Energy Performance Indicators
description
Transcript of Energy Performance Indicators
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Energy Performance Indicators
Liam Tolton
Second Sight Technical
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Topics
• Energy Performance Indicators• What are they ?• How to Develop your own EPIs• Getting the best use from your EPIs
• Workshop• Plan your EPI Development
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Introduction to Energy Performance Indicators (EPIs)Step 17 Monitor
• What is an EPI ?• A means of Comparison of Performance versus a
standard• Internal EPI
• e.g. compare one machine or line against another• External EPI
• Compare two sites against each other• Compare sites against a Best Practice Site• Compare sites against a selection of similar sites.
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Developing your own EPIs Step 17 Monitor
• Each site is DIFFERENT• However,
• Most sites can develop OVERALL SITE EPIs• Units of Energy per Unit of product• e.g. kWhrs / Tonne of Product• kWrs / unit of product produced
• (If all products are the same)• The EPI is a good measure of ENERGY INTENSITY
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What does a good EPI Depend on ?
• DATA• A good measure of your overall consumption• A good measure of your output
• This may not be as easy as it sounds…..• Overall Consumption
• From Energy Bills…..• Overall Production
• From Production Manager….
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Let’s look at both of these..
• The Energy Bill• Electricity : Meter Reading Dates can vary….• Gas: Meter reading dates can vary…• Oil : Deliveries dates / oil stock levels can vary…
• The Production Output• This information may be gathered WEEKLY…• The Shift Pattern can vary…• The Product Mix can vary…
• NOT So Simple after all……
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What can we do ?
• STANDARDISE as much as possible• Time Interval Determination
• Decide on • Calendar Month ?• Every 4 weeks ?• Weekly ?
• Stick with this approach • Ensures Consistency in the Long Run
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Reading your own Meters Step 18 Measuring
• Learn How to Read YOUR Meter• Find out where the main meter is located• Find out if there is any Sub Metering on
• Buildings• Processes• Equipment
• Know your METER FACTOR (multiplier)
Gather ALL information from the meter• Reactive Power & Maximum Demand
• Can be done Manually but On Line is Better• Watch for Meter Overrun …..
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Decide the Time Interval
• Weekly• At the end of Production Period• Again at the Start of the Next Period• This allows you to work out FIXED / VARIABLE
Split• Monthly
• On the same day as the ESB Meters are read• Try to do it at the same time if possible
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Determining the Production OutputStep 18 Measuring
• Ask the Production Manager …..• Prompt the additional questions
• Was the product mix similar to last period?• Were there any unusual interruptions?• Did the Shift Pattern Change ?• Was there a holiday period ?• Was there a Plant Shutdown ?
• This information helps you explain changes
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Calculating your EPI
• Simplest way is to set up a spreadsheet to • Input Meter Readings• Input Production Data• Calculate the EPI• Portray the EPI graphically over time
• Add some sophistication• Include Energy Prices• Calculate and Average Energy Cost
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A Simple EPI
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EPI Graph
Energy Performance Indicator
2400
25002600
27002800
2900
30003100
3200
1 2 3
Month
EPI
EPI kWhrs/tonne forPeriodEPI kWhrs/ tonne Yearto Date
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Line Graph Format
Energy Performance Indicator
2400
25002600
2700
2800
29003000
3100
3200
1 2 3
Month
EP
I
EPI kWhrs/tonne forPeriodEPI kWhrs/ tonneYear to Date
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Graphical Portrayal
• Advantages• Clear Representation of Progress• Trends can be seen immediately • Corrective Action can be taken immediately• Effects of Corrective Action should be clear• May be posted on notice boards
• The COMMUNICATION of this Information is Very Important
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Example Energy Report
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Graphical OutputYTD Energy Use per tonne
10
510
1010
1510
2010
2510
3010
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Month
Electricity Budget Use/MT
Electricity Actual YTD /MT
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Getting the Most from your EPI
• Best Practice • Usually an External Comparator• Relies on independent accurate assessment of
best practice sites• Past Performance
• Usually an Internal Comparator• Relies on gathering good measurement data for
comparison
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Overall Site EPI
• An overall site EPI is very useful• Keep it Simple• Ensure it is easily measured• Communicate it to everyone on site
• The Simplest EPIs are:• Units of Energy per unit of Output• Cost of Energy per unit of Output
• Can be used in your ELEVATOR SPEECH
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What do you do with your EPI ?Step 19 Review
• Communicate them ….• To Management as part of a Regular Energy Report• To Staff via Notice boards
• Use them for Benchmarking• Compare to other sites• Compare to Industry Surveys
• Annual Energy Budget• Compare to Annual Energy Budget
• Set Targets for Site Wide Energy Reduction
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How do YOU compare ?
• European Benchmarking Survey • European Plastics Industry • April to September 2005• Energy Consumption • Energy Awareness
• Ref: Low Energy Plastics Processing • Reduced Energy Consumption in Plastics Engineering• European Best Practice Guide• Oct 2006
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Results
• Energy Consumption• Average Site Specific Energy Consumption (SEC)
• 2.87 kW/kg/hr = 2870 kWhrs / tonne• Range 0.63 for compounding to 6.2 for vacuum
thermoforming • SEC higher for Small machines• SEC was lower for Electric versus Hydraulic Machines
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SEC by Business Type
Business Type Average SEC kW/kg/hr
Thermoforming 6.179
Rotational Moulding 5.828
Compression Moulding 3.168
Injection Moulding 3.118
Profile Extrusion 1.506
Film Extrusion 1.346
Fibre Extrusion 0.850
Compounding 0.631
Overall Average 2.811
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Management Actions & AwarenessTAKE ACTION PILLAR
• Energy Actions• 30 % had a written energy policy• 5 % employed a dedicated Energy Manager• 40 % had used Energy Consultants• 30 % had measured down to machine level
• Energy Awareness Score 1 to 16• 60 % scored < 4• Only 1 % was in the 14 to 16 range
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Summary
• The Concept of EPIs• How to Determine your EPI• The Pitfalls in determining your EPI• Using your EPI
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Workshop : Plan your EPI Development
• The Four Fundamental Planning Questions :• What ?• Who ?• How ?• When ?
• The What Question defines the SCOPE• The Who Question defines the TEAM• The How Question defines the METHOD• The When Question defines the SCHEDULE
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What & Who ?
• Decide WHAT is your optimum EPI ?• Select 2 possible EPIs
• Write out the PRO’s• Write out the CON’s
• Decide WHO does the following:• Data Gathering (Meter reading)• Set up Spreadsheet• Data Input• EPI Calculation• EPI Checking• Who will see the information ?
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How & When
• How • How will the data be gathered?• How will it be processed?• How will it be checked?• How will it be publicised
• When• When will it be done : Agree DEADLINES
• Meter Reading• EPI Calculation• EPI Reporting
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What use will be made of the EPI
• Monthly Reporting ?• Quarterly Reporting?• Annual Reporting ?• Energy Budget Preparation?• Project Evaluation?• Others?