Energy Efficiency in Industrial Systems

Maintenance and Engineering October 25, 2025
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Introduction

Energy consumption is a major operational expense and a significant environmental factor for industrial organizations. This course equips maintenance and engineering personnel with the knowledge to identify, quantify, and implement energy-saving opportunities across key plant systems. The focus is on optimizing the operation and maintenance of compressed air, steam, pumping, and lighting systems, which are often the largest consumers of energy. Participants will gain practical skills in conducting energy audits, calculating savings, and using maintenance practices to drive down utility costs and contribute to sustainability goals.

Objectives

Upon completion of this course, participants will be able to:

  • Conduct a preliminary energy audit and prioritize major energy-consuming systems.
  • Identify and quantify energy savings opportunities in compressed air systems (leak detection, pressure optimization).
  • Implement maintenance best practices for steam traps and condensate return systems.
  • Calculate the energy consumption and efficiency of pumping and fan systems.
  • Select and justify the implementation of high-efficiency motors and variable speed drives (VFDs).
  • Utilize energy monitoring tools and data to track and report savings.
  • Develop an energy-focused preventive maintenance program.
  • Understand the role of HVAC and building envelope maintenance in energy consumption.

Target Audience

  • Maintenance and Facilities Managers
  • Energy Management and Sustainability Coordinators
  • Mechanical and Electrical Maintenance Technicians
  • Plant and Manufacturing Engineers
  • Continuous Improvement Specialists (Lean/Six Sigma)
  • Financial Analysts supporting energy conservation projects

Methodology

  • Case studies demonstrating successful industrial energy savings projects
  • Hands-on exercise calculating the cost of compressed air leaks
  • Group workshop on prioritizing Energy Conservation Measures (ECMs) by ROI
  • Discussions on best practices for steam trap testing and replacement
  • Individual assignment developing an energy-focused PM checklist for a system.

Personal Impact

  • Gain expertise in a high-demand, cross-functional area (Energy Management).
  • Develop strong analytical and ROI justification skills.
  • Improve ability to find and quantify tangible cost savings.
  • Become a key driver for corporate sustainability goals.
  • Enhance understanding of how maintenance directly impacts utility costs.

Organizational Impact

  • Achieve sustained and verifiable reduction in overall utility and energy costs.
  • Improve the operational efficiency and reliability of key systems (air, steam, pumps).
  • Contribute significantly to corporate environmental and sustainability goals.
  • Reduce the carbon footprint and ensure regulatory compliance.
  • Extend the life of equipment by reducing operational stress.
  • Secure financial incentives from utilities for upgrades.

Course Outline

Unit 1: Energy Audit and Management Fundamentals

Industrial Energy Consumption Profile
  • Identifying the top energy consumers in typical industrial facilities.
  • The relationship between poor maintenance and high energy use.
  • Developing an energy management policy and setting reduction goals.
Energy Audit Methodology
  • The process of conducting a walk-through and detailed energy audit.
  • Prioritizing energy conservation measures (ECMs) based on ROI.
  • Utilizing baseline energy data and metering for measurement and verification (M&V).

Unit 2: Compressed Air System Optimization

Air System Efficiency
  • Calculating the cost of compressed air and its utilization.
  • Using ultrasonic testing for leak detection and repair.
  • Strategies for pressure reduction and optimizing compressor control.
Maintenance of Compressors
  • PM procedures for air compressors (oil quality, cooling, filtration).
  • Heat recovery potential from compressed air systems.
  • Sizing and maintaining air storage and drying equipment.

Unit 3: Steam and Pumping System Efficiency

Steam System Maintenance
  • Diagnosis and maintenance of steam traps (failure modes, testing).
  • Importance of condensate return systems and flash steam recovery.
  • Boiler efficiency maintenance and blowdown optimization.
Pump and Fan Optimization
  • Analyzing pump performance against the best efficiency point (BEP).
  • Energy savings potential from impeller trimming and system re-design.
  • Applying variable frequency drives (VFDs) to flow control.

Unit 4: Motor, Lighting, and Electrical Efficiency

Motor and Drive Systems
  • Selecting NEMA Premium and high-efficiency motors.
  • Maintenance and application of Variable Frequency Drives (VFDs).
  • Power factor correction and its impact on energy costs.
Lighting and HVAC
  • Upgrading to LED lighting and implementing lighting controls.
  • Maintenance of HVAC systems (filtration, damper control).
  • Sealing building envelope leaks and insulation maintenance.

Unit 5: Implementation and Sustained Savings

Project Implementation
  • Developing a clear implementation and commissioning plan for ECMs.
  • Calculating the financial return on investment (ROI) for energy projects.
  • Securing utility incentives and rebates for efficiency upgrades.
Sustainability and Monitoring
  • Establishing continuous energy monitoring and targeting systems.
  • Integrating energy checks into standard PM routines.
  • Communicating energy savings and recognizing team contributions.

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