Sustainable Assets School

Decarbonisation and the need for companies to achieve net-zero greenhouse gas emissions by a specified date is disrupting previous lifecycle plans, investment and reinvestment decisions, and the physical asset manager’s role. This course is designed for Asset Managers to explore best practices in energy consumption reduction, including reducing GHG emissions, managing energy conversion effectiveness and transfer along its intended electrical, mechanical, and chemical pathways, and reducing wear and tear on production.

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Course Outline

4 Days

11 Core Modules

Introduction to ESG and Sustainable Manufacturing

  • Environmental, Societal and Governance (ESG) Goals and Trends
  • The "Triple Bottom Line"
  • Introduction to Environmental Life Cycle Assessment (ELCA)
  • Mapping Impacts and Setting Priorities
  • Choosing Key Performance Indicators (KPIs) for Sustainable Manufacturing
    - Inputs
    - Operations
    - Products Including Production Assets
  • Sustainable Life Cycle Asset Management Practices
  • Design
  • Operations
  • Maintenance
  • Life Extension, Recycle/Reuse
  • Asset Managers Role in Sustainability

Energy Savings and GHG Reduction Potential

  • Energy vs Exergy Explained
  • Common Energy Losses
  • Parasitic Frictional Losses
  • Adiabatic Losses
  • Emissions Losses
  • Intentional
    - Venting of Compressed or Pressurized Fluids
    - Flaring
  • Unintentional Fugitive Emissions
    - Compressed Air and Gases
    - Pressurized Steam
    - Pressurized Liquids
    - Compressed Natural Gas and Other VOCs
  • Radiant Energy
  • Combustion Efficiency
  • Recovery Opportunities
  • Reduced Energy Cost
  • Reduced Greenhouse Gas (GHG) Emissions and Carbon Footprint
  • Energy Savings Opportunities for Industry:
    - By Deploying Existing Technology
    - With Investment in New Technology

Energy Efficiency of Industrial Electric Motors and the Machines They Drive

  • When to Purchase Premium Efficiency Motors
  • How to Estimate Motor Efficiency in the Field
  • Strategies to Extend the Operating Life of Electric Motors
  • The Importance of Motor Shaft Alignment
  • When to Replace V-belts with Synchronized Belts
  • How to Avoid Nuisance Trips with Premium Efficiency Motors
  • How to Eliminate Voltage Unbalance
  • Strategies to Eliminate In-Plant Distribution System Voltage Drops
  • How to Improve Motor Operation at Off-Design Voltages
  • When It Makes Sense to Turn Motors Off
  • How to Improve Efficiency of Adjustable Speed Drives Operating at Partial Load
  • Is it Cost-Effective to Replace Old Eddy-Current Drives?
  • Magnetically Coupled Adjustable Speed Drives
  • When Should Inverter-Duty Motors be Specified?
  • Minimize Adverse Motor and Adjustable Speed Drive Interactions

Diesel Engine Combustion Efficiency

  • Regular Maintenance
  • Fuel Quality Management
  • Fuel Injection System Optimization
  • Combustion Chamber Optimization
  • Turbocharging
  • Exhaust Gas Recirculation (EGR)
  • Air Intake System Optimization
  • Engine Control Unit Calibration
  • Idle Reduction
  • Driver Training
  • Aerodynamic Improvements
  • Payload Optimization

Pumping System Efficiency

  • Conduct an In-plant Pumping System Survey
  • Match Pumps to System Requirements
  • Adjustable Speed Pumping Applications
  • Control Strategies for Centrifugal Pumps with Variable Flow Rate Requirements
  • Energy Savings Opportunities in Control Valves
  • Reduce Pumping Costs Through Optimum Pipe Sizing
  • Optimize Parallel Pumping Systems
  • Pump Selection Considerations
  • Select and Energy Efficient Centrifugal Pump
  • Trim or Replace Impellers on Oversized Pumps
  • Test for System Efficiency
  • Maintain Pumping Systems Effectively

Compressed Air Energy Efficiency

  • How to Analyse Compressed Air Systems
  • Alternative Strategies for Low Pressure End Uses
  • Strategies for Storing Compressed Air Systems
  • Strategies for Energy Efficient Compressed Air Systems
  • How to Determine the Cost of Compressed Air in Your Plant
  • How to Determine the Correct Air Quality for the Application
  • Effective Management of Air Intake Systems
  • Eliminating Inappropriate Application and Uses of Compressed Air
  • Engineering End Uses for Maximum Efficiency
  • Maintaining Compressed Air Quality
  • Finding and Eliminating Compressed Air Leaks
  • Proactive, Predictive and Precision Maintenance for Compressed Air Systems
  • How to Minimize Air Losses When Removing Condensate 
  • How to Stabilize System Pressure
  • Capturing and Reusing Adiabatic Losses

Process Heating Energy Efficiency

  • Maintaining Proper Fuel to Air Ratios
  • How to Check Heat Transfer Surfaces
  • Managing Furnace Pressure Controllers
  • Installing Waste Heat Recovery Systems
  • Load Preheating Using Flue Gases for a Fuel Fired Heating System
  • How to Oxygen-Enrich Combustion
  • Preheated Combustion Air
  • Reducing Air Infiltration in Furnaces
  • Minimizing Radiant Energy Losses from Heating Equipment
  • Using Lower Flammable Limit Monitoring to Improve Efficiency
  • Reclaiming Waste Heat for External Processes

Steam System Energy Efficiency

  • How to Benchmark the Fuel Cost of Steam Generation
  • How to Clean Boiler Waterside Heat Transfer Surfaces
  • When to Install and Condensing Economizer
  • When to Install High-Pressure Boiler with Backpressure Turbine Generators
  • When to Install Turbulators on Two- and Three-Pass Firetube Boilers
  • When Does It Make Sense to Drive Rotating Equipment with Steam Turbines?
  • What to Consider When Selecting a Condensing Economizer
  • Coving Heated, Open Vessels
  • Employing Deaerators in Industrial Steam Systems
  • How to Flash High-Pressure Condensate to Regenerate Low-Pressure Steam
  • How to Inspect and Repair Steam Traps
  • Installing an Automatic Blowdown-Control System
  • Installing Removable Insulation on Valves and Fittings
  • How to Insulate Steam Distribution and Condensate Return Lines
  • How to Improve Combustion Efficiency in Boilers
  • How to Minimize Boiler Blowdown
  • Minimizing Boiler Short-Cycling Losses
  • Heat Recovery from Boiler Blowdown
  • Replacing Pressure-Reducing Valves with Backpressure Turbogenerators
  • Effective Return of Condensate to the Boiler
  • Upgrading Boilers with Energy-Efficient Burners
  • Using Feedwater Economizers for Waste Heat Recovery
  • Using Low-Grade Waste Steam to Power Absorption Chillers
  • Employing Steam Jet Ejectors to Reduce Low-Pressure Venting
  • Employing Vapor Recompression to Recover Low-Pressure Waste Steam
  • Using a Vent Condenser to Recover Flash Steam Energy

Buildings And Lighting

  • Reducing Energy Consumption with Intelligent Industrial Buildings
  • Upgrading Industrial Lighting with Energy Efficient Technologies
  • Utilizing Drones Equipment with IR Cameras to Identify Fugitive Energy Emissions from Industrial Buildings

Electrical Transformers

  • How to Control I2R Copper Losses
  • Minimizing Hysteresis and Eddy Current Losses (Iron Losses)
  • Managing Stray Current Losses Induced by Magnetic Fields
  • How Winding Resistance and Leakage Flux Produce Load Losses
  • Minimizing Hysteresis and Eddy Current Losses Under No-Load Conditions
  • Addressing Leakage Flux
  • Managing Insulating Materials to Minimize Dielectric Losses
  • Maintaining Energy Efficiency of Transformer Cooling Systems
  • Employing Active and Passive Filters to Minimize Harmonic-Induced Losses
  • Minimizing Phase-to-Phase Electrical Unbalance Losses
  • Assuring Proper Frequency Selection for the Application
  • How to Keep Overloading Losses to a Minimum

Implementing Industrial Energy Management Best Practices

  • How to Set Energy Management Goals for Industrial Assets 
  • How to Conduct and Energy Audit for Industrial Assets 
  • How to Develop and Energy Management Plan for Industrial Assets 
  • Energy Monitoring and Metering for Industrial Assets 
  • Training and Engaging Employees in the Process 
  • How to Implement Your Plan to Improve Industrial Energy Efficiency  
  • Continuous Monitoring, Auditing, and Improvement 
  • Seeking Recognition and Certification for Your Organization

Who Should Attend

Workshop Objectives

Snapshot

Introduction to ESG and Sustainable Manufacturing

Energy Savings and GHG Reduction Potential

Energy Efficiency of Industrial Electric Motors and the Machines They Drive

Diesel Engine Combustion Efficiency

Pumping System Efficiency

Compressed Air Energy Efficiency

Process Heating Energy Efficiency

Steam System Energy Efficiency

Buildings And Lighting

Electrical Transformers

Implementing Industrial Energy Management Best Practices

Need more info?

Get in touch with our team

Your Instructors

Drew Troyer

Drew Troyer

Principal Director

Bootleg Advisors

30+ years of expertise in sustainable manufacturing, asset management, energy & reliability engineering. Renowned author & keynote speaker. Certified Reliability Engineer & Energy Manager.

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Our Clients

Asset Management School was absolutely fantastic! Not just the content, but also the networking evening, the whole experience. Despite 23 years as a maintenance engineer and planner, I learnt so much to take back to apply in my business.

Salman Rashed

Assets Maintenance Planner

Waikato Regional Council

Asset Schools give peace of mind that the investment in our Maintenance and Reliability professionals will provide a great return to both them and the business.

Gwyn Garland

Senior Manager

Asset Health Newmont

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