On-Farm Energy Management Program popular with Alberta farmers
- Efficiency Nova Scotia's On-Site Energy Manager program a sound business cost-saving solution for industry
- CIPEC upcoming meetings
- Dollars to $ense Energy Management Workshops – fall schedule
- Call for story ideas
Call for nominations for the CIPEC Leadership Awards - new deadline
Applicants now have until March 3, 2014 to submit nominations for the CIPEC Leadership Awards, which will be presented at Energy Summit 2014 in Niagara Falls (more information on the conference will follow). Industrial companies, students and graduates that have completed an energy efficiency project or initiative between June 1, 2011 and March 3, 2014, are now eligible to apply for this prestigious award.
Since their inception in 2005, the CIPEC Leadership Awards have showcased the outstanding achievements of CIPEC companies that have distinguished themselves in their work to improve energy efficiency and reduce greenhouse gas emissions (GHG). Since 2011, the CIPEC Leadership Awards have also honoured post-secondary students and graduates whose projects or initiatives demonstrate energy efficiency improvements in industrial settings or applications.
Winning a CIPEC Leadership Award has numerous perks. In addition to presenting an award to recipients, Natural Resources Canada (NRCan) will recognize all winners in the CIPEC Annual Report and national news releases. Recipients will also be featured in CIPEC’s newsletter, Heads Up CIPEC, which is delivered to more than 10 000 industry and government officials.
The CIPEC Leadership Awards comprise the following six categories:
Corporate Stewardship Award – recognizes companies that promote energy efficiency at the corporate level, such as the creation and engagement of an energy management team, the development of a corporate energy management plan or policy, or the implementation of a formalized management system.
Process and Technology Improvement Award – recognizes companies that reduce energy intensity in an industrial process by improving procedures and equipment such as refrigeration or compressed air systems.
Energy Performance Management Award – recognizes companies that improve their energy performance through enhancements to their monitoring, measuring and reporting processes relating to facility or company-wide energy consumption.
Employee Awareness and Training Award – recognizes companies that raise employee awareness and understanding of energy efficiency and promote best practices through knowledge exchange.
Integrated Energy Efficiency Strategy Award – recognizes companies that improve energy efficiency at a facility or company-wide level through a range of initiatives as a result of an integrated strategy.
Future Leaders Award – recognizes individuals who are studying or have recently graduated and have completed a project (theoretical or applied) that advances industrial energy efficiency in Canada.
All nominated energy efficiency projects or initiatives will be evaluated by a panel of judges against the following criteria:
- Energy performance – reduction in energy use per unit of production
- Innovation – ingenuity and creativity in the use of an improved or novel idea, method, or process
- Potential for broad application – transferability to other companies or industry sectors
- Environmental contribution – reduction in GHG emissions and improvement in environmental sustainability
To be considered for an award, facilities or companies must be registered with Natural Resources Canada as a CIPEC Leader. Future Leaders Award nominees must be energy-related practitioners who are either enrolled in an academic institution or have recently graduated (up to five years) and who have completed research or a project pertaining to energy efficiency in the industrial sector.
All projects nominated for the 2014 CIPEC Leadership Awards must have been completed between June 1, 2011, and March 3, 2014. The deadline for submitting completed nominations to CIPEC at Natural Resources Canada is March 3, 2014.
To register your interest in the 2014 CIPEC Awards, please send a request to
Canadian Industry Program for Energy Conservation
Natural Resources Canada
580 Booth Street, 12th Floor
Ottawa ON K1A 0E4
Employee awareness campaign accounts for nearly 25 percent energy savings at KI
“We are building a lot of momentum around energy efficiency simply by increasing employee awareness about it,” says Michael Kelly, Process Engineer and Engineer Champion at KI Pembroke, a CIPEC Leader in the General Manufacturing sector. He explains further, “I have to credit our technicians for their continued participation in our awareness campaign; they have allowed us to take our energy efficiency initiatives to a whole new level with their incredible buy-in.” Kelly attributes the buy-in and subsequent energy savings, in part, to a two-day Dollars to $ense customized energy management workshop offered by NRCan’s Office of Energy Efficiency.
KI’s Pembroke, Ontario facility manufactures steel office furniture destined for the corporate or government market. The facility is approximately 25 000 square metres and operates on a two-shift schedule consisting of fabrication, welding, paint and assembly.
Kelly explains that the facility’s momentum towards energy sustainability started last October when the new corporate energy policy was rolled out. Soon after, the facility became ANSI/BIFMA e3-2012 Furniture Sustainability Standard certified, having obtained the Business and Institutional Furniture Manufacturers Association certification that specifies energy and water use. The Dollars to $ense workshops – Spot the Energy Management Savings Opportunities and Energy Monitoring – were the next key pieces in KI Pembroke’s momentum towards energy management. “From there on we built our energy awareness campaign and energy management plans,” notes Kelly, adding that, “thanks to this campaign we have reduced our energy consumption by an estimated 25 percent simply by changing employee behaviour.” KI has energy teams and champions at every subsidiary who are responsible for crafting new energy initiatives.
Even prior to the new energy policy, KI Pembroke had already significantly reduced its energy consumption through various measures. For example, annual electricity use was reduced from 6.8 to 3.8 gigawatt hours (GWh) between 2009 and 2012, while yearly gas consumption decreased from 2.2 million to 1.3 million cubic metres (m3).
For 2013, “our target is a 10 percent energy reduction over the 2012 baseline normalized against sales figures, namely 840 000 kWh of electricity and 200 000 m3 of gas,” states Kelly. The facility has already exceeded that goal by saving 425 000 m3 in natural gas and 970 000 kWh in electrical consumption in the first eight months of 2013. Water conservation has also been a focus, says Kelly, noting that so far in 2013, various measures have resulted in saving over 1.3 million gallons of water. These savings represent reductions of 35, 43 and 35 percent compared to 2012 consumption for electrical, gas and water use, respectively.
Kelly attributes the reduction in gas consumption largely to setbacks and effective shutdown procedures, which were direct results of the awareness campaign. “Shutdown and setbacks used to be maintenance staff responsibilities; now every employee has taken on that responsibility.” Moreover, six 24-foot ceiling de-stratification fans (low velocity/high volume) were installed and have resulted in a much reduced need for space heating; another two will be installed in early 2014. Shipping doors have been insulated and wall leaks are continuously identified and sealed.
Electrical savings are also due, in large part, to the facility’s energy awareness campaign since employees are now shutting off motors, compressors, HVAC systems and associated pumps when not needed. Kelly explains that one-quarter of the electricity consumption savings are due to upgraded compressor controls on the facility’s three 300-hp and one 175-hp compressors. Newly installed automatic controls now analyze pressure demands, avoiding any demand mismatches; this project had a four-month payback period.
Kelly notes that timers on about 50 percent of equipment motors were installed to avoid the need for manual shutdown. Additionally, the installation of variable frequency drives has reduced peak demand.
On the horizon is the installation of radiant heat in the shipping area and the warehouse to replace inefficient forced air heating. There are also plans to install VFDs in the paint lines and the process ovens. Heat pipes and other heat recovery alternatives will be reviewed after the VFDs have been installed. Kelly also envisions roof-top solar farms or solar walls in the future, saying that “we are always looking for new ideas to reduce our energy use.”
A public event on September 9 showcased the company’s successful energy initiatives to its employees and clients. Residential incentives and free home energy savings prizes from Hydro One, Enbridge Gas and Ottawa River Power Corporation supported the next phase of the company’s 2013 Energy Awareness Campaign, which is to encourage energy conservation in employees’ homes and within the Pembroke community. “We want to make energy visible in their daily lives – at home and at work.”
CIPEC webinar highlights the value of motor management
Recent Office of Energy Efficiency (OEE) webinars provided an introduction to industrial motor management. Over 350 participants learned about various tools and available resources that could assist them in motor management decisions.
Taylor Lallemand, Industrial Program Associate at the Consortium for Energy Efficiency (CEE) explained that Motor Decisions MatterSM (MDM) is a binational awareness campaign promoting management practices to help improve reliability and efficiency in motor-driven systems. Motor management, defined by the sponsors, is a set of ongoing business policies and practices that help commercial and industrial customers efficiently manage their motor fleet. These policies and practices include repair-replace decision making based on lifecycle cost and planning in advance of failure, thus reducing equipment downtime and, ultimately, energy costs. Helpful MDM tools are available to implement management practices including the Motor Planning Kit with resources on motor selection and consideration for drives in proper applications, as well as calculation tools to quickly estimate potential savings including the Simple Savings Chart and the MotorSlide Calculator. “Our tools are a great way to get started on motor management by identifying savings and making a motor management plan,” notes Lallemand.
Terry Brennan, Senior Standards Engineer at Natural Resources Canada, provided an overview of NRCan’s CanMOST tool. The downloadable CanMOST software is free and easy to use and makes it possible for users to select efficient motors and to calculate the energy and cost savings over a motor’s life. Brennan noted that “users can also find data on new motors or compare new, rewind or replacement options.” CanMOST is based on the U.S. MotorMaster+ tool and the International Motor Selection and Savings Analysis (IMSSA) but has some additional features including a French version, the ability to calculate greenhouse gas emissions reductions, and data for 575 volt motors.
Vladimir Rabinovitch, Project Manager of Manufacturing & Engineering at Global Wood Group gave an industry perspective of motor management. He noted that the dust collection systems at both of the company’s Toronto facilities account for 31 percent of hydro use. Given the potential for energy savings, a new system – EcoGate’s Smart Dust Collection System – was piloted at one of the plants. Rabinovitch provided participants with a detailed account of the EcoGate system, its installation and the 50 percent savings achieved. He advised others to take the time to research the best available technology and to invest in variable speed drives and control systems to maximize energy savings.
Numerous questions followed the presentations. One participant asked about estimating motor efficiency with variable frequency drives (VFDs) at higher or lower pressure. Brennan noted that a system to assess this is being investigated. Measuring efficiency of VFD motors depends on the imposed load, and while data is lacking, efficiency losses are most likely when VFD motors are used above rated loads.
When asked about CanMOST, Brennan indicated that the software is loaded with default settings that can be overridden with data that reflect the user’s situation. These include motor pricing, operating hours, rewind efficiency losses and electricity charges to name a few. “Most of the functions can be manipulated using the Options Page or in the analysis page itself.”
Rabinovitch was asked if electronically-mutated motors (i.e. the new VFD permanent magnetic motors) could replace the older standard pole motors that are typically used in refrigeration units and if the new motors would also be suitable as small fan motors for evaporator applications. He noted that SI Energy has developed such motors with VFDs for different purposes but based on the same principle. One webinar attendee added that while these motors are very efficient, they also have high power density and, therefore, might require particular considerations/system modifications.
Asked about the difference between the Canadian and American motor tools, Brennan noted that the U.S. version, MotorMaster+, has more functionality but that the Canadian software has some unique features, including functions that reflect Canadian utility rate structures. A participant added that MotorMaster+ has the ability to maintain an in-plant motor inventory that includes maintenance logs for the management of individual motor and back-ups. Batch runs of hundreds of motors to identify replacement candidates are also possible with this software.
Building on the success of the webinars, the OEE’s Industry and Transportation Division is planning a Motor Management Part 2 webinar to be presented in December. For more information, contact Francis Charette, Program Officer, Industry and Transportation Division, tel.: 613-996-7744 or e-mail Francis.Charette@nrcan-rncan.gc.ca.
Groupe Leclerc takes holistic view on resource savings
“It’s the company’s philosophy to control and reduce energy and other resource consumption and move towards renewable energy and resource strategies,” says Wilson Ochoa, Director of Corporate Social Responsibility at Groupe Leclerc. The company is actively implementing and investigating a variety of electricity, natural gas, water and other resource reduction measures.
Groupe Leclerc, a CIPEC Leader in the Food and Beverage sector, is a manufacturer of snack bars, cookies and crackers with two plants in Quebec, one in Ontario and two in the United States, with a total of over 650 employees.
Several years ago, Groupe Leclerc carried out an energy analysis of its facilities that resulted in major changes to its Canadian plants. Upgrades included lighting retrofits, compressed air repairs and a biofiltration project for its waste water.
Ochoa explains that the lighting retrofit is almost completed in all plants with only a few fixtures left to replace and motion detectors to install. All T-12 and metal halide lamps have been or are being replaced with T-5 and T-8 fixtures. Ochoa estimates that there are about 1000 fixtures per facility. In their respective plants, both Hydro-Québec and Hydro Ottawa helped to bring this retrofit project to a payback period in under eighteen months. At the Ontario facility, the retrofit has already saved 140 000 kilowatt hours (kWh) of electricity a year.
Repairs to leaks in compressed air systems at its Quebec facilities have saved the company 324 000 kWh in electricity annually. There has also been work to insulate hot and cold zones, particularly in the Quebec warehouse, along with the installation of a geothermal system back in 2004 that considerably reduced building heating and cooling costs.
“In 2006, boiler heat recovery projects were completed in order to heat cleaning water, and several other heat recovery projects are currently underway,” says Ochoa. He notes that gas meters have been installed in all the plants and that a heat recovery pilot project, at one of the Quebec plants, will redirect heat from the compressor room for space heating.
At the same time, the company is working on a number of water consumption reduction initiatives. “We are currently testing dry-blasting and steam cleaning as alternatives to conventional facility cleaning.” One of the company’s plants in Quebec has a physico-chemical treatment plant on site for the treatment of the facility’s wastewater. After more fine-tuning, Ochoa expects the system to save a significant amount of transportation costs (i.e., fuel) by reducing the amount of sluge produced annually, aiming for a 50 percent reduction. Groupe Leclerc is also working to reduce and reuse its waste materials and is actively investigating ways to optimize its packaging.
On-Farm Energy Management Program popular with Alberta farmers
“We are seeing significant uptake from farmers,” says Jason Price, On-Farm Energy Management Program at Alberta Agriculture & Rural Development, about the current program designed to improve energy efficiency on Alberta farms.
The program is part of the Growing Forward 2 funding initiative whose goal is to increase industry competitiveness and improve environmental stewardship and energy management.
Price explains that the program offers a cost-sharing incentive of 50 percent for eligible projects to a maximum of $50,000 for producers creating a minimum of $10,000 in farm commodity or livestock income. Construction and retrofit projects using high-efficiency equipment can qualify, as can the installation of sub-meters.
Cost-sharing is available for equipment such as energy curtains, heat storage and CO2 recovery systems for greenhouses, compressor heat recovery equipment, natural gas boilers and furnaces (AFUE > 95 percent), and high-efficiency agricultural ventilation fans. “Building insulation also qualifies for incentives under the program”, says Price. For example, building wall insulation for new construction projects are cost-shared at $0.50 per square foot of wall area (R25 or greater) or at $1.00 per square foot of wall area (R35 or greater).
New to the program in 2013 is sub-meter funding. “An electric sub-meter is mandatory with every project funded, as measuring and reporting energy use data are now funded project requirements,” notes Price. Moreover, the program will fund three additional sub-meters to a maximum of $2,000. The Alberta government will be able to collect participant energy use data to establish energy benchmarks for different agricultural operations, and farmers will be able to monitor their real-time power usage online and view historical usage charts.
Also new this year is the funding of energy audits and combustion efficiency analyzers.
Price adds that “we have also focused funding for select lighting retrofits and agricultural ventilation fans with a view to funding only those upgrades that result in very significant energy savings.”
“We’ve had a very strong response from small to large farming operations and are processing 100 to 150 application grants per year,” says Price, noting that the average project is about $20,000 cost-shared at our usual 50/50 rate. Boilers and furnaces have been particularly popular equipment upgrades for chicken and hog producers while variable frequency drives have seen significant uptake among dairy farmers.
The On-Farm Energy Management Program is currently accepting applications. For more details on program funding, please visit the Growing Forward 2 – On-farm energy management website.
Efficiency Nova Scotia's On-Site Energy Manager program a sound business cost-saving solution for industry
“We recognize the importance of having someone in an organization dedicated to energy management,” says Daryl Hill, Sector Manager, Efficiency Nova Scotia, in explaining the genesis of the On-Site Energy Manager Program. The program provides funds for trained energy efficiency professionals to help organizations identify and implement energy saving initiatives.
“Many of our large accounts are telling us their resources are focused on core business,” notes Hill, adding that many do not have the human or financial resources to dedicate to energy management. Dedicated energy managers can focus 100 percent of their efforts on energy management activities. “Our goal is to facilitate a culture change within the organization.”
Hill explains that Efficiency Nova Scotia either funds one of their employees to act as an energy specialist for up to 12 months or funds a company to hire their own full-time energy manager. Efficiency Nova Scotia will also offset training costs. Once in place, on-site energy advisors/managers will determine a facility’s current energy use and compare it to similar organizations. They will also design and help implement an energy management plan as well as build business cases for energy efficiency projects.
All organizations spending over $1 million in energy costs annually are eligible for the program. Getting started is an easy process; however, the organization’s senior management must commit the time and resources to work with Efficiency Nova Scotia.
Hill notes that since the launch of the program in early 2012, five organizations have taken advantage of the program and now have embedded energy managers, two of whom are new hires, while three were existing positions. All five businesses have realized great success in achieving energy savings. He adds that Efficiency Nova Scotia is currently in discussion with companies in NS that have already taken advantage of the Energy Management Information Systems incentive program.
There is significant funding available for the on-site energy advisor/manager program, as Efficiency Nova Scotia’s goal is to promote energy management to their large account clients. “We are aiming for 10 energy managers embedded in various organizations by 2014.”
Long term, Efficiency Nova Scotia is looking at integrating energy management vertically by funding energy managers within sector organizations, such as the dairy industry.
CIPEC upcoming meetings
November CIPEC energy efficiency session to promote best practices for the Transportation Equipment Manufacturing sector
If you want to learn about the latest energy management best practices, incentives and tools to help your organization cut costs and increase competitiveness, you should attend the energy efficiency awareness session offered by Natural Resources Canada’s (NRCan’s) Office of Energy Efficiency (OEE) and hosted by Magna International Inc. in mid-November.
During this free session, geared towards the transportation equipment manufacturing sector, participants will learn how to maximize their energy management performance by applying the principles underlying the ISO 50001 Energy Management Systems standard.
The Canadian Industry Program for Energy Conservation (CIPEC) partnership between government and industry has also been an invaluable instrument that has already helped many organizations take steps towards improved energy efficiency and significant savings. Session participants will obtain information on how to join CIPEC and take advantage of available tools and expertise to manage energy use better.
Attendees will also find out about cost-share financial assistance, energy management tools and training offered by NRCan.
The session will be held on Thursday, November 14, 2013 from 8 a.m. to 1 p.m. at Magna International Inc., 50 Casmir Court, Vaughn, Ontario.
To register, or for more information, contact Anita Kuipers, Senior Industry Officer, Industry and Transportation Division, Office of Energy Efficiency at 613-996-8278 or Anita.Kuipers@nrcan-rncan.gc.ca.
Energy efficiency session for Ontario’s general manufacturing to focus on cost reduction
The opportunity to learn from the energy efficiency experiences of other industry members is just one of the many reasons to attend the upcoming, free-of-charge meeting of the Canadian Industry Program for Energy Conservation’s (CIPEC’s) General Manufacturing Sector Taskforce. The session to be held in Chatham on Thursday, November 28, 2013 is designed to help Ontario companies identify new opportunities in energy efficiency and cost reduction.
The meeting, jointly hosted by CIPEC and Crown Metal Packaging Canada LP, will give participants an opportunity to discuss how to leverage energy efficiency initiatives for cost reduction. They will also have opportunities to share best practices in energy efficiency and learn about federal and provincial energy efficiency incentives.
This session promises to set the stage for future energy efficiency meetings that will help the general manufacturing sector in Ontario stay competitive through energy efficiency improvements.
To register, or for more information, contact Maia Konrad, Industry Officer, Industry and Transportation Division, Office of Energy Efficiency at 613-947-1223 or via e-mail at Maia.Konrad@nrcan-rncan.gc.ca.
Dollars to $ense Energy Management Workshops – fall schedule
Energy Efficiency Financing (offered in English)
Date: November 21
Location: Dartmouth, Nova Scotia
Offered in Collaboration with Efficiency Nova Scotia
To register, visit oee.nrcan.gc.ca/industrial/training-awareness/4481
For a complete list of industrial events, visit oee.nrcan.gc.ca/industrial/opportunities/calendar/417.
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