Fitesa Case Study January 18, 2012

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Create an Opportunity Register � Meet with all plant personnel. Educate them on the mission and goals of the HPUM Team. Ask for their ideas to reduce our carbon footprint. . � As a HPUM team, created initial list of utility saving ideas. � List included all ideas. They are then prioritized. – Some go into Project Hopper and become Capital projects for coming years. – Most ideas will be non-capital projects. The highest priority items will be on a Fitesa Action Plan, the rest left on the Opportunity Register. CONFIDENTIAL – 18
Example of Opportunity Register Opportunity # Date Type Submitted By HPUM0001 7/16/10 E Shelley F. HPUM0002 7/16/10 E Connie C. HPUM0003 7/16/10 E Connie C. HPUM0004 07/16/10 E Albert HPUM0005 07/16/10 E Albert HPUM0006 07/16/10 NG Albert HPUM0007 07/16/10 E Tom S. HPUM0008 07/16/10 E Steve S. HPUM0009 07/16/10 E Tom S. HPUM0010 07/16/10 E JD HPUM0011 07/16/10 E JD HPUM0012 07/16/10 E JD HPUM0013 07/21/10 E JD HPUM0014 07/21/10 E JD HPUM0015 07/21/10 E JD HPUM0016 07/22/10 W Albert Present Situation Idea Air Conditioners in Office - Cool at 74 degrees F, heat at 72 degrees F all the time. Air conditioner runs full time in the Laminator/Documents Room Air conditioner in the exercise room gets left on all the time Linde Room - Lights are on all the time RT Switch Room has lights on all the time Heater in the Surfactant room is set for 72 degrees and control is unstable Railcar loaders running more than they need to Lights are always on in the welding shop/roll storage area Candle Filter oven on 4th floor is on all the time at 600 degrees. Light in minilab on at all time. Air conditioner set at 65 degrees F. Lights in old foreman's office on at all times. Air conditioner set at 65 degrees. Many lights on at all times on 2nd, 3rd, 4th floors in old line 1 & 2 areas. Lights on at all times in old L2 gun bridge. Air conditioner on. Resin dryer turned on 24 hours prior to a PLA run, shut off at the end of the PLA run Pack Ovens on at 600 degrees all the time. Extruder for Erema kept on at full temp at all times Toilets and urinals are high use designs For offices, lower set points for cooling to 76 degrees F during occupied times, 85degrees F for unoccupied times. For Heating, lower to 70 degrees F for occupied times, 55 degrees F for unoccupied times Transfer Laminator and documents to an empty office on 2nd floor and turn off or eliminate the air conditioner. Install a timer switch so the air conditioner shuts off after a period of time once activated. Ended up setting AC at 81 degrees. Shutting off would cause excessive failure of AC. CONFIDENTIAL – 19 Repair the Motion detectors in the Linde room Put a motion sensor in the room so that only come on as needed or at least shut off whenever leave the room Determine lowest set point needed for the room, then control room to that temperature. Best temp determined to be 60 degrees. Thermostat set. Put lights on motion detectors or a program Implementation Date 7/16/2010 10-Sep 18-Oct Lower temp to 400 degrees 25-Jul Put motion detector on lights. Lock air conditioner controls at 75 degrees. Put motion detector on lights. Lock air conditioner controls at 75 degrees. Remove or put motion detectors on all lights in old L1 and L2 areas. Remove all air conditioners on L1 and L2 gun bridges. Turn on resin dryer 8 hours before a PLA run, shut off 2 hours before end of PLA run. Keep pack ovens at 300 degrees all the time. Turn up to 600 degrees when know will probably need to install pack. First step completed on 9/21 to set at 500 degrees. Turn down to 250 degrees?? if know that following shift will not run extruder. Turn back up to full temperature when new shift comes on board to run Erema Install controls on Urinals and toilets so have lower flow options 24-Jul 21-Sep
Page 1 and 2: Fitesa Case Study January 18, 2012
Page 3 and 4: CONFIDENTIAL - 3
Page 5 and 6: Spinning Pack Face CONFIDENTIAL - 5
Page 7 and 8: Slitting To Customer Rolls CONFIDEN
Page 9 and 10: Case Study - Fitesa - Phase 1 � C
Page 11 and 12: Case Study - Fitesa - Phase 1 � C
Page 13 and 14: Case Study - Fitesa � Chilled Wat
Page 15 and 16: Formation of an HPUM Team � Form
Page 17: Develop Plant Policy, Metrics, & Go
Page 21 and 22: Create Fitesa Action Plans CONFIDEN
Page 23 and 24: Develop Baseline CUSUM SUMMARY OUTP
Page 25 and 26: Washougal Site HPUM Best Practices
Page 27 and 28: Natural Gas - 67.7% Reduction Year
Page 29 and 30: Sewer Outfall - 94.6% Reduction Yea
Page 31 and 32: HPUM Committee Meeting Schedule Spo
Page 33 and 34: Plant Energy Metric Review - KWh/Kg

Fitesa Case Study January 18, 2012

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