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Sheet 1: Instructions
| Automobile Engine Plant Energy Performance Indicator | |||||||||||||||||
| for Engine Plants in the United States and Canada | |||||||||||||||||
| Version 1.2, Release 08/19/2019 | |||||||||||||||||
| Introduction | |||||||||||||||||
| The ENERGY STAR® Automobile Engine Plant Energy Performance Indicator (EPI) enables engine plants to compare their energy performance to similar engine plants operating in the United States and Canada. | |||||||||||||||||
| The EPI is an energy management tool, designed to support companies and plants that seek to improve the energy efficiency of their operations. This EPI was developed as part of the EPA's voluntary ENERGY STAR program and supports benchmarking, a critical component of the comprehensive energy management approach embodied in ENERGY STAR's Guidelines for Energy Management (www.energystar.gov/guidelines). | |||||||||||||||||
| The EPI produces an Energy Performance Score on a scale from 1 to 100, with a score of 100 reflecting the most efficient level of performance. This score provides a relative measure of performance of the plant as compared to other plants. The EPI normalizes for differences between plants using the plant characteristics described in the Required Data section below. | |||||||||||||||||
| Manufacturing plants in the U.S. and Canada that score a 75 or higher using this EPI are eligible to earn ENERGY STAR certification as recognition for superior energy performance. U.S. based facilities should consult www.energystar.gov/plants, while Canadian facilities should contact Natural Resources Canada at info.ind@nrcan.gc.ca for further information. | |||||||||||||||||
| The Automobile Engine Plant EPI is based on actual plant-level data. The EPI was developed through a collaborative process with the industry and was tested and validated by companies participating in the ENERGY STAR Motor Vehicle Industry Focus. | |||||||||||||||||
| Eligible Facilities & Space Types | |||||||||||||||||
| Engine fabrication and assembly plants (NAICS 336310-using 2012 NAICS code classifications) are defined as those that produce engines and related parts for passenger cars, sport utility vehicles, light-duty trucks and vans. The EPI does not account for other operations such as casting or assembly into final vehicles, etc. Metered energy data for operations other than engine fabrication and assembly must be removed from any data used as input for the EPI. | |||||||||||||||||
| To be eligible for ENERGY STAR certification, the plant must produce only products that meet the definition above, or have been metered such that energy data for the operations that are outside the scope of the tool are removed from any data used as input for the EPI. For plants that do not meet the minimum requirements for ENERGY STAR recognition, the EPI may still be used as a management tool. For further information on the development of this EPI, see the documentation at www.energystar.gov/motorvehiclemanufacturingfocus. | |||||||||||||||||
| Required Data | |||||||||||||||||
| The following information is required in order to use the EPI. | |||||||||||||||||
| Users may enter production inputs in US or international (metric) units by choosing from a pull-down menu. Users also will select units for each site energy input, and choose whether results are displayed in US or international units. | |||||||||||||||||
| Energy Data: | Annual energy purchases or transfers for the "current" year (and optionally for a "reference" year or plant, defined by user) for each energy source and fuel type. All units are based on U.S. thermal conversion factors. If your facility tracks site energy using units other than those offered in the EPI, convert the site energy into MMBtu or GJ before entering into the EPI sheet. Annual is defined as a continuous 12-month period of data as defined by the user, such as a calendar year or fiscal year. Energy cost data may be entered, but is not necessary. Energy from on-site dynamometer labs used for QA/QC checking and hot testing or R&D should be excluded from total plant energy use. | ||||||||||||||||
| Plant Area: | Total plant footprint (area under roof) in square feet or square meters. Do not include mezzanines or second floors. | ||||||||||||||||
| Design Jobs per Hour Total Line Rate (JPH): | Total number of finished engines the plant is designed to produce, or the maximum production rate in the last five years, on an hourly basis. See definition below for more information. | ||||||||||||||||
| Production of Finished Engines: | Quantity of finished engines produced in the current year and the reference year. | ||||||||||||||||
| Crank Machining: | Quantity of all crankshafts produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation below. | ||||||||||||||||
| Block Machining: | Quantity of all blocks produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation below. | ||||||||||||||||
| Head Set Machining: | Quantity of all head sets (e.g., two heads=one head set for a V engine) produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation below. | ||||||||||||||||
| Cam Set Machining: | Quantity of all camshaft sets (e.g., two camshafts=one camshaft set for DOHC engine, one camshaft=one camshaft set for a SOHC engine) produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation below. | ||||||||||||||||
| Rod Set Machining: | Quantity of all rod sets (e.g., six rods=one rod set for a V6 engine) produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation below. | ||||||||||||||||
| Is this plant air-tempered?: | Indicate "yes" if inside air is cooled, and "no" if it is not cooled. | ||||||||||||||||
| HDD, CDD: | Heating degree day (HDD) and cooling degree day (CDD) values for the current 12-month period and for the reference year for the actual location of the plant (if weather and temperature are measured and monitored at the plant) or for a tracked weather station nearest the plant. Note: Default values for HDD and CDD based on long run averages are provided in the tool to assist users who wish to test the EPI. However, to obtain a more accurate reading from this tool and for purposes of certification of plant performance, a user must enter HDD and CDD values obtained using EPA's Degree Days Calculator at www.energystar.gov/degreedayscalculator. | ||||||||||||||||
| All data values must be inserted in the white boxes on the EPI tab. Definitions are given below. | |||||||||||||||||
| EPI Line Item Definitions and Instructions | |||||||||||||||||
| Plant Characteristics | Definitions of terms used in the plant characteristics section | ||||||||||||||||
| NAICS Code: | The North American Industry Classification System (NAICS) is the standard used by Federal statistical agencies in classifying business establishments for the purpose of collecting, analyzing, and publishing statistical data related to the U.S. business economy. For this analysis, 336310 (Motor vehicle gasoline engine and engine parts manufacturing-using 2012 NAICS code classifications) is relevant. | ||||||||||||||||
| ZIP Code: | A 5-digit U.S. Postal Service ZIP code used to assign the plant location. For Canadian locations, enter the 6-character alphanumeric postal code for the plant location. | ||||||||||||||||
| Location: | General plant location is based on the ZIP or postal code entered by user. User should confirm location matches ZIP or postal code. | ||||||||||||||||
| Current Plant & Year: | Most recent year of data for the plant the user wishes to score, or other year selected by the user for evaluation. | ||||||||||||||||
| Reference Plant & Year: | User-defined reference plant and year for comparison purposes. Since scores for current plant and reference plant are calculated independently, the choice of reference year does NOT impact current year score. The reference plant can be the same plant as the "current plant" with a different year, or a different plant. | ||||||||||||||||
| Plant Area: | Total plant footprint (area under roof) in square feet or square meters. Do not include mezzanines or second floors. | ||||||||||||||||
| Design Jobs per Hour Total Line Rate (JPH): | Total number of finished engines the plant is designed to produce, or the maximum production rate in the last five years, on an hourly basis. | ||||||||||||||||
| JPH is intended to capture plant capacity. To compute JPH, use the larger of the following two items: 1) the plant designed rate, or 2) the maximum monthly realized jobs per hour over the past 5 years, depending on data availability. For example, suppose the plant is designed to operate at 200 JPH, but during one month in the past 5 years the plant achieved 210 JPH. In this case, enter 210. | |||||||||||||||||
| Production of Finished Engines: | Quantity of finished engines produced in the current year and the reference year. | ||||||||||||||||
| For the following five engine components, include all parts that are included in a finished engine, plus all parts produced for shipment to other locations, less all parts imported from other locations. Engine components that are in sets (i.e., more than one component per engine) should be counted as one set. For example, six rods would comprise one set for a V6 engine, therefore the number of rods would be divided by six to calculate the number of rod sets. | |||||||||||||||||
| Example A: A plant makes 400,000 finished engines, but also makes an additional 12,000 crankshafts for the parts market; enter 412,000 under Crank Machining. | |||||||||||||||||
| Example B: A plant makes 400,000 finished engines, but only machines 200,000 of the heads in this plant and receives another 200,000 from another plant. There are 400,000 heads in the finished engines, less 200,000 received from another plant; enter 200,000 under Head Set Machining. | |||||||||||||||||
| Crank Machining: | Quantity of all crankshafts produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation immediately above. | ||||||||||||||||
| Block Machining: | Quantity of all blocks produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation immediately above. | ||||||||||||||||
| Head Set Machining: | Quantity of all head sets (e.g., two heads=one head set for a V engine) produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation immediately above. | ||||||||||||||||
| Cam Set Machining: | Quantity of all camshaft sets (e.g., two camshafts=one camshaft set for DOHC engine, one camshaft=one camshaft set for a SOHC engine) produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation immediately above. | ||||||||||||||||
| Rod Set Machining: | Quantity of all rod sets (e.g., six rods=one rod set for a V6 engine) produced in the current year and the reference year, regardless of whether they are included in a finished engine or shipped elsewhere. See example calculation immediately above. | ||||||||||||||||
| Is this plant air-tempered?: | Indicate "yes" if inside air is cooled, and "no" if it is not cooled. | ||||||||||||||||
| HDD, CDD: | Heating degree day (HDD) and cooling degree day (CDD) values for the same 12-month period used for energy use and production figures for the current and reference year for the actual location of the plant (if measured and monitored at the plant) or for the nearest tracked weather station in the U.S. or Canada. Default values based on long run averages are provided in the tool to assist users who wish to test the EPI. To obtain a more accurate reading from the tool and for purposes of recognition of plant performance, a user must enter HDD and CDD values obtained using EPA's Degree Days Calculator at www.energystar.gov/degreedayscalculator. | ||||||||||||||||
| NOTE: If the user calculates HDD/CDD values from their own weather station data, use the average temperature for the day (based on average of the minimum and maximum temperatures for the day). Calculate the HDD and CDD values on a base of 65 degrees. If the average temperature for the day is 65, there will be no value for either HDD or CDD for that day. If the average temperature is below 65, the day will have an HDD value. Calculate the HDD value by subtracting the average temperature from 65 (HDD = 65 - average temperature). If the temperature is above 65, the day will have a CDD value. Calculate the CDD value by subtracting 65 from the average temperature (CDD = average temperature - 65). The user must sum all HDD values and all CDD values for the 12-month period for use in the model. For purposes of ENERGY STAR certification, the EPA's Degree Days Calculator at www.energystar.gov/degreedayscalculator must be used for the weather station nearest to the plant. EPA's Degree Days Calculator performs all of these calculations and provides the annual values needed for the EPI. | |||||||||||||||||
| Annual: | Refers to a continuous 12-month period of data as defined by the user, such as a calendar year or fiscal year. | ||||||||||||||||
| Energy Accounting | Definitions of terms used for energy accounting | ||||||||||||||||
| Energy Data: | All energy inputs must be metered or otherwise verifiable (e.g., utility bills, delivery receipts). Energy values are entered as net values (i.e., purchases and transfers in minus sales and transfers out), subject to the descriptions below. Energy from on-site dynamometer labs used for QA/QC checking and hot testing or R&D should be excluded from total plant energy use. | ||||||||||||||||
| Electricity: | Data for electricity includes only total electricity purchased or transferred into the plant from another facility, net of sales or transfers (see special case below for electricity generated from onsite renewables). Purchased or transferred electricity is entered into the Electricity column on the EPI worksheet. Units are in terms of site energy, in kWh or MWh. | ||||||||||||||||
| Compressed Air: Account for the energy used to produce compressed air if compressed air is transferred in from an external or third-party site whose energy does not appear in your plant's energy total. The kWh for producing compressed air is calculated using actual conversion efficiencies of the external or third-party producer, and added to your plant's Electricity column. For example, | |||||||||||||||||
| 100 SCFM compressed air x 0.2 kW/SCFM x 4800 hours (per year) = 96,000 kWh (SCFM is Standard Cubic Feet of air per Minute. Convert cubic meters to cubic feet by multiplying by 35.31) |
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| (Example for illustration only. Your factors and method will vary.) | |||||||||||||||||
| Chilled Water: Account for the electricity used to produce chilled water if chilled water is transferred in from an external or third-party site whose energy does not appear in your plant's energy total. The electricity for producing chilled water is calculated using actual chiller conversion efficiencies of the external or third-party producer, and added to your plant's Electricity column. If thermal energy is used to produce chilled water, see the Thermal Energy Use section below. | |||||||||||||||||
| Electricity from Onsite Renewables: Include the electricity consumed from onsite renewable generation (e.g., solar photovoltaic (PV), wind, small hydro, but not renewable energy certificates (RECS), virtual power purchase agreements (vPPAs), or other off-site renewable electricity purchases) in the Onsite Renewables column. Excess electricity from onsite renewable generation that is sold or transferred offsite is not accounted for in the EPI. All electricity purchases or transfers into the plant are entered in the Electricity column on the EPI worksheet, as specified above. The EPI recognizes the efficiency benefits of onsite generation by applying the site thermal conversion factor of 3,412 Btu/kWh rather than the higher source energy conversion factor that is used for grid-sourced electricity. |
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| Electricity from All Other Onsite Generation: Do not include the electricity consumed from all other onsite generation (e.g., combined heat and power (CHP), diesel generators) in your total energy consumption. When electricity is generated onsite from these other sources, include the fuel that is purchased or transferred into the plant to operate other onsite generation, but do not include the electricity generated by those systems. Electricity from onsite generation that is sold or transferred offsite must be subtracted from the total purchased electricity to represent "net of sales or transfer." Enter your electricity purchases net of sales and transfers in the Electricity column. |
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| Thermal Energy Use: | Include all other forms of energy purchased or transferred (natural gas, oil, coal, etc.), net of sales or transfers, subject to details below. For fuels not defined in the EPI, use the Other column. | ||||||||||||||||
| Recovered Energy: Do not include energy recovered from the production process (e.g., waste heat, process byproducts) in the energy accounting of the EPI. The EPI’s underlying statistical model recognizes that plants have an opportunity to recover or self-produce a portion of the energy they require, and is adjusted based on plant characteristics and purchased energy inputs to the EPI. | |||||||||||||||||
| Steam: Account for the energy used to produce steam if steam is transferred in from an external or third-party site whose energy does not appear in your plant's energy total. The heat for producing steam is calculated using actual boiler conversion efficiencies of the external or third-party producer, and added to your plant's energy total (i.e., the heat value of the fuel used to make the steam). For example, | |||||||||||||||||
| 10 million lbs steam (per year) x 1128 Btu/lb @ 150 psig / 85% boiler efficiency = 13,271 MMBtu natural gas (before adjusting for steam distribution losses) or multiply MMBtu by 1.05587 to convert to GJ |
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| (Example for illustration only. Your factors and method will vary.) | |||||||||||||||||
| Chilled Water: Account for the energy used to produce chilled water if chilled water is transferred in from an external or third-party site whose energy does not appear in your plant's energy total. The heat for producing chilled water is calculated using actual chiller conversion efficiencies of the external or third-party producer, and added to your plant's fuel columns (based on the fuel used). If electricity is used to produce chilled water, see the Electricity section above. | |||||||||||||||||
| Annual Cost: | Total annual energy cost for each fuel type in current year dollars. Input of cost data is optional and does not impact the Energy Performance Score. This feature is provided for your convenience and use. | ||||||||||||||||
| Results | Definitions of terms used in the results section | ||||||||||||||||
| Energy Performance Score: | The Energy Performance Score is a percentile ranking for your plant normalized for the plant characteristics listed above. This score provides a relative measure of performance of the plant as compared to similar plants in this industry. | ||||||||||||||||
| Source Energy: | Source energy traces the energy consumed directly at a plant back to the raw fuel input. Source energy for electricity accounts for energy conversion losses during electricity generation plus transmission and distribution losses. Using a source energy basis enables a more equitable thermodynamic assessment of all energy sources. The EPI converts purchased (site) electricity to source energy using a multiplier of 2.80 from site energy (9,554 Btu/kWh). The EPI converts electricity from onsite renewables to source energy using a multiplier of 1 from site energy (3,412 Btu/kWh or 0.0036 GJ/kWh). Source energy for other fuel types accounts for losses during delivery to the end-user site, but does not account for energy that is consumed in mining, transporting, and refining crude products. For more information on source energy and conversion methodologies, see https://portfoliomanager.energystar.gov/pdf/reference/Source%20Energy.pdf | ||||||||||||||||
| Site Energy: | Site energy reflects the amount of energy consumed directly at a plant, which usually is reflected on utility bills. The EPI converts electricity and all fuel types to Btus and sums those values to reflect total site energy. The EPI converts electricity from kWh to Btu (or GJ) using the thermal conversion factor for electricity (3,412 Btu/kWh or 0.0036 GJ/kWh). | ||||||||||||||||
| Energy Intensity (Source Energy/Finished Engine) and (Site Energy/Finished Engine): |
The source and site energy use per finished engine produced, for the current, reference, average and efficient plant. The first two ratios are directly based on input data, and the latter two are the projected normalized values for an efficient and average plant (see below) relative to the current plant performance. | ||||||||||||||||
| Efficient Plant: | Defined at the values associated with a plant operating at the 75th percentile. | ||||||||||||||||
| Average Plant: | Defined at the values associated with a plant operating at the 50th percentile. | ||||||||||||||||
| Charts: | The charts plot the Energy Performance Scores of the current and reference plants relative to the observed performance of the industry (normalized for production variables). | ||||||||||||||||
| Electric and Thermal Tabs | |||||||||||||||||
| Electric & Thermal Tabs: | These tabs provide additional comparative analysis on the energy performance for electricity and thermal processes, including energy type-specific ratings and results. | ||||||||||||||||
| Electric & Thermal Ratings: | These energy type-specific ratings show how your plant compares to the industry in terms of electricity and thermal fuel use. These ratings provide insight into how electricity and thermal processes contribute individually to the overall score. For example, if the electrical rating is lower than the thermal rating, then there may be more potential for improving efficiency in electricity-consuming processes. These ratings are calculated independently of the overall Energy Performance Score in the EPI. The Energy Performance Score in the EPI is not an average of the electric and thermal ratings. |
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| Report Tabs | Statement of Energy Performance & Facility Performance Report | ||||||||||||||||
| Statement of Energy Performance: | The workbook tab labeled Statement of Energy Performance (SEP) contains a printable form that is used only when submitting an application for ENERGY STAR plant certification. The results from the EPI will be automatically populated in the appropriate fields in the SEP form. For further information on earning the ENERGY STAR, see http://www.energystar.gov/plants. | ||||||||||||||||
| Facility Performance Report: | The workbook tab labeled Facility Performance Report provides a printable form that can be used to summarize the results from the EPI. This report is intended to be used by plants or companies for their own internal records. | ||||||||||||||||
| About The EPI | |||||||||||||||||
| This ENERGY STAR Plant EPI was developed by the US EPA in collaboration Natural Resources Canada and with companies participating in the ENERGY STAR Motor Vehicle Manufacturing Focus and with technical support from Duke University and ICF International. The EPI is based upon confidential plant-level information. Technical documentation on the design of the EPI is available at www.energystar.gov/EPIs. This EPI will be updated periodically and revised by the US EPA and Natural Resources Canada as part of the ENERGY STAR Industry Focus. For more information on the Industry Focus, visit www.energystar.gov/motorvehiclemanufacturingfocus or contact energystrategy@energystar.gov. | |||||||||||||||||
| The research results have been screened to insure that no confidential data are revealed in this spreadsheet or other documentation. | |||||||||||||||||
| Volume Notes & Updates | |||||||||||||||||
| Version 1.0 released on 11/22/2017. | |||||||||||||||||
| Version 1.1 released on 10/26/2018 updates electricity source conversion factor and language in the Instructions worksheet. | |||||||||||||||||
| Version 1.2 released on 08/19/2019 updates language on component set manufacturing in the Instructions and EPI worksheets. | |||||||||||||||||
| Automobile Engine Plant Energy Performance Indicator | |||||||||||||
| Version 1.2, Release 08/19/2019 | |||||||||||||
| Electricity Results | Your Current Plant | Your Reference Plant | Average Plant | Efficient Plant | |||||||||
| Enter Name | Enter Name | Enter Name | Enter Name | ||||||||||
| 2017 | 2016 | 2017 | 2017 | ||||||||||
| Electric Rating (ER) | Err:502 | Err:502 | 50 | 75 | |||||||||
| Annual Electricity Cost ($/year) | $0 | $0 | #DIV/0! | #DIV/0! | |||||||||
| Number of Finished Engines Produced | 1 | 1 | 1 | 1 | |||||||||
| Electricity Cost/Finished Engine ($/engine) | 0.00 | 0.00 | #DIV/0! | #DIV/0! | |||||||||
| Electricity (Source MMBtu) | 0 | 0 | 11 | 8 | |||||||||
| Electricity (Site MMBtu) | 0 | 0 | #DIV/0! | #DIV/0! | |||||||||
| Electricity (kWh) | 0 | 0 | #DIV/0! | #DIV/0! | |||||||||
| Electric Energy Intensity (Source MMBtu/Finished Engine) | 0.00 | 0.00 | 11.03 | 7.59 | |||||||||
| Electric Energy Intensity (kWh/Finished Engine) |
0.00 | 0.00 | #DIV/0! | #DIV/0! | |||||||||
| Enter Name (2017) | Enter Name (2016) | ||||||||||||
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