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					Training program EnergyManager Thailand
Final report – Development of concept




                       September & October 2000

            Bangkok, Thailand and Spardorf, Germany

                                  Customer:

                                 DEDP/ENEP
                                    GTZ


               projects, Andreas-Paulus-Strasse 57, D-91080 Spardorf            1
                    Fon: ++49/9131/50460 Fax: ++49/9131/50462
      E-Mail: info@projects-online.de Internet: http://www.projects-online.de
Training program EnergyManager Thailand
Final report – Development of concept



Table of contents:



1. Background, aim, target group                                                    3
   1.1. Present situation                                                           3
   1.2. Key ideas of the training                                                   4
   1.3. Target of the training                                                      4
   1.4. Target group for the training                                               4
   1.5. Desirable profile of participants                                           5
2. Contents and expiry                                                              5
   2.1. Contents of the training                                                    5
   2.2. Curriculum                                                                  6
   2.3. Written test                                                                22
   2.4. Completion of training                                                      23
3. Training methodology                                                             24
   3.1. Self-learning of Basic knowledge                                            24
   3.2. Work on Case-Studies                                                        24
   3.3. Project work and Tutor-system                                               25
4. Training materials                                                               26
   4.1. Preparation material                                                        26
   4.2. Overhead foils                                                              27
   4.3. Case-Studies                                                                28
   4.4. Calculation Tools (Excel)                                                   29
   4.5. Check lists                                                                 30
   4.6. Online training                                                             30
5. Trainer                                                                          31
   5.1. Availability of local trainers                                              31
   5.2. Required profile of trainers                                                31
   5.3. Train The Trainer                                                           32
6. Training organization                                                            33
   6.1. Cooperation with DEDP, Industry associations, NEPO, Universities            33
   6.2. Training Provider                                                           34
   6.3. Marketing                                                                   35
   6.4. Calculation and financing                                                   36
   6.5. Cooperation model training provider & foreign consultant                    37
   6.6. Tasks and time schedule for the next steps to implementation                38

Appendix: Check list for certification of the training program                      39




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Training program EnergyManager Thailand
Final report – Development of concept

1. Background, aims, target group
1.1 Present situation:
The starting position is very multilayered and complex. The concept of the training reflects
these basic conditions, derived from numerous conversations. A successful translation into
action of the training can only be achieved if the concept reflects and integrates these basic
conditions. In the following section the most essential basic conditions are discussed:

•   The law on energy saving (Energy Conservation Promotion Act) and the duty to record
    the most important energy data as well as to appoint a person responsible for energy
    management (PRE) have brought the topic of energy use into consciousness.
•   The person responsible for energy (PRE) is too low in the company hierarchy in most
    cases. His power to initiate energy reduction projects is very small.
•   For this reason, projects which lead to greater savings are still an absolute exception.
    New efficiency technologies have usually only been introduced when it was anyway
    necessary to change plant and components.
•   Some enterprises already have a very good data collection and evaluation system on
    energy applications – almost at the level of an implemented energy management system.
    Other companies have no summary of their energy consumption and costs.
•   The situation is similar in the quality of the energy-audits carried out by registered
    consultants: large quality differences were noticed.
•   The knowledge of employees in leading positions about production problems and weak
    points in the energy area is good. These employees (plant managers, process engineers
    etc.) need knowledge and support in translating projects into action (which technical
    solutions are possible, what they will cost, how much can be saved, how they can get
    management to agree to the project)
•   The energy situation of many enterprises offers large saving potentials
•   Energy costs are of subordinate importance (some as little as 10% of the total costs) and
    not high in the consciousness of top management.
•   Previous information events, seminars and training have creating awareness, but the
    concept has not focused on translation into action. The target has been information
    transfer, not the initiation of real saving projects. Usually the PREs were the target group.
•   The content focus of the training has been on technology. For the concrete translation
    into action very important aspects including management qualifications and the economic
    issues have not been adequately considered.
•   Training is mostly subsidized with corresponding consequences: the training is not
    suitable for the needs of the customers, quality & service are not of high quality, the
    motivation of the participants is often low. Commercial training in which the training-
    provider offers excellent quality and direct application (because otherwise he cannot find
    any customers who are ready to pay the fees) does not exist at the moment.
•   At the moment the companies have no interest in a further seminar with pure information
    content. Only a concept which translates training into action and leads concretely to
    savings has any prospect of success.
•   Translation into energy cost reduction and returns on investment is the central starting-
    point in the acquisition of participating companies.




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Training program EnergyManager Thailand
Final report – Development of concept

1.2 Key ideas of the training:

The following central ideas build on the base of the situation described above for the training
program:

•   High quality
•   Participation of the leading management
•   Practice-proven trainers
•   Consistent focus on translation into action
•   Financed without subsidies
•   Fast return of investment through energy-saving projects

1.3 Target of the training

The central aim of the training is to initiate projects which lead to reduced energy costs. To
achieve this the six-step control system shown below must be implemented as an initial
measure:




       What are the tasks of the Energy Manager =
             Target of the training program:
                                  Analyse energy situation,
                                         potentials

                                                                     Selection of a subject,
    Evaluation of success                                              Development of a
                                       Six steps                     energy saving solution
                                       to energy
     Implementation of               cost reduction                 Calculation of economy,
    energy saving project                                               Return of invest

                                  Presentation to the Top-
                                 Management, get the budget


1.4 Target group for the training:

Leading employees of enterprises who perform the following duties:

•   Plant Manager
•   Production Engineer
•   Process Engineer
•   Utility Manager etc..


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Training program EnergyManager Thailand
Final report – Development of concept

1.5 Desirable profile of training participants:
• Functionally on higher management level (second or third hierarchy level)
• Decision-making powers (in the context of tasks and budgets)
• Good knowledge of production and energy-relevant processes
• Access to the top management (for presentation of project suggestions)
• University degree and EDP knowledge (Windows, Word, Excel), Basic English
• Intensive professional experience

To reach the central target of the training (energy cost reduction), the participants must have
acquired the following skills by the end of the training:
• Able to analyze the energy situation
• Able to develop saving projects
• Able to sell the project to top management (Return on investment)
• Project initiation and coordination
• Evaluating and securing the targeted savings
• Keeping a continuous improvement process in motion

2. Contents and expiry of the training:
2.1 Contents of the training
The training is split up into seminar modules which each last 2-3 days. The topics have been
arranged in the light of experiences gained in company visits and evaluations. On this basis
the training participant will cover all the contents which he needs as an energy manager in
Thai industry.
The division between management qualifications and technology qualifications is approx.
50:50. All management modules are compulsory, as are the technology topics of air
conditioning systems, electrical applications and motors, and lighting. The other technology
modules cover topics not relevant to every enterprise. Because of this the participant must
cover only three modules, selected from six possible topics according to his needs.
                  Management Modules (compulsory)                    Days
                  Energy fundamentals                                1
                  EDP, MS-Excel                                      1
                  Economy Calculation                                3
                  Energy Management System                           2
                  Project management                                 2
                  Technology Modules (compulsory)
                  Air conditioning                                   3
                  Electrical applications and motors                 1
                  Light                                              1
                  Technology Modules optional (3 of 6)
                  Process heat, Steam, heat recovery                 2
                  Chilling                                           2
                  Combined heat & power                              2
                  Compressed air                                     2
                  Energy from wood                                   1
                  Biogas, vegetable oil                              1
                  Measurement technique & process management 2
                  Sum                                                20
The following curriculum describes the exact targets, contents and procedures of the seminar
modules.


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Training program EnergyManager Thailand
Final report – Development of concept

2.2. Curriculum Energy Manager

                        Module: Energy fundamentals                                 1 day
Target                     Contents                                       Procedure
                           Energy fundamentals: (4h)
To be able to use and      • work, energy, performance
                                                                          •   Study material
explain the
                               (measurement units for energy)
fundamentals and laws                                                     •   Lecture
of science and their       •   energy forms, source of energy
relevance for energy
                               - electrical   energy
                               - heat

                               - cold

                               - pressure
                                                                          •   Case study Part 1
                           •   physical fundamentals
                                                                          • Excel-Calculation
To be able to calculate      − energy levels
performance factors          − energy flow and
                             − energy transformation steps (heating
                               values)
                             − degree of effectiveness
                             − degree of effectiveness for the
                               process, regarding the heating
                               values,
                             − distribution losses
                             − gas laws
                             − thermodynamic cycle processes
                           Optimising strategies: (4h)
To know the basics of      •   system analysis and interaction            •   Lecture,
optimising systems                                                            Overhead
(technical, operational)   •   optimising effectiveness
                           -   production                                 •   Case study Part 2

                           -   distribution
                           -   use
                               Module: Excel                              1 day
Targets                    Contents                                       Procedure
                           Microsoft Excel (8h)
                               − Programme use                            •   Examples
To work with standard
software like Excel            − Data input
                               − Programming calculations
                               − Graphics

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Training program EnergyManager Thailand
Final report – Development of concept

                   Module: Economy calculation                        2 days
Targets                    Contents                                   Procedure
                           Fundamentals (6h)
To be able to do own       • cost determination/ -investment
                                                                      •   Study material
economy calculation
                               calculation
                                                                      •   Lecture
                           •   capital costs
                           •   Energy rates and contracts
                               − Fuel oil, Gas, electrical power
                                                                      •   Calculations-e.g. in
                               − Price for work and power                 small groups
                           •   Energy costs
                           •   business related costs
                               − Maintenance costs
                               − Service costs
                               − Personnel costs
                           Analysis (4h)                              •   Case study Part 1
To be able to
calculate energy costs     •   consumption data acquisition           •   Excel-Calculation
                           •   calculating the specific energy
                               costs
To be able to              optimising variants (6h)                   •   Case study Part 2
calculate and compare
economy calculation        •   Comparative cost/benefit               • Excel-Calculation
                               calculation                            •   Input: specification
                           •   payback periods                            of NEPO-
                                                                          programm




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Training program EnergyManager Thailand
Final report – Development of concept

          Module: Energy management systems                                3 days
Targets                     Contents                                   Procedure
                            Fundamentals (8h)
To understand the           • energy management tasks
                                                                       •   Study material
scope and structure of      -  consumption evaluations
energy management –         -  performance figures /                   •   Lecture
systems                        benchmarking
                            -  integration of process                  •   Overhead
                            -  organise the energy buying
                            -  planning energy savings
                            -  optimising the use of energy
                            -  communication
                            • structure of an energy
                               management system
                            -  consumption data acquisition
                            -  consumption analysis
                            -  Checklists
                            -  automated data acquisition:
                               hardware + software
                            -   continuous energy control
                            -  Interfaces to quality management
                               (ISO 9000) & environment
                               management (ISO 14000)
                            • Energy management team
                            -  Organization of Structure and
                               processes
                            -  Distribution of tasks
                            -  Cooperation in the team
                            -  Project ideas: brainstorming
                            -  Suggestion system in the company
                            -  Further education of employees
                            Analysis (8h)
                            • consumption data acquisition as
                               related to:
To be able to get and                                                  •   Case study Part 1
                              − source of energy (electrical
work with                        power, gas, fuel oil, fuel, water)    •   Excel-Calculation
consumption data and          − objects, buildings
costs                                                                   • Check list
                              − consumption/ function
                                 parameters e.g.
                                  ⇒ heated water
                                  ⇒ process heat, steam, kitchen
                                  ⇒ special plants (e.g. TNV)
                                  ⇒ ventilation, air conditioning
                                    engineering, heat recovery
                                  ⇒ heating
                                  ⇒ housing technology , EDP use
                                  ⇒ illumination
                                  ⇒ compressed air

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Training program EnergyManager Thailand
Final report – Development of concept

                                  ⇒ cooling
                                  ⇒ drive system engineering
                            Evaluation (8h)
                            • carrying out cost allocation
To be able to use           • consumption and cost evaluations • Case study Part 2
evaluation                  • comparison of performance figures
                            • Identification of action fields & • Excel-Calculation
                              collection of project ideas


                         Module: Project management                      2 Days
Targets                     Contents                            Procedure
                            Working out a project proposal (4h)
To make a solid             • situation, problem
                                                                • Case study out of
proposal
                            • technical solution
                                                                   one of the
                            • amount of investment                 technical modules
                            •   payback time
                            •   improvements
                            Present the proposal to the
To make a presentation      top management (8h)
of the proposal to get      • how to make it clear                    • Exercise:
the budget                  •   how to argue                             presentation

                            •   Convince the decider                  • Feedback

                            •   Budget-permission                        (convincing ?!)

                            Co-ordination of the project (4h)
To be able to co-           • Exact specifications
ordinate an energy
saving project and to       • deadlines & costs                       • Case study
finish it successfully      • target and measures                     • In small groups
                            • responsible persons for the
                                measures (internal or external)
                            • Participation of the areas and
                                employee concerned
                            • Further education of employees
                            • verify the target
                            • necessary adjustments
                            • project acceptance


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Training program EnergyManager Thailand
Final report – Development of concept

                               Module: Air conditioning                  3 Days
Targets                    Contents                                       Procedure
                            Fundamentals (8h)
Understand the             • Physiological bases (well-being,
                                                                   •          Study material
function and the physics
                           snugness, airflow, humidity)
of Air-conditioning –                                              •          Lecture
systems                  • basic humidity/temperature relationship
                               diagram
                                                                          •   Example h/x-
                           • airflow, contamination
                                                                              Diagram
                           • calculation of the cooling demand
                                                                          • Example
                           • basic principles of the heat pump,
                               refrigeration plants
                                                                          •   Performance
                           •    COP
                                                                              factor
                           Components (4h)
                           • Air conditioning parts
To know the energy
saving potential of the    −   Ventilator
                                                                          •   Lecture,
elements of Air-           −   Heat exchanger
conditioning systems       −   Air humidifier/dryer                           Overhead
                           −   filter
                           −   ducts
                           −   regulators

                           • usual air conditioning systems
                           •    cold recovery
                           − recuperative heat exchanger
                           − regenerative heat exchanger
                           Analysis (4h)
Calculation of                 − Volume, airflow
performance factors for
                               − Temperature difference                   •   Excursion
efficiency ranking
                               − Energy consumption                       •   Case study Part 1
                               − Distribution losses                      •   Check list
                               − degree of effectiveness for the          •   Excel-Calculation
                                 process
                               − cost calculation


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Training program EnergyManager Thailand
Final report – Development of concept


                           Optimising variants (4h)
                           • Behaviour
                               − Employee awareness
Optimising air
conditioning systems       -     Coordination of measurements with        • Check list
(technical, operational)
                                 participation of the persons affected
                           -     Definition of maintenance tasks and
                                 –intervals
                           •     Process optimising
                                − Well-being parameters
                                − Regulation and control (night
                                   cooling)
                                − Maintenance
                           •     Investment
To be able to calculate    − Exchange the chiller                         •   Case study Part 2
the energy saving
                           − Absorption-, Adsorption                      •   Excel-Calculation

                           − fountain water cooling
                           − Adiabate cooling
                           − Renew distribution net
                           − Use of the waste heat
                           • Calculation of the energy savings
                           Cost-benefit calculation (4h)
To be able to calculate                                                   • Case study Part 3
the cost saving and the    •     Investment needs
pay back time                                                             •   Excel-Calculation
                           •     Energy costs savings
                           •     Payback time




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Training program EnergyManager Thailand
Final report – Development of concept

          Module: Electrical applications and motors                                1 Day
Targets                    Contents                                Procedure
                           Fundamentals (2h)
To know the basics of      • grid
                                                                   • Study material
electricity and            - losses
technology                 - transformers                          • Lecture
                           - power factor and compensation
                           • motors (AC,3-phase, DC, Linear motor)
                           •     efficiency
                           •     applications (power, advancement)
                           •     Regulation and controls
                           Analysis (2h)
                           •     Measurement grid +motor
Calculation of                                                             •   Case study Part 1
                           •     Distribution losses
performance factors for                                                    • Excel-Calculation
efficiency ranking         •     Energy costs
                           Optimising variants (2h)
                           • Behaviour
                               − Employee awareness
                           -     Coordination of measurements with         •   Lecture,

                                 participation of the persons affected         Overhead

                           -     Definition of maintenance tasks and       •   Case study Part 2
                                 –intervals                                •   Check list
                           •     star wiring compared to triangle wiring   • Excel-Calculation
Optimising the system
(technical, operational)   •     Electronic revolution control
To be able to calculate
the energy saving          •     Pumps / Ventilators
                           • adapting drive power to actual
                                requirements
                           •     System optimising
                           •     Calculation of the energy savings
                           Cost-benefit calculation (2h)
                                                                           •   Case study Part 3
To be able to calculate    •     Investment needs
the cost saving and the                                                    • Excel-Calculation
                           •     Energy costs savings
pay back time
                           •     Payback time


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Training program EnergyManager Thailand
Final report – Development of concept

                               Module: Light                              1 Day
Targets                    Contents                                       Procedure
                           Fundamentals (2h)
To understand the          • light engineering
                                                                          •   Study material
basics of light
                           − lay-out of lighting installations
                                                                          •   Lecture
                           − flux, efficiency
                                                                          • Overhead
To know about the      •       lamps (glow, phosphorous, plasma,
function of the                induction, LED)
elements of light
systems and the energy •       electronic adapting equipment,
saving potential               transformers
                           •   Light systems (pale, prism, reflector)
                           •   automatic switch-off timing program,
                               movement detector
                           •   daylight compensating regulation

                           Analysis (2h)
Calculation of                                                            •   Case study Part 1
                           •   light measurement
performance factors for                                                   •   Excel-Calculation
efficiency ranking         •   calculating consumption
                           •   light costs calculation
                           Optimising variants (2h)
                           • lay-out of lighting installations by

Optimising the system          efficiency
(technical, operational)   •   Process optimising                         • Case study Part 2
To be able to calculate
the energy saving          •   Regulation and control, (time, daylight) •     Excel-Calculation

                           •   Investment
                           •   Calculation of the energy savings
                           Cost-benefit calculation (2h)
To be able to calculate    •   Investment needs                           •   Case study Part 3
the cost saving and the
                           •   Energy costs savings                       • Excel-Calculation
pay back time
                           •   Payback time




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Training program EnergyManager Thailand
Final report – Development of concept

    Module: Process heat, steam, heat recovery                                2 Days
Targets                    Contents                                       Procedure
                           Fundamentals (4h)
To understand process      • System analysis
                                                                          •   Study material
chains and interaction
                           -   Elements
                                                                          •   Lecture
                           -   Functions
                           -   Thermal levels
                           -   Process chains and interaction
                                                                          •   Overhead
                           •   Heating
To know about the              - boiler   construction
function of the
                               - Thermo     oil
elements of the systems
and the energy saving          - steam/hot    water
potential
                               - low   temperature, condensation heat
                               - steam    compression
                           •   heat distribution
                           -   elements
                           -   Actor
                           •   Heat exchanger
                           •   Process regulation and control
                           Analysis (4h)
Calculation of                 − Process data                             •   Case study Part 1
performance factors for        − Boiler temperature regulation and        •   Excel-Calculation
efficiency ranking
                                  control
                               − exhaust and boiler losses
                               − stand still losses
                               − Water and steam losses
                               − Distribution losses
                               − Boiler efficiency
                               − degree of effectiveness for the
                                  process, regarding the heating
                                  values
                               − Heat cost calculation


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Training program EnergyManager Thailand
Final report – Development of concept




Optimising the system      Optimising variants (6h)
(technical, operational)                                                  •   Check list
To be able to calculate    •   Process optimising
the energy saving              − Typical weak points
                               − Behaviour
                               − Participation and awareness of
                                 employees
                               − operating state
                               − stand still times
                               − unnecessarily high temperatures
                               − Regulation and control
                               − Maintenance
                               − degasing                                 •   Lecture
                           • Investment                                   •   Excursion
                               − Pumps                                    •   Case study Part 2
                               − Heat net                                 •   Check list
                               − Heat recovery                            •   Excel-Calculation
                               − Waste heat use in the processes
                                 (steam compression)
                               − Waste heat use for other processes
                                 (low pressure cooking/ destilation)
                               − Calculation of the energy savings        •   Case study Part 3
To be able to calculate
the cost saving and the    Cost-benefit calculation (2h)                  •   Excel-Calculation
pay back time                  − Investment needs
                               − Energy costs savings
                               − Payback time




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Training program EnergyManager Thailand
Final report – Development of concept

                             Module: Chilling                     2 Days
Targets                    Contents                                       Procedure
                           Fundamentals (4h)
To know about the          • Elements and Function:
                                                                          •   Study material
function of the
elements of the systems − Heat exchanger, Actor                           •   Lecture
and the energy saving   − Compression
potential                                                                 • Overhead
                        − Absorption
                           − Ejector
                           − Refrigerant
                           − COP
                           − Cold distribution                            • Example
                           − Calculating chilling requirements
                           Analysis (4h)                                  •   Case study Part 1
                              − COP                                       •   Excel-Calculation
Calculation of                − Still stand losses, Distribution losses
performance factors for
efficiency ranking            − degree of effectiveness for the
                                 process
                              − chilling costs calculation
                           Optimising variants (4h)
Optimising the system         − Behaviour
(technical, operational)      − minimise chilling requirements            •   Lecture
To be able to calculate
the energy saving             − Process optimising (defrost)              •   Case study Part 2
                              − Regulation and control                    •   Check list
                              − Maintenance
                              − Investment
                              − Use of waste heat
                              − Absorption chiller                        • Excel-Calculation
                              − Calculation of the energy savings
                           Cost-benefit calculation (4h)
To be able to calculate
                              − Investment needs                          •   Case study Part 3
the cost saving and the
pay back time                 − Energy costs savings                      •   Excel-Calculation
                              − Payback time

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Training program EnergyManager Thailand
Final report – Development of concept

             Module: Combined heat & power (CHP)                               2 Days
Targets                    Contents                                       Procedure
                           Fundamentals (4h)
                           • basic concepts and variants of CHP
To know about the                                                         •   Study material
function of the            -   power production and heat use
                                                                          •   Lecture
elements of the systems    -   Combined heat & power(CHP)
and the energy
production potential       -   Combined heat, cooling &
                               power(CHCP)
                           •   components of CHP plants
                           -   Gas turbine, steam turbine, ORC
                           -   motor types (gas, steam, Diesel, Otto)
                           -   Fuel cell
                           •   Gas expansion
                           •   Periphery systems                          Overhead
To know about the
elements of the            −   top boilers, buffer storage
peripheral systems         −   heat exchanger
                           −   net integration
                           −   Synchronous- and
                           −   Asynchronous generator
                           −   Grid integration
                           −   Regulation and control
                           −   Absorption-/Adsorption

                           Analysis (4h)                                  •   Case study Part 1
To know how to get the
lay-out parameters         •   Annual heat demand                         • Excel-Calculation
                           •   Annual cooling demand
                           •   time/performance relationship lines
                           •   Daily power demand
                                                                          •   Lecture
To fit the CHP into the    lay-out of a CHP-plant (4h)
energy consumption         • Heat- /power lay-out                         •   Case study Part 2
                           -   Calculation of the heat, cooling and       •   Excel-Calculation
                               power output
                                                                          •   Check list
                           •   Calculation of the energy savings
                           Cost-benefit calculation (4h)
To be able to calculate                                                   •   Case study Part 3
the cost saving and the    •   Investment needs
                                                                          •   Excel-Calculation
pay back time              •   Energy costs savings
                           •   Payback time

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                               Module: Compressed air                    2 Days
Targets                    Contents                                       Procedure
                           Fundamentals (4h)
To know about              • basics
                                                                          •   Study material
compressed air             • basic compressor construction
                           • consumption machine/ISO 1217                 •   Lecture
To know about the          • air conditioning
function of the            • Regulation and control
elements of the systems                                                   •   Example
and the energy saving   •      revolution control
potential               •      compressed air distribution
                           -   pipe lay-out
                           -   Fittings
                           -   Pressure losses
                           •   Compressed air users
                           - Pneumatic
                           - Vacuum- / lift technique
                           - advancement
                           Analysis (6h)
                           • measure compressed air consumption
                           • power consumption
Calculation of             • Distribution losses
performance factors for                                                   •   Case study Part 1
efficiency ranking         • measure leakage
                                                                          •   Check list
                           • degree of effectiveness for the process
                                                                          • Excel-Calculation
                           • compressed air costs
                           Optimising variants (4h)
                           • pressure standards
                           • Regulation and control
Optimising the system
(technical, operational)   • net, maintenance
To be able to calculate                                                   •   Case study Part 2
                           • use of waste heat
the energy saving
                                                                          • Excel-Calculation
                           • Investment
                           • Calculation of the energy savings
                           Cost-benefit calculation (2h)
To be able to calculate                                                   •   Case study Part 3
the cost saving and the        − Investment needs
pay back time                                                             •   Excel-Calculation
                               − Energy costs savings
                               − Payback time

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                          Module: Energy from wood                            1 Day
Targets                    Contents                                       Procedure
                           Fundamentals (2h)
To know the types of       • types of biomass
                                                                          •   Study material
biomass
                           -   solid : wood, bamboo
                           -   liquid: food industry waste, vegetable
                               oil and fat
                           -   gas: bio gas from fermentation
                           •   Elements and Function:
                           − Wood boilers (hot water , steam)
                                                                          • Lecture
                           − Steam production
                                                                          • Overhead
To know about the      − Power production (Steam motor)
elements of the system
                       − advancement
                           − Silo technique
                           − Fire prevention
                           − filters, Emission reduction
                           − Ash use
                           − top boilers, buffer storage
                           − Regulation and controls
                           Analysis (2h)
                           • Annual heat demand                           •   Case study Part 1
To know how to get the     • time/performance relationship lines
lay-out parameters                                                        •   Excel-Calculation
                           • Daily power demand

                           Lay-out of wood heating systems (2h)
To fit the system into the                                                •
                           •   Heat power control of wood heating             Case study Part 2
energy consumption
                               systems                                    • Excel-Calculation
                           •   Calculation of the energy saving
                           Cost-benefit calculation (2h)
                           • Investment needs                             •   Case study Part 3
To be able to calculate
the cost saving and the    • Energy costs savings                         •   Excel-Calculation
pay back time
                           • Payback time


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                          Module: Bio gas, vegetable oil                      1 Day
Targets                    Contents                                       Procedure
                           Fundamentals (2h)
                           •   Bio chemical processes, fermentation       • Lecture
                           •   production of bio gas                      •   Overhead
To know about the
function of the            −   Fresh substrate tank
elements of the systems    −   Fermentation tank
and the energy             −   Bio gas cleaning
production potential       −   Bio gas tank
                           −   Fertiliser tank
                           −   Water treatment

                           Analysis (2h)
To know how to get the
lay-out parameters         • Waste input                                  •   Check list

                           •   Possible bio gas production                •   Case study Part 1

                           •   Annual heat demand                         •   Excel-Calculation

To fit the system into the Lay-out bio gas system (1h)
energy consumption         • Components                                   •   Case study Part 2

                           •   Gas production                             • Excel-Calculation

                           •   Power production
                           Cost-benefit calculation (1h)
                           • Investment needs                             •   Case study Part 3
To be able to calculate
                           • Energy costs savings                         • Excel-Calculation
the cost saving and the
pay back time
                           • Payback time
                           Vegetable oils in drive system
                           engineering and at CHP plants (2h)
Where to use vegetable • Oil quality                                      • Lecture
oil                                                                       • Overhead
                       • Oil input
                           • Motor for water pumps
                           • Motor for vehicles
                           • CHP




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 Module: Measurement technique & process management 2 Days
                           Fundamentals (4h)
To know about the basic
                        •      basic concepts and wiring                  •   Study material
concepts
                        •      components of equipment and                •   Lecture
                               systems:
                           -   Field controllers (Sensors + actor)
                           -   DDC- stations, control station
                           Analysis (2h)
To be able to get the
parameters for the         •   Regulation parameters                      •   Case study Part 1
controller                 •   Regulation schemes                         •   Check list
                           •   Hardware
                           •   Not regulated processes (losses)
                           Optimising variants (4h)
Optimising the system      •   Demand driven regulation and control       •   Case study Part 2
(technical, operational)
                           •   Regulation and control of processes
                           •   DDC-based regulation and control
                               equipment
                           •   Calculation of the energy savings          •   Example


                           Cost-benefit calculation (2h)                  •   Case study Part 3
To be able to calculate    •   Investment needs
the energy saving          •   Energy costs savings
                           • Payback time
                           Process management (4h)
To understand the          • process data transfer and -evaluation
possibilities of process   •   Central server, bus systems
management
                           •   Evaluations- and controlling software
To know the elements of
                          •    Control via modem
process management
                                                                          • Calculations-
                          •    power management systems for
To know how a power                                                           example power
                               reducing peak loading demands
management system
                                                                              management
works. To be able to      •    Cost-benefit calculation power
calculate the cost saving                                                     system
and the pay back time          management system

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2.3. Written Test

At the end of the seminar modules a written test takes place. The following subject areas are
checked:

•   Air conditioning
•   Electrical drives
•   Energy management system
•   Economy calculation
•   A topic from the optional modules (can be suggested by the participant)

Every subject area is checked by two tasks: A knowledge question (text) and a calculation.
The subject areas and exercises which are similar to the test tasks are announced to the
participants approx. four weeks before the test. The knowledge questions can each be
answered in 5-10 minutes, solving the calculation tasks needs 10-20 minutes for each area.
Permitted aid is a pocket calculator.

Example of test tasks from the area air conditioning:

Knowledge question:

Explain the procedure for the optimization of an air conditioning plant

Which variables determine the energy consumption of an air conditioning plant with the
functions humidification, dissecation, heating, cooling? How can these be influenced?

Calculation task:

An existing air conditioning plant shall be optimized by customization of the running time.

Formulas:
Q = c x V´ x LGH                             c = 0,34 Wh / m³K
,                                            LGH = 110.000Kh / a
W el = P el x b                              b = running time
V´ new / V´old         = n new / n old       n = rotational speed
P new / P old          = (n new / n old)³

Data:
Volume current V´      old            20.000 m³ / h from 00.00 until 24.00
                       new            20.000 m³ / h from 07.00 until 19.00
                                      10.000 m³ / h from 19.00 until 07.00;
Warmth price                          30 € / MWh
P el ventilators                      12 kW
Price of electricity                  50 € / MWh

Calculate:
• the warmth saving
• P El at 10.000 m ³/H
• the current saving
• the cost saving



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2.4. Completion of the training

The training extends over a period of approx. six - eight months. The seminar modules are
two or three-day and cover 1-2 topics. The first four seminar modules take place at intervals
of two weeks, the following seminar modules at intervals of three or four weeks. By this
interval principle too much time-pressure on the participants is avoided (the absence times
from the company are tolerable). It is a further advantage of this procedure that the acquired
knowledge can be immediately used in the practice and that translation into action comes
very quickly into play. After all seminar modules are completed the written test takes place. In
parallel to studying in the seminars translation into action is established through execution of
a project work. After two to four months the project work starts with a topic or problem
chosen by the participant from his own company. The project work extends over a period of
three months and is carried out directly on-site in the company by the participant. When
questions and problems appear during the project work the participant gets support through
a tutor system (for detailled description of project work and tutor system see the Chapter on
training methodology). At the end of the training the exam takes place: the written test and
the project work each accounts for 50%.

The following graphic illustrates the course of the training with all essential elements:



                        Steps of the training program:
                    April       May   June   July   August   September October November

   Seminar          1       2     3     4     5         6    7       8      9
   modules:

                                                                                 Exam: Certified
                                                                                 Energy Manager

            Translation into             1          2            3        Finished
           action:one Project-                                           project work
          Work with for example
               three steps
                                                                           Benefit for the company:
                                       Support at the implementation:      Energy cost reduction
                                         Tutoring system, external
                                           trainers and experts




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Training program EnergyManager Thailand
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3. Training methodology
The main aim of the training program is the translation into action of saving projects and the
achievement of reductions in the energy costs of the companies. Because of this only very
practice-oriented training methods (learning by doing) are used.

The training methods are:

3.1 Self-learning of basic knowledge in each subject area:

Without a minimum of basic knowledge an understanding of the subject area is not possible.
On the other hand it is not necessary to know the last technical details of a subject area to
successfully save energy. Therefore the most essential background information is
summarized very briefly and understandably in preparatory materials. The participants get
this preparation material (by e-mail as pdf-file or as Printout) 2-4 weeks before the respective
seminar module to allow them to acquire the base knowledge. In this way the seminar
module can be worked in a very practice-oriented way without having to spend a long time
on theoretical background.

3.2 Work on Case-Studies in the seminar modules

At the beginning of every seminar module the basics covered in the preparation material are
repeated briefly. This makes sure that all participants are at the same knowledge level.
The knowledge essential for the practice is acquired by working-through of prepared Case-
Studies. The basic idea is that working and calculating concrete tasks from beginning to end
leads to a much better learning process than only listening passively. The procedure is
reflected in the case-studies in which the energy manager directly uses the company
practice. This procedure consists of the following three main steps:

1. Analysis
• Analyse a plant for weak points
• Collect and evaluate the relevant data
• Calculate current energy consumption
• Calculate performance factors
• Judge the condition of the plant with the performance factors

2. Optimization possibilities
• Technical and operative possibilities for the elimination of weak points
• Choice and layout of the most favorable variants
• Calculation of the energy savings

3. Economy calculation
• Investigation of investment needs
• Calculation of the energy cost saving
• Calculation of the payback period




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This procedure is the key thread of the training program. In every seminar module the
participants themselves work out for the topic these three main steps. The aim is to commit
the participants to this procedure and to ensure they use it permanently. This procedure
makes the application in their own enterprise very much easier.
With the calculation tasks in the case-studies the participants can develop a sense for the
energy saving and cost reduction potentials through optimized applications.
The case-studies provide a real situation and the necessary data for every processing step.
The trainer explains the current situation and demonstrates the next processing step. The
participants then calculate this processing step with data that is easily changed. Depending
on the topic, Excel-Tools are sometimes used (see chapter on training material). The trainer
supports the participants with questions or problems. In this way the trainer proceeds in the
role of a coach and not as a traditional "teacher". When all participants have completed the
processing step successfully, the trainer moves to the next step.

3.3. Translation into practice by project work, support by tutor system

A very important methodical element is the project work. The project work ensures the
immediate practical translation into action of the knowledge acquired in the training. The
project work has direct usefulness for the participant and for the company. Through the
project work, a concrete saving project for the company is already initiated during the training
preiod. This practice project is worked out using the procedure studied in the seminar
modules: Is-analysis, optimization possibilities and economy calculation. Appproximately half
way through training the participants are asked to suggest a topic from their own company as
project work. It should be a topic which represents a weak point in the company’s energy use
(this weak point might have been known before the training or become obvious in the course
of the seminar modules). The topic is defined as a project with the following structure:

•   Project topic
•   Target & contents
•   Deadlines
•   Project leader & Tutor

The topic of the project work should not be too complex (otherwise processing is hardly
possible in the defined time). Using the tools learned in the training (check lists, Excel-
Sheets), every participant develops his project work. Experience shows that most
participants meet problems which they cannot solve immediately. In such a situation the
participant can get the advice of a tutor. The participant sends a short description of his
problem to the training provider (by telephone, fax or e-mail). The training provider consults
the corresponding expert (normally the trainer responsible for the topic of the project work,
but in special cases also foreign experts). The participant then directly receives support from
"his" tutor. The tutor system makes sure that none of the participants gets stuck in his project
work and all project work is completed successfully.
The project work shows usually medium- to large-reduction potential. If the company
undertakes the suggested optimization measures, an often considerable cost reduction
which clearly exceeds the cost of the training charges is already achieved during the training
period. The methodical element of the project work guarantees the companies fast, visible
translation into action and the corresponding return on investment. The completed project
work is presented at the end of training as if the participants were selling the project
suggestion to their top management.




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4. Training materials
Preliminary note: All training materials must be in the Thai language and in English to make
use possible for all participants. Without translation of the materials into Thai a meaningful
training realisation is not possible. Materials used in the Training Division of DEDP could be
used.

4.1. Preparation material
The preparatory material serves to transfer the most essential background information in
compressed form. The participants work alone in the subject area and obtain a summary.
The time-consuming introduction to the theoretical background is dropped in the seminar
module. An example of preparatory material from the area of Chilling:

             Direct-fired absorption water chillers (Natural Gas)




Cooling Cycle
The absorbent/refrigerant combination is a traditional lithium bromide/water solution. The
dilute solution is first pumped from the absorber to the low temperature generator, where it is
partially concentrated. A heat exchanger transfers heat from the generator and preheats the
incoming solution. Part of the solution is then pumped to the direct-fired (high temperature)
generator where it is further concentrated, while the rest of the flow from the low temperature
generator is mixed with the strong, concentrated solution coming back from the direct-fired
generator. This mixed solution is then combined with additional solution from the absorber to
form the absorber spray.

and so on ......


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4.2 Overhead foils

For every topic the trainer can use a package of foils. With the help of this foil package the
trainer can present informations which goes deeper than the contents of the preparatory
material:

• Introducing new technologies
• Explaining functional principles
• Showing expiry scheme
• Introducing optimization strategies
• Showing coherences
• Explaining calculation techniques


These foil packages can be completed and enlarged by the own foils of the trainers.


Example of a foil from the area air conditioning:




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4.3. Case-Studies:

The case-studies represent a central component of the methodical concept. Through the
case-studies the consistent practice orientation of the seminar modules is achieved. Because
of this a concrete project is contained in the case-studies. The case-studies contain the
following elements:

• Description of the initial situation and the target
• Pictures and drawings/plans as required
• Compilation of the relevant data
• Formulation for the is-analysis
• Variants for the optimization
• Formulation of the calculation of an optimization variant
• Costs and prices for the optimization variant
• Formulation for the economy calculation

An example of a case-study from the topic of compressed air:

Initial situation:
Two compressors are used for operating 4 machines. A blowing gun is at every machine to
blow out shavings from the machines. A maintenance unit sits in every machine to de-
condense the incoming compressed air and to oil the pressure cylinder. Water filters are
located in the main line and in the tap lines to de-condense the compressed air. Condensate
nevertheless repeatedly arises at the machines and the blowing guns. The factory works in 2
shifts (16 hours).




and so on ........



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4.4 Calculation Tools (Excel)

The main steps of the energy optimization (analysis, optimization possibilities, economy
calculation) require a considerable number to calculations. To make this calculation work
easier and to ensure a correct calculation method Excel-Tools are used. The calculation
steps and the necessary formulae are saved already. The calculation comes down therefore
to the participant working correctly with the software Excel, the correct input of data (yellow
fields) and the plausibility check. With help of Excel-Tools calculations to show first-trend
statements (are actions worth-while or not?) can be made very quickly and simply. The Excel
- Tools are developed to be immediately usable for the calculation tasks of the case-studies.
Through this the case-studies can be coped with in the defined time and further time remains
for discussion and reflection on the learned techniques and methods. Beside the use of the
Excel-Tools in the case-studies they can also be used for calculations in the project work
and within the participant’s own company. The participants get real added value.

Example from the area Combined heat & Power:
  Legend:       Infos for use     Data input              Text input
                results of calculation                    results from other calculation sheets

  Lay-Out cogeneration moduls:                                                             Heat consumption/year:                          15000 MWh/a
                               Continous consumption                          Th. Power
  Heat peak            3000 kW    of process heat                  910 kW      Modul 1:                     900 kW Th. Power Modul 2:           500 kW


                                                          Heat demand over the year
   4.500 kW
                3.910 kW
   4.000 kW

   3.500 kW                                                                                         Heat demand


   3.000 kW
                                                                                                    Th. Power
   2.500 kW                                                                                         Cogeneration
   Q'
   2.000 kW

   1.500 kW

   1.000 kW

     500 kW

        0 kW
                 0    500   1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500
                                                                          [h/a]


                                   energy source Gas=1;      Electrical           source                                                consumption of
                Running time               Oil=2              power               power       Heat-production      Power-production      energy source

  CHP 1                8.700 h/a               1              450 kW          1530 kW             7830,0 MWh/a       3915,0 MWh/a       13311,0 MWh/a

  CHP 2                6.341 h/a               1              250 kW              850 kW          3170,5 MWh/a       1585,3 MWh/a       5389,9 MWh/a

  peak boiler                                  1               0 kW           3910 kW             3999,5 MWh/a         0,0 MWh/a        4705,3 MWh/a

     Sum                                                      700 kW                              15000,0 MWh/a      5500,3 MWh/a       23406,1 MWh/a




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4.5. Check lists

The participants can systematically check their energy applications, identify weak points and
recognize meaningful optimization possibilities with help of the check lists. In daily work
check lists have a high value because they make ‚pack & go’ procedure possible: Check list
on a writing board and begin the on-site analysis of possible energy optimizations.
The check lists also support the design of saving projects: Have I thought of all important
points?

Statement from a check list from the area compressed air:

                                                                                       S   M    L

Maintenance work
•   Noting down and evaluating running hours regularly (monthly), distinguishing       X
    between load and neutral hours.
•   If a central instrumentation system records the on-period and turn-off time of
    the compressed air station, these data should evaluated regularly and the
    control should be optimized if necessary.
•   An increase in the running hours without plausible explanation has caused
    increased losses or a drop in performance of the compressor or necessary
    maintenance work.
•   Checking loss of pressure of the compressor to the consumers. Not more than        X
    0.5 bar (cold dryers 0.3 bar, lines 0.1 bar, filter etc. 0.1bar).
•   Carrying out regular leakage search and elimination. Determining the leakage       X
    performance by the following test after turning all consumers off: Set the plant
    running on maximum overpressure and then switch off. Measure the time until
    1 bar of operating overpressure has decreased (repeat and calculate mean
    average value).

•   Dissipation power = volume (pipe and container) x pressure losses/time

•   Leaks can be found quickly with a leak search spray or a soap solution. Also it
    is possible to determine leakages through regular walks during production-free
    times listening for whistling noises. From a leak of 1 mm escape at a operating
    overpressure of 7 bar of approx. 0.1 m³/min, at 10 bar of already 0.2 m ³/min.

S = Short-Term         M = Medium-Term              L = Long-Term

4. 6 Online training

Direct on-line training is not possible at the moment because of the still not universally
available computer infrastructure and the very varied use habits. A preliminary stage of
computer-assisted and internet based training is introuced in the preparatory material (by e-
mail as appended file) and Excel - Tools. By developing the habital use of computers this
makes later online training more easily introduced.




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5. Trainer
5.1 Availability of local trainers

The quality of a training program is strongly influenced by the quality of the trainers. As they
work with the participants directly their didactic skils, content competence and appearance
largely determine the participants’ opinions of the training. A thorough procedure is therefore
important in the choice of trainers and their preparation for the training.
Based on different conversations in Bangkok the following points are noted:

• Practice-proven experts in the area of energy management & efficiency technologies are
    very rare, and still more so with didactic experience
• Visits to universities (King Mongkut in North Bangkok and in Thonburi) suggested that no
    practice-experienced trainers can be offered by this source
• Further enquiries suggested that possible trainers could be found from the following
    sources:
    - Plant   producers
    - Planning   and executing companies
    - Energy   advice companies
• They have the necessary practice experience, though there is the danger that they would
    be too strongly product or sale orientated. To avoid this clear briefing and evaluation
    measures are needed.
• On the basis of present experience and dicussions it seems possible to arrange a team of
    trainers which is practice-tested and engaged

5.2. Required profile of trainers

The main focus lies in practice knowledge for the ‚translation into action’ orientation of the
training program. The required profile to the trainers can be outlined:

•   University degree in technical or scientific or business management studies
•   Good specialized knowledge in his subject area, specialist in the field of the application
•   Practical experience (proof of projects planned and carried out)
•   Didactic experience (proof of seminars, teaching events etc. carried out)
•   Methodical work (ability to structure the subject area and to work step-by-step)
•   Tutor (readiness to work as tutor and to support training participants in their project work)
•   Good EDP and English knowledge (written and spoken English)

This profile is an ideal type which cannot be always be achieved in all points, however it
should be a guideline for the choice of trainers.




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Training program EnergyManager Thailand
Final report – Development of concept

5.3. Train The Trainer

A preparatory Train The Trainer program is essential:

•   Knowledge gaps can be closed
•   The training methodology to be used will be applied uniformly
•   Interfaces with colleagues can be regulated

The training of the trainers can be carried out in the following steps:

1. The trainers work through the preparatory material and bring in their suggestions.
   Questions or knowledge gaps can be immediately cleared.

2. Train The Trainer in Bangkok, complete duration approx. 4 weeks

•   Work through the prepared case-studies as the training participants will later do.
    Instruction will be by the foreign expert who designed the case-studies

    - Transfer  of all necessary knowledge
    - Coordination   of understanding
    - Clarification of open points
    - Completion of necessary additional topics
    - Discussion of materials
    - Calculating the calculation tasks
    - Work with Excel - Tools
    - Training in standardized procedures
    - Advice on the use of the various materials
    - Coordination of the training understanding and the role of the coach


•   Check-up of practice experience by factory visits with local trainers and foreign expert
    together. The aim is the coordination of important practical topics through the use and
    test-practice of the check lists

    - Typicalweak points (to what must we draw the attention of the participant?)
    - Analysis(How can the participant find out and calculate this)?
    - Optimization possibilities (what can we offer the participant?)


•   Test training with an experiment group, e.g. the employees of the training division of
    DEDP and other persons from industry companies

    - Localtrainer teaches selected parts of his subject area
    - Feedback  of the experimental group
    - Feedback from the observing foreign expert




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Training program EnergyManager Thailand
Final report – Development of concept

6 Training organization
6.1. Cooperation with DEDP, Industry associations, NEPO, Universities

Without good links to the relevant partners and promotors a successful start to the training
program is very difficult. As well as technical and methodical work, therefore, attention must
be given to this area. It is not neccessary to bring all possible participants and persons
affected into the project (this is almost impossible in Thailand in view of the very complex
structures), but it is absolutely necessary to involve DEDP/ENEP.

Co-operation with DEDP/ENEP already started should be deepened continuously. It would
be important to keep DEDP/ENEP regularly informed about each step of the project’s
progress, new knowledge gained and first results and to obtain corresponding feedback.
Such an iterative training development should ield a fully worked out training program
supported and certified by DEDP/ENEP (a check list with criteria which should be fulfilled for
certification is suggested in the Appendix). Similar steps should be taken to integrate the
industry associations. In the first conversations some interest was noted but a support or
endorsement by the industry associations is currently far away. The provision of regular
information should build up the confidence of the associations. The ENCON-Fund as a
promoting organisation is not involved in the training program directly (companies will pay the
training charges at commercial rates). In a second phase, however, saving projects will arise
out of the training. These projects could apply to ENCON-Fund (about DEDP) for subsidies
for necessary investments. The integration of ENCON-Fund is important in the form already
described. For the participants it can be furthermore very helpful to be able to retrieve further
information about special training courses and training materials from training resource
center of DEDP.
Because the universities cannot offer either practice-experienced trainers (see chapter on
trainers) or the organization of the training, cooperation with the universities visited (King
Mongkut North Bangkok and Thonburi) cannot be recommended at the moment.
The organizational anchorage is summarized in the following graphic:



                         Training organisation
    DEDP                                                             NEPO, Industry
                             Training provider                        associations
                         Internal training manager


   Foreign experts                                           External thai trainers




                            Companies, Factories

               Tutoring


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Training program EnergyManager Thailand
Final report – Development of concept

6.2. Training provider

The search for possible Thai Training-providers was relatively difficult. The only clear
commitment to include the training in a regular training programm and to organize the project
in Thailand came from the Thai German Institute in Chonburi. TGI agreed to provide its
infrastructure of classrooms, computers and technology equipment. TGI is also ready to
invest in necessary advance preparations from its side. Together these are good
prerequisites, although the TGI does not currently have any employees with know-how in the
energy area. This must be provided by the foreign consultant in the start-up phase and then
be completely built up at TGI (through a transfer of technology).

The marketing and organization of the training program must be done entirely by the Thai
Training-provider. This covers the following tasks:

•   Marketing, participant acquisition
•   Planning of rooms and dates
•   Coordination of the external trainers
•   Organizational support for the participants
•   Coordination of the project work and the tutor system
•   Conception of the testing and certification system
•   Providing a contact point for the foreign consultant

For this tasks a Thai training manager who has corresponding qualifications is necessary:

•   Spoken and written English and Thai
•   Professional experience in the industrial area
•   Access to industrial companies, connections in the target group
•   Involvement in sales
•   Organizing ability
•   Ability to cover single seminar modules as trainer

Most seminar modules can be carried out by local external trainers working on a fee basis. In
the pilot training single seminar modules should be handled by the foreign consultant. This
would have the following benefits:

•   Marketing: The use of foreign specialists improves the image of the training and the
    readiness of the customers to take part in the training (and to pay for this)

•   Quality assurance: The experience of the foreign specialist in training energy managers
    guarantees a corresponding quality standard




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Training program EnergyManager Thailand
Final report – Development of concept

    6.3 Marketing

It has to be assumed that barriers and scepticism will be high for a new product in which
there is still no practice experiences. Because of this a purely commercial training which runs
without any subsidies will require considerable marketing effort at the start.

The proposed training has some conceptually unusual features which give it high value
(practice orientation, translation into action, support systems like check lists and Excel-Tools,
project work & tutor system). These unusual features need to be explained. For this reason
personal marketing commends itself for the acquisition of trainees in the pilot phase. This
personal marketing should contain the following elements:

•   Information events for the top management, with the incentive of a special event and an
    attractive framing, to raise awareness of the topic. The topic should be presented briefly
    and crisply with a focus on the possibilities for cost reductions and profit increases
    through consistent energy management. The aim should be to win top management
    support for the topic and to motivate them to send participants to the training from their
    companies

•   Direct acquisition through personal contacts, recommendations, company visits. In the
    company visits the special benefits of the training concept and their usefulness should be
    explained in personal conversation. Examples of the usual saving potentials and resulting
    cost reductions should be given

•   Appearances at trade fairs could also be an effective instrument, though only if the target
    group is really represented at the fair. Recommended after the first training has started

•    Mailings should used for acquisition of the second training wave

•   For the acquisition of the second and subsequent trainings it will be very helpful if
    participants from the pilot training report their experiences (success stories). Nothing is
    more convincing than positive experiences from first hand ! These reports can presented
    in the context of

    - Information    events
    - Internet   presentations
    - Professional    journals
    - PR   actions
    - Information    booklets
    - Mailing    actions
    - Conferences     & meetings
    - Association    magazines




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Training program EnergyManager Thailand
Final report – Development of concept

6.4. Calculation and financing

The training concept does not include any Goverment subsidiy. On the contrary: The
willingness to make full payment for the training charges can be taken as the yardstick of
willingness to translate training into action. Logically, if the company pays the training
charges, they have a strong interest in the translation into action of at least one saving
project, to secure a fast return on investment.

The calculation contains the following expenditure categories:

•   Marketing & acquisition                  80.000
•   Administration                           60.000
•   Rooms                                    40.000
•   Trainers                                280.000
•   Test & project work                     140.000
•   Depreciation of the investments         170.000
•   Further development of the training      50.000
•   Sum                                     820.000

•   Profit                                   80.000
•   Necessary sales volume                  900.000

The results are based on a rough estimate of cost structure. The largest uncertainty lies in
the effort of marketing & acquisition. If considerable additional expenses should be
necessary here, the training will quickly run into losses.

On the basis of this calculation and using an average of 13 participants per course, a price of
70.000 Baht per participant arises. This covers a complete package:
• 20 seminar days
• Tutoring of the project work
• Translation into action-supporting materials (Case-Studies, Check lists, Excel-Tools)

The central question is whether this price is attainable in Thailand and whether a
corresponding market exists. To answer this the following comparison criteria can be
consulted:
• Market rates for seminars which were visited by the second/third management level:
    Prices for high-quality seminars are normally within the calculated range
• A positive return on investment in the training charges within seven months (average
    training duration) is possible for enterprises with monthly energy costs of 200.000 Baht
    and more. This is based on an energy cost reduction of 5% through the project work of
    the participants (practical experiences shows that very often even better results are
    achieved). All 2500 factories participating in the Compulsory program and many other
    companies as well have energy costs of more as 200.000 Baht
•
Against this background the market size seems acceptable and the calculated training
charge realistic.

Only the program of the Department of Industrial Promotion (training fund to support
industrial personnel development) currently offers possible support: it offers subsidies for
training of employees of SMEs. By these subsidies SMEs can also obtain payback periods of
under one year. For the medium and small enterprises such an unbureaucratic subsidy could
make training participation easier.
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Training program EnergyManager Thailand
Final report – Development of concept

6. 5 Cooperation model between Thai training provider and foreign consultant

In principle, two different models are possible:

1.   Order model: In this model the Thai Training Provider engages the foreign Consultant to
     produce all necessary groundwork (development of training material, translation, Train
     The Trainer) and pays correspondingly. This model requires a high investment by the
     Thai training Provider at the beginning. In this model all usufructs lie with the Thai
     Training Provider.

2.   License model: Here the foreign Consultant produces the same groundwork on its own
     invoice. The Thai Training Provider only invests in the organization andl preparation of
     the training. Such a cooperation contract is closed which secures the foreign Consultant
     the license and a continuing license fee per training. This license fee makes the
     financing of the starting investments possible for the foreign consultant.

The following tasks have to be performed in the training development by the two partners:

Task:                                                       Who:

•    Development of the training material                   Foreign Consultant

•    Translation of the training material                   Thai training Provider

•    Train The Trainer                                      Foreign Consultant

•    Marketing & acquisition                                Thai training Provider

•    Organizational preparation of the training             Thai training Provider


The following distribution of tasks is recommended in the training realisation:

•    Marketing & acquisition                                Thai training Provider

•    Coordination of the Training                           Thai training Provider

•    Coordination of trainers                               Thai training Provider

•    Training                                               Thai training Provider
                                                            Local external trainer
                                                            Foreign Consultant

•    Coordination of test, project work                     Thai training Provider

•    Tutoring                                               Local external trainer
                                                            Foreign Consultant

•    Input new technologies & methods                       Foreign Consultant




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Training program EnergyManager Thailand
Final report – Development of concept

The share of the foreign Consultant goes back gradually to this:




            70%


               Input of
               foreign consultant                                                                                                                    15-20%

                                  2000                                             2001                                    2002
In the development phase of the training the FC carries out approx. 70% of the work. The
main emphasis is the working-out of the training material and the Train The Trainer program.
During the pilot training the share of the FC goes down to 40-50 %, the main jobs being the
support of the training as regards content and the input of experienced trainers & tutors. After
the pilot training the training is mainly managed by the Thai training provider. The role of the
FC in the regular training business is:

•        Input on new technologies
•        Further development of the methods and the training material
•        Support of the project works (when difficult questions arise) – tutor system
•        One visit per training with the following tasks:
        - Two days training
        - Company visits to participants with complex project work in the context of the tutor-
            system

The share of the FC in the regular training business is approx. 15-20 %. This share should
remain constant to ensure quality, technology transfer and continous development of the
training.

6.6. Tasks and time schedule for the next steps to the implementation

The next steps to the implementation of the training EnergyManager are:
• Training development (contents, methods, materials)
• Train-The-Trainer in Thailand (preparation of the local trainers by the FC)
• Pilot training (first paid course)
• Start of the regular training business with two trainings per annum
The temporal sequence of these steps is represented in the following graphic:
                                            2001                                                           2002
Nr.        Task Name              Nov Dez    Jan Feb Mrz   Apr   Mai   Jun   Jul   Aug Sep   Okt Nov Dez   Jan Feb Mrz   Apr   Mai   Jun   Jul   Aug Sep   Okt Nov Dez
 1         Training development
    2      Train the Trainer
    3      Pilot-Training
    4      1. Regular training
    5      2. Regular training
    6      3. Regular training




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Training program EnergyManager Thailand
Final report – Development of concept

Appendix: Check list certification of the training program EnergyManager

The fulfillment of the following criteria should be checked. To this the training supplier has to
present corresponding documents and proofs.

Criterion: Training contents & curriculum
Important is to proof whether all energy applications appearing in the Thai industry are
considered in the training program.
       A detailed curriculum exists
       Technology modules and management modules are represented equally
       The contents of every seminar module are listed exactly on 1-2 sides
       To every topic the planned hours are given in the curriculum
       To every topic the method is named with which the topic shall be conveyed
       At the optimization possibilities new, innovative technologies and measures are
       included

Criterion: Training methods
A clearly structured didactic concept whose main emphasis is the transfer in the practice is
unconditional prerequisite. The following topics must be contained in this:
       The single methods are described concretely concerning their use area and effects
       Theoretical knowledge learning is only one method in a mix of different methods, not
       the main element of the didactic concept
       It is made sure by the methods that the participants collaborate actively for a most
       part of the time (Learning by doing principle)
       The methods don't only confine themselves to the seminar modules, but support the
       participant at the translation into action at the workplace
       The initiation of improvement measures in the companies must be component of the
       concept

Criterion: Training material
The training material should contain the following components:
       Understandable information material and scripts to every seminar module is available
       It exists an case-study to every seminar module, with which the procedure in the
       practice is trained and the participants can work actively on that one
       The participants get aids like check lists and calculation helps with which they can
       work on own projects

Criterion: Trainer
The employed trainers contribute very strongly to the quality of the training. Because of this
they must fulfill the following requests:
       University degree in technical scientific or business management studies
       Practical experience (to prove about projects which are planned and carried out by
       him, this projects has led to energy savings and new efficiency technologies were
       used)
       Didactic experience (to prove about seminars, teaching events carried out by him)
       Good EDP and English knowledge (Windows, Word, Excel, Internet as well as
       English in word and document)
       Experts who have already internationally carried out energy management training and
       saving projects are integrated in the trainer team




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Training program EnergyManager Thailand
Final report – Development of concept

Criterion: Training provider
The training provider must have competence in the energy area, organizational experience
and a very good infrastructure. To this the following prerequisites have to be fulfilled:
       The Trainingsprovider has seminar rooms equipped professionally
       For EDP based working is available as hardware/software:
               At least 1 PC for two participants, Beamer, Internet access
               Standard software: Windows, Word, Excel, Powerpoint, Acrobat reader
       Break rooms and a canteen are available
       The training provider offers continous seminars and courses on commercial base for
       industrial companies (in other topics than in the energy area) for several years
       The training provider has already implemented and carried out training for
       EnergyManager in other countries
       The training is coached from a permanently available training manager with the
       following qualification profile:
               English and Thai in word and document
               Professional experience in the industry area
               Entry to industrial companies
               Trainer for 2-3 of the seminar modules
       The training provider already has carried out projects in the area energy efficiency at
       international level (outside Thailand, mention references):
               Advice of industrial companies and concept development
               Translation into action of saving measures
               Engineering and realization of efficiency technologies
       The training provider qualifies the trainers in a preconnected Train-The-Trainer
       program. To this the training provider has developed a concept, which contains at
       least the following elements:
               Working through the case-studies
               Check-up of the practice experience by factory visits
               Test training with an experiment group

Criterion: Exam
A standardized method to the removal of the exam must be.
       The final test is carried out in written form. At this text questions and calculation tasks
       are used. The training provider has a pool of test tasks.
       A practice work which is worked out by the participant is component of the exam.
       Written test and practice work are graded by a standardized assessment scheme.

Criterion: Quality protection
The training provider must have a quality protection concept:
       Method and criteria to the choice of the trainers
       Instruments to the elevation of the participant feedbacks and evaluation methodology
       Method to control the training quality
       Processes to the translation into action of the founded optimization potentials
       Systematics of the continuous improvement process




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