1. 7 Habits of Highly
Effective Energy
Managers
& Real Time Survey –
Energy Checkup
Dr. Ken Currie, Director
Center for Manufacturing Research
Tennessee Tech University
Associate Director of Industrial Assessment Center

2. Identify the sector that best represents
your organization.
A. Commercial
B. Large Industrial
C. Small/Medium
Industrial
D. Public
E. Other

3. Shameless Advertising
Tennessee 3-Star Industrial Assessment Center
• FREE!!! Energy Assessments to Small &
Medium-Sized Facilities
• Within SIC Codes 20-39
• Gross Annual Sales < $100 Million
• Employment < 500
• $100K < Annual Energy Bills < $2.5 Million
• No Permanent Energy Professional
• Primary Focus is Workforce Development
• In Partnership with University of Memphis
and ETSU
• Unique capabilities to assisting TN Industry
in ISO 50001 Implementation and
Certification

4. Shameless Advertising
Industrial Assessment Components
• Gather plant data
including product type,
annual sales levels,
production levels,
operating hours
• Study processes and
plant layout
• Analyze utility billing
data
• Identify key energy
systems
• Develop assessment day
strategy
• To be completed before
assessment visit
Pre-Assessment
• Meet with plant
management team
• Present details of pre-
assessment analysis
• Tour plant
• Collect operating data
• Conduct diagnostic testing
• Discuss preliminary
assessment findings with
plant management
• Prioritize potential
recommendations for
further analysis
• Duration: One Day
• Conduct engineering
and financial
analyses of priority
recommendations
• Develop first order
estimates of
implementation
costs
• Document results in
“GOLD Standard”
format assessment
report
• Upload report data
into IAC database
• Deliver report to
plant within 60 days
from plant visit
•Conduct follow up
discussions with plant, 6-
9 months following
assessment visit
•Identify implemented
energy savings
•Upload implementation
data into the IAC
database
Analysis & Reporting Follow UpAssessment Visit

5. Shameless Advertising
Tennessee 3-Star IAC Performance
ASSESSMENTS
70 Completed
FOLLOW-UPS AT 6 – 9 MONTHS
50 Completed (Of those, 1 plant had closed)
Recommendations
Made
Recommendations
Made
Recommendations
Implemented
Percent
# of Recommendations 443 335 134 40%
Energy Dollar Savings $8,730,665 $7,022,291 $2,084,081 30%
Electric Usage Savings
(kWh)
74,146,120 kWh 59,041,051 kWh 17,754,813 kWh 30%
Electric Demand Savings
(kW)
680,189 kW 72,832 kW 40,041 kW 55%
Natural Gas / Liquid
Propane Savings
(MMBtu)
529,499 MMBtu 450,752 MMBtu 193,742 MMBtu 43%

6. Has your organization established required
payback periods for energy projects?
A. Yes
B. No
C. Don’t Know

7. Shameless Advertising
Implementing ISO 50001 – Energy Management Systems
• Requires an organization to establish, implement, maintain, and improve
an energy management system, enabling continual improvement in
energy efficiency.
• Imposes requirements on energy supply and consumption:
− Measurement
− Documentation and reporting
− Design and procurement practices for energy-using equipment and
systems
− Processes and personnel
• TTU has capabilities for coaching, mentoring, and training organizations
seeking certification.
• Successfully coached Schneider Electric, Smyrna to
achieve ISO 50001 certification and Superior Energy
Performance – Platinum.
• Two Certified Practitioners in EnMS, ISO 50001 Lead
Auditor, and CP in SEP Verification

8. Has your organization established energy-
per-unit metrics?
(Ex: energy cost per pound of product)
A. Yes
B. No
C. Don’t Know

9. • Fans & Pumps are usually oversized to
consider worse case scenarios. Variable
speed drives allow for a throttled output
with a corresponding variable electrical load
to reduce flow.
• Furnaces are designed for peak product flow
but typical flow may only require a subset of
the burners to be in service.
Habit #1: Engineers Design for “Just-
In-Case” NOT Energy Efficiency

10. Does your organization have a formal
written energy management plan or
energy policy?
A. Yes
B. No
C. Don’t know

11. • Compared to electric motors, the work that is
conducted by compressed air is 7 times more
expensive.
• Inappropriate uses and leaks are common losses
in a compressed air system resulting in
significant wasted energy – i.e. In a system that
is running a 200 hp compressor, 30%
represented by inappropriate uses and leaks can
cost approximately $4,500/yr in a single shift
operation.
Habit #2: Air is Free, but Compressed
Air is Very Expensive
• Poor management of air supply can
yield inefficiencies for costs and
also in meeting demand events.

12. Has your organization had energy
assessments done at its facilities
in the past?
A. Yes
B. No
C. Don’t know

13. Habit #3: Motel 6 Got it All Wrong – They
Should Not Have Left the Lights On
• Changing bulbs is a good first step, but all
light is not created equal and replacing one
fixture for another fixture may yield more
lumens than what is needed. Consider
reducing the number of bulbs to reduce
lighting levels as appropriate for the task.
• Sensors and controls allow for occupancy
sensors, daylighting, and timers.

14. Do you use occupancy sensors?
(warehouses, manufacturing areas, conference
rooms, copy rooms, etc.)
A. Yes
B. No
C. Don’t know

15. • Few industrial operations are truly 24/7
• One company assumed that these compressors
were being turned off when in fact there was a
perceived production requirement that they be
left on – reality was quite different.
• Improper compressor sequencing and controls
can adversely affect energy efficiency.
Habit #4: Reality is Usually Somewhere
Between our Expectations and Total
Chaos.

16. Are fixtures or equipment turned off
during extended unoccupied periods?
(Ex: evenings, weekends, plant shut-downs)
A. Yes
B. No
C. Some, but not all
D. Don’t know

17. • Air & steam leaks, HVAC efficiency losses,
results of poor maintenance, equipment
degradation all result in the need for a
continual management process.
Habit #5: Low Hanging Fruit Always
Seem to Grow Back

18. Does your organization have a procedure
for employees to suggest energy savings
opportunities?
A. Yes
B. No
C. Don’t know

19. Habit #6: Production Needs vs. Energy
Reduction – Can’t We Just All Get Along!
• Perceived needs for quality, production
throughput, and refusing to change anything
that may cause a production perturbation often
conflict with changes to reduce energy.
• Energy Management Systems create a cross-
functional energy management team working
to analyze and improve processes at the lowest
possible energy consumption.

20. Does your organization have an energy
management team?
A. Yes
B. No
C. Don’t know

21. Habit #7: You Can’t Reduce What You
Don’t Measure, and You Can’t Measure
What You Don’t Meter
This project is funded under an agreement with the State of Tennessee. This
material is based upon work supported by the Department of Energy under
Award Number DE-EE0000160. CFDA 81.041.
• Sub-metering helps to align energy
consumption with significant energy uses
allowing for concentration of effort.
• Measuring energy performance should be
calculated as a basis of production (energy
intensity) without consideration for rate
changes – MMBtu/unit production

22. Are departments in your organization
required to track energy usage?
A. Yes
B. No
C. Some, but not all
D. Don’t know

23. Thank You for Participating in Our
Survey!
This project is funded under an agreement with the State of Tennessee. This
material is based upon work supported by the Department of Energy under
Award Number DE-EE0000160. CFDA 81.041.