Co-funded by the Intelligent Energy Europe Programme of ... · The Energy Saving Scheme developed in the EU-project SESEC does provide you with the following tools: • Overall SESEC

Co-funded by the Intelligent

Energy Europe Programme of

the European Union 1

Overview

� Introduction

� Manual

− System Requirements

− Analysis

− Results




Results

− Data for EMBT

Introduction – Manual




Distribute consumption by segment and throughout the various production

processes, for both thermal and electrical energy;

The tool assists companies to find answers to the following questions:

�Where is energy being consumed?

�How is energy being consumed?

Purpose of the ESS-EDST




�How is energy being consumed?


The Energy Saving Scheme developed in the EU-project SESEC does provide

you with the following tools:

• Overall SESEC Approach

• EBMT (Energy Management and Benchmark Tool)

• EDST (Energy Distribution Support Tool) , based on Excel, described in this

presentation

• SAT (Self Assessment Tool)

• Nine presentations on energy saving best practices:

• Supply Contracts and shifting – Grid

Tools and resources available




• Supply Contracts and shifting – Grid

• Utilization - Production machines

• Compressed Air

• Steam and Heat Production

• Renewable Energy and Co-generation

• Lighting

• HVAC I (Heating)

• HVAC II (Ventilation, Air Conditioning)

• Vacuum, Cleaning

For more information consider [1] and [2]


�Electrical distribution by consumer type. Monthly separation of the total electrical

consumption between Production machines, Heat generators, Compressed air,

Lighting, Auxiliaries and others.

�Fuel distribution by consumer type. Monthly separation of the total fuel

consumption between Production machines, Heat generators, Auxiliaries and Others

for each month.

�Electrical distribution by process/section (production machinery), all electricity is

distributed by processes.

Preview: Results to expect





� Thermal energy distribution by process/section (production), all thermal energy is


�Full electrical discretization including both consumer type and productive

process/section.

�Full thermal energy discretization including both consumer type and productive

process/section.

�Data to be used in EMBT.

Note: Due to the fact that in this energy distribution tool calculates based on machine data and estimations, it can be replaced by direct

measurements using portable or fixed energy meters, providing that the inputs necessary for EMBT are observed.







the European Union 8Introduction – Manual

Steps1. Set the Scope

2. Setup the Excel

3. Input Technical Data

4. Check Distribution Output, Thermal and

Electrical Energy

5. Data for EMBT (data to be exported and

used in EMBT)




1. Set the scope

�What do you expect to get from the ESS-EDST-tool? E.g.:

� Energy distribution within the plant per segment and/or process

�Who in your company will work with the ESS-EDST-tool?

� You will need the company machine list with technical data, this list

should also include lighting technical data. If company wishes to be

thorough and include all consumers don’t forget the office equipment




thorough and include all consumers don’t forget the office equipment

and non productive (e.g. food conservation and confection, etc.)

� Work hours per process and machine workload

�What will be the next steps?

� E. g. Attribute energy cost within the plant per segment and/or process


2. Setup the Excel

�MS-Excel 2010 or later required

�The most current version is available on www.sesec-

training.eu

�Macros have to be enabled

The ESS-EDST was developed using macros. You need to




The ESS-EDST was developed using macros. You need to

enable macros in order to be able to fully use the ESS-EDST


2. Activate Macros




3. Sheet: Introduction

Read the full intro, it

will help to

understand tool inner

works




All sheets are

navigable but tool

use should follow a

left to right order


Sheet: Introduction

In this module we will use an example of a theoretical company named XPTO. This company produces

two segments:

� Socks that are included in segment “Underwear and Bras” and

� Seamless T-Shirts that are included in segment “T-shirts and related - knitted”.

The main output from the company are socks that represent nearly 100% of the production , T-shirts

represent a very small percentage of production being considered almost as sample production.




represent a very small percentage of production being considered almost as sample production.

The EDST is a tool that’s only able to analyse one segment at a time, this implies that one EDST excel

file must be filled per each segment produced by a company.

In this example, the XPTO company produces two segments, the “Underwear and Bras” segment and

the “T-shirts and related - knitted” segments, this means that two EDST files must be created, one per

segment.

Note: The EDST tools with the examples (one per segment) are also available in SESEC’s website.

The first sheet is the “Start up & Company Data” sheet. In this sheet you’ll be asked to identify the

company, the user and the year that is currently being analyzed.

You will also be asked, in case the company has more than one segment, to perform a first attempt to

distribute electrical and thermal energy trough the various segments based on company's experience.

Finally you will be asked to input the amount of hours worked in each process per month on each

specific segment.

Sheet: Start up & Company Data (1)




Fill company data. All data to be inserted is to

be related to the indicated year

In these tables you must input an estimation of the monthly energy that is used in each segment, the

idea behind this is use the company’s experience to make a first division of energy consumption by

segment. As the user becomes familiar with the SESEC tools, with energy management concepts and

its implementation, this energy allocation will be tuned and consequently closer to reality.

Consider our example of the XPTO company, this company produces two segments “Underwear and

Bras“ and “T-shirts and related - knitted” where the T-shirts segment is regarded as sample

production (read slide 14). The following images show the preliminary distribution in the example.





Table for “Underwear and

Bras“ segment EDST file

Table for “T-shirts and related -

knitted” segment EDST file

As you can see the bulk of energy consumption is allocated to the “Underwear and Bras“ segment

due to the fact that almost all production is related to this segment, also note that in each month

both the electrical and thermal energy adds to 100% (e.g. January electrical consumption is 98% for

“Underwear and Bras“ and 2% for “T-shirts and related – knitted”) also in August there was no T-

shirts production so, inevitably, it appears as 0%. The “Control” cell is there to warn if values are

lower than 0% or higher than 100%.

The final input in this sheet concerns the

hours worked in each process of each

segment.

When filling these tables don’t be

concerned by particular machines, the

objective is to input the monthly work

hours of the process even if only one

machine is working. The fine tune for

hourly attribution is foreseen in


Table for “Underwear

and Bras“ segment EDST




hourly attribution is foreseen in

subsequent sheets.

In the example presented by the images

on the left, the monthly work hours are

the same for each segment because in

each segment the work areas are mixed,

meaning that the area where T-shirts are

knitted is the same where Socks are

knitted, same thing for finishing.


and Bras“ segment EDST

file Table for “T-shirts and

related - knitted”

segment EDST file

Sheet: Machinery (1)

In the “Machinery” sheet, user is asked to input all energy consuming machines within the company

except steam/hot water generators and compressed air (consider compressors and dryers), these have

specific sheets for data input. This should be considered as an equipment list so input all machines

regardless of segment, so the same list can be used in multiple EDST files.

... input them here for

Use numbers 1 trough

9 from this list, and...




... input them here for

process identification.

“Designation” field will

filled automatically.

“Observations” and

electrical data are fields

are optional but useful

to input important

information. Note: All green fields are optional

and are not required by the tool

for calculation.


In the “Equipment/Machine” column (see picture below) user is asked to input each machine, or group

of machines, related to the indicated process. User can either input one machine per cell or group similar

machines that usually work the same hours and have the same electrical characteristics, i.e. similar

consumption. As an example consider a company with 5 knitting machines;

Example 1: Machines are of the same model and/or same electrical characteristics, machine 1, 2 and 3

usually work all production hours and the 4th and 5th usually work half the time. In this example user

should input machines 1,2 and 3 in one row and 4 and 5 in a different row.

Example 2: Machines are of the same model and/or same

electrical characteristics but have totally different work




electrical characteristics but have totally different work

hours. User should input each machine in a different row.

Example 3: Machines are NOT of the same model and/or

same electrical characteristics but work continuously

trough all work hours. User should input each machine in

a different row. Nevertheless if the electrical

characteristics can be considered the same, meaning they

have similar consumption, these can be grouped in one

single row.

Justification � when grouping similar machines consider

not only the electrical characteristics, i.e. similar

consumption, but also if they have similar work hours.





“Apparent Power”

calculation can be made

by using the support tool

available in the same

sheet.

Retrieve electrical data

from each machine and

follow the tool indication

for kVA calculus

Sheet: Machinery Electrical Energy (1)

In the “Machinery Electrical Energy” sheet, user is asked to input, in a monthly basis, the specific hours

worked and the workload of all energy consuming machines inputted in the previous sheet, the

“Machinery” sheet. Calculus here will convert the “Apparent Power” to “Apparent Energy”. Concerning:

� Work hours � This represents the total monthly work hours of a machine or group of “similar”

machines. Please note that you should NOT add work hours if inputting for a group of machines, i.e.

if the group includes 2 machines and 1 works 185h and the other works 200h do not input 385h,

input an average or a value between 185 and 200;

� Workload � Work load is an

estimate percentage of the




estimate percentage of the

effective work done by the

machine within it's work

hours, i.e. consider a value

between 0% if machine is

stopped and 100% if machine

is at full power/load.

Note that all other fields were

automatically filled based on data

already inserted in the

“Machinery” sheet.

Sheet: Machinery Electrical Energy (2)

These two images depict the January month

of both EDST files concerning the two

produced segments of the example, the

“Underwear and Bras“ and “T-shirts and

related - knitted”.

The most important thing to note is that the

values for “T-shirts and related - knitted”

machines in the “Underwear and Bras“ table

are marked as 0 and vice-versa in the “T-

shirts and related - knitted” table.




Table for “T-shirts

and related -

knitted” segment

EDST file

Table for

“Underwear and

Bras“ segment

EDST file

shirts and related - knitted” table.

In the “Lighting” sheet, user is asked to input all lighting within the company. Much like the “Machinery”

this should be considered as an equipment list so input all lighting regardless of segment, so the same list

can be used in multiple EDST files.

Sheet: Lighting (1)

... input them here for process identification. “Area

designation” field will be automatically filled.

Use numbers 1 trough

8 from this list, and...




Sheet: Lighting (2)

Use numbers 1 trough 58 from this list, and...

The next step is to input the type of lighting used in the various areas, the

list in the right has 58 combinations of lighting that is commonly used,

cycle trough the list and match each area with its installed lighting types.

In the image below note that for both “Knitting” and “Finishing” the

“Observations” field indicates “Socks & T-Shirts”, this means that both

segments are knitted and finished in the same areas. Because of this, in

both EDST files the “Lighting” sheet has the same data for production

areas.




... input them here for equipment identification.

“Type” field will be automatically filled .

Use numbers 1 trough 58 from this list, and...

Sheet: Lighting (2)

Finally, in the same table, user is asked to input the quantity of selected lighting types and their

utilization coefficient. With all data inputted in this sheet the tool calculates the “Apparent Power” and in

the background, using the work hours inputted earlier, calculates to “Apparent Energy”. Concerning:

� Quantity � Always assume “Quantity” as quantity of lamps even if in the company there are double

or triple light fixtures, i.e. there are 10 double light fixtures, when inputting quantity input 20 lamps.

Include all working lamps even if usually they’re turned off.

� Utilization coefficient � Although all were accounted for, not all lamps are turned on during work

time, use "Utilization coefficient" to tune the amount of time lamps are turned on.

In the example (see image below) in the “knitting” area there are 150 fluorescent tube 36W lamps with




In the example (see image below) in the “knitting” area there are 150 fluorescent tube 36W lamps with

electronic ballast that are, in average, turned on 70% of the time.

In the “Compressed air” sheet, user is asked to input the “Apparent power” the “Average work load” and

an theoretical airflow distribution. Concerning:

• Apparent power � this calculation can be made by using the support tool available in the

“Machinery” sheet (slide 20). Retrieve electrical data from each active compressor and dryer and

follow the tool indication for kVA calculus.

• Average work load � the average work load can be seen as the ratio between the compression time

and the total working time.

Although the best way is to proceed with electrical measurements, a practical method can be applied

by only using a watch, imagine a compressor that in an 60 min time frame effectively compresses

Sheet: Compressed Air (1)




by only using a watch, imagine a compressor that in an 60 min time frame effectively compresses

during 30 min, the average work load is 30/60=50% (if you have enough patience increase the time

frame for better results). The previous method applies to on/off compressor type, if compressor has

variable speed then the data to retrieve the average work load should be available in the compressor

controller.

• Theoretical airflow distribution � Because it's very difficult, without measurements, to distribute

compressed air consumption the best approach is to estimate consumptions throughout the

installation based on company's experience. The best way to estimate is to identify, in all processes,

where are the biggest compressed air consumers their quantity and average work hours, and

correlate the three, then fine tune the results with the same data but from the less intensive

compressed air consumers.


In the examples both segments have the same theoretical distribution for two main reasons:

• The main concern while analyzing distribution was the “Underwear and Bras” segment because this

is the main segment in the company;

• The weight for compressed air consumption machines concerning Knitting and Finishing is practically

the same in both segments, i.e., ratio for Knitting and Finishing is about 60%-40% regardless of

product.

Sheet: Compressed Air (2)




The “Steam / Hot water” sheet has a similar approach as the “Compressed air” sheet. Here user is asked

to input the “Apparent power” the “Average work load”, an theoretical steam/hot water flow

distribution, and the main difference between this and the compressed air sheet is the introduction of an

reduction coefficient. Also the sheet predicts both fuel and electrical steam/hot water generators

Concerning:

• Apparent power � this calculation can be made by using the support tool available in the

“Machinery” sheet (slide 20). Retrieve electrical data from each active steam/hot water generator

and follow the tool indication for kVA calculus. Remember that this is electrical consumption related

and has nothing to do with thermal power.

Sheet: Steam / Hot water (1)




and has nothing to do with thermal power.

• Average work load � the average work load can be seen as the ratio between the effective

burn/resistance activation time and the total working time.

Although the best way is to proceed with electrical measurements, a practical method similar to one

in the the compressed air, can be applied by only using a watch, imagine a steam/hot water

generator that in an 60 min time frame effectively burns/activates resistance during 30 min, the

average work load is 30/60=50% (if you have enough patience increase the time frame for better

results).


• Reduction coefficient � Reduction coefficient works basically the same way has the “Utilization

coefficient” in the “Lighting” sheet (slide 25), the work hours were already identified in "Company

data" page but not all generators are turned on during that time, use "Reduction coefficient" to tune

the amount of time generators are turned on;





Note that steam/hot water generators, both electrical and combustible generators, are available for data

input. You can input data in one or both types and if you have more than one equipment in one of type

input “Apparent power” sum and fine tune with “Average work load” and “Reduction coefficient”.

• Theoretical steam/hot water flow

distribution � Because it's very

difficult, without measurements, to

distribute steam/hot water

consumption the best approach is to

estimate consumptions throughout

the installation based on company's

experience. The best way to estimate

is to identify, in all processes, where





is to identify, in all processes, where

are the biggest steam/hot water

consumers their quantity and average

work hours, and correlate the three,

then fine tune the results with the

same data but from the less intensive

steam/hot water consumers. The

main difference between this and

“Compressed air” sheet is a monthly

distribution because heat

consumption is more affected by

season, e.g. comfort heating.


The “Fuel” sheet was created to

differentiate the fuel consumption that is

used to produce steam/hot water via heat

generators (indirect heat production) and

the combustible that is used directly in a

production machine like a dryer, so a

division of the total consumed fuel directly

and indirectly is imperative.

Concerning distribution, a recurrent

Sheet: Fuel (1)




Concerning distribution, a recurrent

problem persists, without measurements

is very difficult to distribute fuel

consumption so the same approach is to

be taken as in "Compressed air" and

"Steam/Hot water" consumption. In the

table input the theoretical distribution all

combustible consumption regardless of

were it is burned (directly or indirectly).


Based on existing meters or on your perception and experience, input here the % of fuel that is

used directly, i.e., the fuel that is burned directly in production machines like dryers and heaters.

While the previous table, in “Steam/hot water” sheet, only asks for steam/hot water distribution, i.e.,

hot fluid distribution, this one wants to know how the consumption of combustible is distributed.

As an example imagine a company that has processes A and B, in process A only steam is consumed while

in process B both steam and combustible are consumed. Steam distribution is 80% in process A and 20 %

in process B, this is the result for “Steam/hot water” sheet. In this sheet, “Fuel” sheet, the combustible

distribution is 50% for both processes, this happened because there are very intensive machines that

burn combustible directly that shifted the thermal weight distribution between processes.

Sheet: Fuel (2)

In our example sheet (see image) the




In our example sheet (see image) the

company does not consume combustibles

directly but when distributing the entire

combustible consumption all of it is used

for finishing (indirectly trough steam)

Note that also here, similarly to the

“Steam/hot water” sheet, there is a

monthly distribution also because heat

consumption is more affected by season,

e.g. comfort heating.

Results in “Results” sheet are presented both numerically and graphically, the data is divided in 6 pages

with specific results:

• Page 1 � In this page you can find the Electrical distribution by consumer type, it separates the total

electrical consumption between Production machines, Heat generators, Compressed air, Lighting,

Auxiliaries and others.

• Page 2 � In this page you can find the Fuel distribution by consumer type, it separates the total fuel

consumption between Production machines, Heat generators, Auxiliaries and Others.

• Page 3 � In this page you can find the monthly Electrical distribution by process/section (production

Sheet: Results (1)




• Page 3 � In this page you can find the monthly Electrical distribution by process/section (production

machinery). Here, all electricity is distributed by processes, so each process includes its relative

electricity portion of compressed air, lighting, etc.

• Page 4 � In this page you can find the monthly Thermal energy distribution by process/section

(production), thermal energy represents the burnt fuel and heat provided by an external source. All

thermal energy is distributed by processes, so each process includes its relative thermal energy

produced in the heat generators and/or from provided by an outside source.

• Page 5 � In this page you can find full Electrical energy discretization including both consumer type

and productive process/section.

• Page 6 � In this page you can find full Thermal energy discretization including both consumer type

and productive process/section. Note that this is where combustibles are burnt - same principles as

in page 2.


Sheet: Results (2)Some results from “Underwear and Bras” segment EDST sheet (example file)




Sheet: Results (3)Some results from “T-shirts and related – knitted” segment EDST sheet (example file)




Sheet: Data for EMBT (1)

Results in this sheet are to be used in EDST's sister tool, the EMBT (Energy Management and

Benchmarking Tool) more particularly in the "Energy input“ and “Benchmark” sheets. As you may

remember, this tool only provides the energy distribution of one production segment, meaning that for

multiple production segments multiple EDST's must be built. The same principle applies to

benchmarking, the data in one EDST is only valid for that specific analyzed.

This sheet has three different results provided by three tables, values are available after clicking the

button:




button:

• Table 1, Energy Distribution in Segment � This table represents the energy distribution in this

segment. Just select and copy all the values in this table and paste them in table "Input Energy

Distribution by Process" of the "Energy input" sheet;

• Tables 2 & 3, Benchmarking for Segment � These tables present the necessary data by providing the

energy ratio, both electrical and thermal, on benchmarkable processes in the selected segment. Just

select and copy all the values in both tables and paste them in tables "Electrical energy

consumption" and "Fuel energy consumption" of the "Benchmarking“ sheet.

Click here to retrieve values. These

values are based on the data from

“Results” sheet.

Sheet: Data for EMBT (2)Data to be inserted in EMBT from “Underwear and Bras” segment EDST sheet (example file)




Sheet: Data for EMBT (3)Data to be inserted in EMBT from “T-shirts and related – knitted” segment EDST sheet (example file)




Readings

� [1] CITEVE (2013): Critical Energy Saving Points for the Clothing Manufacturing Process/Factory

Environment, Deliverable D3.1

� [2] CITEVE (2013): O3.2 “Energy Saving Scheme (ESS) Guide for Companies” and O3.5 “Guidance

Document”

� [3] GHERZI (2013): Energy Data, Deliverable D2.2

� [4] DITF (2014): Euratex Overall SESEC Approach, presentation available on www.sesec-training.eu

� [5] CITEVE (2014): EMBT (Energy Management and Benchmarking Tool), presentation available on

www.sesec-training.eu




www.sesec-training.eu

� [6] ENEA (2014): SAT (Self Assessment Tool), presentation available on www.sesec-training.eu


Pictures

� Slide 8 – Dennis Skley: *grübel* – URI: http://www.flickr.com/photos/dskley/8627475625/sizes/z/in/photostream/ License: CC BY-ND 2.0 (http://creativecommons.org/licenses/by-nd/2.0/legalcode)

� Slide 9 – Carissa Rogers: kid to do list, list, Be happy and go home – URI:http://www.flickr.com/photos/rog2bark/3437630552/sizes/m/in/photolist-6eLKNh-c1mn5W-9Lcbki-9jeZKu-CdE9B-6tQG1N-8cuPQg-6oCMfR-5R2t5b-9uCMNF-7WWKna-82Z8Cz-87uSWj-839wC-8QW9Yq-7pHc1U-6qsYHC-gu1Ra-7Jq5QH-7Mfehz-7VWPxJ-6J37Hp-4QCVn9-8QzzeL-8w3ARY-5JaQRk-5wvNsm-fMnd2-ffgRgs-4yar1X-dr9xUw-dJLTso-3bLKoc-5sane8-eT8xC-5QjTMr-55xTxK-iYZum-i8xKL-61m8xK-6YzqVs-7JKQkd-5SyRgw-4VSKqq-avZUVo-4ZwxHC-3svSV-4qU25r-4sCr3S-PVLFS-5rMwqS/ License: CC BY 2.0 (http://creativecommons.org/licenses/by/2.0/legalcode)

� All other pictures (except the logos) are screenshots of the EDST-Tool by SESEC CC BY-SA 2.0 (http://creativecommons.org/licenses/by-sa/2.0/legalcode),




Documents

Co-funded by the Intelligent Energy Europe Programme of ... · The Energy Saving Scheme developed in the EU-project SESEC does provide you with the following tools: • Overall SESEC