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The Key Tool in Energy Management Andrew Ibbotson Joe Flanagan

Monitoring and Targeting. The Key Tool in Energy Management Andrew Ibbotson Joe Flanagan. Monitoring and Targeting (M&T). Provides lowest payback savings Provides excellent basis to identify, justify and monitor major projects Provides most robust way of reporting back to Govt.

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The Key Tool in Energy Management Andrew Ibbotson Joe Flanagan

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  1. Monitoring and Targeting The Key Tool in Energy Management Andrew Ibbotson Joe Flanagan

  2. Monitoring and Targeting (M&T) • Provides lowest payback savings • Provides excellent basis to identify, justify and monitor major projects • Provides most robust way of reporting back to Govt.

  3. What is M&T • A management tool to help reduce energy and utility usage using a proven methodology. • A rigorous and well structured analysis of energy and production data • Identification of new cost saving opportunities • Maintains saving performance

  4. Identify where Energy is Used and Develop an Action Plan Audit Senior Management Commitment Measure Energy Consumption and Production Review Performance and Action Plan Develop Targets Implement Energy Saving Measures Produce Reports to Monitor Energy Use Against Output The energy management process

  5. M&T System Scoping Study PeopleManagement ProcessesAwareness & Motivation Training SystemsMetering & Data Acquisition Software Analysis and Reporting TechnologyProject Identification Financial EvaluationEngineering Integration

  6. Site Commitment • Gain senior management commitment • Construct / develop site energy and environmental policy • Develop a specific implementation plan • Time scales • Resources (site metering and capital funds) • Performance measures • Project champion and site team

  7. Meeting every 1-2 Months Meeting every 2 weeks Awareness & Motivation • High profile project launch meetings • Define departmental reporting system • Start training programme (software, methodology & technical) • Implement communications programme (policy, reports & competitions)

  8. Training Methodology • Principles of a M&T programme Technology • Boilers, Steam Systems, Refrigeration, Compressed Air, Drives & Motors, Lighting, Process Systems Software • Data collection systems, M&T software and opportunities database

  9. m3 Metering Review and Data Collection • Map the utility, resource and production networks • Establish the data collection methods • Manual, Psion, File Transfer, Mixture • Model the site in software • Establish correlation and KPI’s • Develop specific reports utilising M&T • Boilerhouse, Refrigeration, CCL, Production, KPI’s

  10. Data Collection and Analysis Using a Spreadsheet

  11. M&T Software Implemented 6 Months

  12. Opportunity Database • Captures all improvement ideas • Allocates individual responsibility with deadlines • Monitors idea progress • Describes and quantifies the opportunities • Potential Savings • Investment Required • Priority (Payback, Technical Difficulty) • Reports the total project status

  13. Opportunity Data Base

  14. Project Review • Monthly Steering Group Meeting • Total Savings • Energy Usage • Projects/Environmental Improvements • Costs • The M&T Quality System • Software Standards • Training and Programme Standards

  15. Year 1 Scoping Audit System Develop People Implement Technology Project Payback Benefits 5% -15% Savings Low Risk Utility Savings Environmental Compliance Project Implementation

  16. Case Study - UK Dairy Group • 5 Site parallel implementation across UK • 5 Teams of 6 people • 20 Utility Sub Meters per site (10 water & 10 electric) £30K • enManage implementation costs £120 K • Utilities Savings £300,000 • Packaging Savings £200,000 • Product Savings £750,000 • Total £1,250,000

  17. Case Study - UK Dairy Group Projects • Group condensate recovery improved from 15% to 80%. Water, effluent, gas and chemical savings £60K. (Improved boiler response) • Compressed air leakage minimised saving £30K • Group CIP benchmarking exercise. Savings cica £120K

  18. The Rewards • Resource cost savings - scope to save • Utilities 5% - 15% • Raw Materials up to 1% • Packaging 5% • Environmental Compliance • IPPC • ISO 14001 • Low Risk

  19. Setting Up M&TData Collection and Meters

  20. Objectives • To determine what should be monitored • To determine areas of accountability • To determine costs of further monitoring equipment required • To propose a cost effective solution

  21. Some Initial Thoughts • How are energy costs monitored? • Who is acountable for usage? • Is the company using energy efficiently?

  22. Typical Scenario • Canned food manufacturer • Energy costs £800,000 (€120,000) per annum • Average monthly bills: • Electricity : £40,000 • Gas : £26,000 • Bills passed to Services Department for checking • Bill paid by the Finance Department • Did they use energy efficiently?

  23. Is Energy Used Efficiently? • How do we measure performance? • Who do we make accountable? • How do we make sure we achieve minimum energy costs?

  24. Level System 1 Monthly bills only 2 Monthly meter readings 3 Monthly readings checked against output to produce a specific energy ratio (S.E.R.) 4 Monthly monitoring system based on submetering 5 Weekly system based on submetering and targeted against output Monitoring Systems

  25. Level System 1 Finance Department 2 Services department 3 Each Production department according to some apportionment 4 Each department according to metered consumption 5 Each department with adjustments made for output Who is Accountable for the Energy

  26. Information Required Prior to Audit • 12 monthly energy bills and costs • Distribution line drawings of all utilities: • Gas • Electricity • Steam • Water etc. • 12 monthly production figures • Major plant ratings

  27. Electrical Audit • Determine major loads from distribution board ammeters • Estimate weekly running hours • Balance against weekly total of electricity consumed

  28. Oil/Gas/Steam/Water Audit • Can estimate against plant ratings and running hours • Production load should be taken into account • Balance against weekly total consumed • Typically simpler than for electricity as fewer and better defined users.

  29. Steel Company • UTILITY BILL : €5 Million • Savings potential : 2%  €100,000 • Metering costs depend on payback criteria: • 12 months payback = €100,000

  30. Typical Energy Balance Plant/Area kWh/wk £/wk £ p.a. Air Compressors 10,000 18,000 800 40,000 1440 72,000 Fridge Compressors 36,000 Bottling Line 9,000 720 Sterilising Line 12,000 960 640 48,000 Cold stores 8,000 32,000 240 12,000 Offices 3,000 General Lighting Main Hall Ventilation 5,000 400 480 20,000 24,000 6,000 7,000 560 28,000 Boilerhouse 11,000 880 44,000 Cartoning Unaccounted Balance 11,000 880 44,000 TOTAL 100,000 8000 400,000

  31. Metering Justification C= A P t 100 C= Justifiable submetering expenditure (£) A= Annual energy costs (£) P= Potential savings (percentage) t= Acceptable payback period (years)

  32. Typical Values of “P” • Electricity 3% • Gas/Oil 5% • Steam 5% • Water 5-10% • Comp. Air 10%

  33. Metering Approach • Take €1 Million p.a. bill (Electric) • 3% savings- €30,000 • Typically 20 meters (installed) • Start with main services • Air Comps. • Fridge Comps. • Boilerhouse • Apportion remainder as distribution boards dictate

  34. Department and Energy Account Centre (EACs) • Definable areas - Department • Definable plant - EAC • Preferably Accountable to one person - EAC • Significant energy costs - EAC

  35. Metering

  36. Electricity Meters • Simple and accurate • Relatively cheap • Turn down ratio - most current transformers inaccurate below 20% full current • Majority of installation can be done whilst board is live • Install meters with kWh & kW read-out

  37. Flow Meters • Different Types • Different Fluids • Accuracy Considerations • Installation Considerations

  38. Flow Meters • Orifice Plate Meters • Variable Area Meters • Turbine Meters • Vortex Shredding Meters • Electromagnetic Meters • Ultrasonic Meters • Rotating Lobe Meters • Rotary Piston Meters • Diaphragm Meters

  39. Gas Meters • Suitable meters include: • turbine • diaphragm • rotating lobe • Temperature and pressure compensation needed, ideally automatic for larger users • Fairly accurate +/-1% • Typical costs: 25mm 50mm 80mm Turbine - €1,800 €2,700 Diaphragm €300 €1,200 -

  40. Steam Meters • Suitable meter types include: • Orifice plate • Variable area • Vortex shedding • Rotary shunt • Relatively expensive • Accurate sizing very important • Temperature and Pressure correction essential • High on maintenance costs • Adequate removal of condensate to stop water hammer is essential

  41. Steam Meter Costs Includes automatic pressure compensation

  42. Water Meters • Suitable meters include: • Rotary piston • Turbine • Vortex shedding • Ultrasonic • Electromagnetic • Standard meters accept 40oC • Relatively cheap if use positive displacement meters • Critical for control of steam usage in some cases • Check flow rates accurately and reduce pipe diameter if possible

  43. Water Meter Costs

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