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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Lets 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
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Line Graph Format
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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 Output
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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 lt 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 PROs
• Write out the CONs
• 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?

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Take Action !

• Liam Tolton
• info_at_secondsighttechnical.com
• Tel [phone]

Technical
www.sei.ie/energymap