Des Murphy

Kovara Energy Consultants

Establish a Measuring and Monitoring System

Energy MAP Step 18K O V A R A

Energy Consultants

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Why Monitor Energy

• Allows you to identify drifts in efficiency due to poor maintenance or operation

• Analysis of data often turns up new ideas for energy saving.

• It allows you to predict the savings to be expected from energy saving investments and actions.

• It gives you control of energy utilisation.

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Links to energy MAP

CommitProof of success needed to maintain commitment

Step 7: Key FactorsData analysis helps us to identify the key factors

Step 8: Survey Large measuring element here

Step 10: Targets Targets based on historical performance

Step 17: Monitoring Step 18 provides the “How To”

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Elements of Step 18

• Record• Normalise• Analyse• Target• Monitor• Report• Control

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Record: What plant to record?

Consumption x “Slippage Potential”

“Slippage Potential”: • Poor maintenance• Poor operation• Raw material

Efficiency Slip Potential

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Record: What to measure

Process

Consumption / Yield meters

Condition Indicators

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Record: What to measure

Process

Consumption / Yield meters

Condition Indicators

Example: Air Compressors

•Meter Electricity•Flow meter on compressed air

•Air off temperature•Filter pressure loss•Loaded and Unloaded hours

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Record: What to measure

Process

Consumption / Yield meters

Condition Indicators

Example: Chiller

•Meter Electricity•Heat meter on chilled water

•Condensing temp – ambient temp•Evaporator tem

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Record: What to measure

Process

Consumption / Yield meters

Condition Indicators

Example: Process CA

•Process compressed air flow meter•Record production

•Identify the easily measurable factors that determine compressed air usage

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Record: How to Measure

Testers

Meters / Sensors

Data Collection•Automatic Data Collection

•Data loggers

•Manual

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Record: How to Measure

Testers

Meters / Sensors

Data Collection•Automatic Data Collection

•Data loggers

•Manual

Digital thermometer Combustion analyser Light meter Manometer Clip-on ammeter Velocity meter

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Record: How to Measure

Testers

Meters / Sensors

Data Collection•Automatic Data Collection

•Data loggers

•Manual

Air flow meter (€1,900) Steam meter (€2,500) Electricity meter (€300)

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Record: How to Measure

Testers

Meters / Sensors

Data Collection•Automatic Data Collection

•Data loggers

•Manual

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Analyse: How?

• “First Principles” approach

The core of energy monitoring is to derive a formula which gives the energy which should have been used for the period and compare the actual to this.

Analyse• Regression analysis

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Analyse: Regression

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Normalise: Secondary Drivers

The concept of Secondary Drivers

Examples:• Air compressor (load pattern)

• Chiller (ambient temp, evaporating temp)

• Process (product weight, raw material, etc

Normalisation factors usually come from the “First Principles” analysis

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Target: On what basis?

Recap: Each week compare ACTUAL with TARGET

How to establish the Target:• First principles, manufacturer’s data

• Regression analysis

• Industry benchmarks

Use All Three:• The “First Principle” gives you a good understanding of

the process from which new ideas are born

• Regression is based on real data (credible)

• Benchmarks are important management information

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Monitor: What it means

1 Each period check actual consumptions against targets

2 Check the “Condition Indicators”

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Monitor: How often?

How often should you collect the data and analyse it?

Examples:

Heating system: Monthly

Chillers: Monthly

Air Compressors: Monthly

Process: Depends on the potential for “efficiency slippage” and its cost

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Report: How detailed?

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Control: Follow up

From the report generate tasks/actions and formally ensure closure.

[Why did it happen? What procedures are being put in place to ensure that it does not happen again?

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Software: How can it help?

Data Collection Automatic, semi-automatic, manual

Data Analysis Regression, Targets, Deviation

Reporting Generate report

Control Control actions/tasks

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Data Loggers

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Data Loggers - Dent

Time-Of-Use (TOU) SmartLoggers™ are small, battery powered activity data loggers. They store events like on/off transitions of lighting, motors and other electrical devices. They record and time stamp the actual time equipment turns on and off. The on/off transition times are stored in the data logger and the data are retrieved using the TOU SmartWare software. http://www.dentinstruments.com

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Data Logger – Log-Tag

Logtag Data Recorders

• Loggers use a convenient docking station

• Ideal for cold chain applications

http://www.logtagrecorders.com/index.html

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Temp Logger - HOBO

HOBO Temp

Basic Hobo single channel temperature data logger

8 bit resolution, 8k memory Reliable, affordable data logger

performance

http://www.microdaq.com/

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Temp Logger – MicroLo

MicroLog Temp with External Sensor Data Logger

• 2 channels: Internal temperature and external input

• Sensors available for external input channel: temperature, pH, 0-10V, 0-20mA and contact adapter

• Weatherproof and dust proof

• LCD display for convenient viewing while logging

• Options for wireless communications   

http://www.microdaq.com/fourier/microlog/temperature-humidity.php

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Multi-Purpose LogBox

• Two channels• Each channel accepts sensors

directly and standard input signals• 0.5 sec – 30 day logging interval• Average up to 250 reading for each

recording• Current transducer selectable 20,

100 , 150 amps• Wireless download

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Thank you

Des Murphy

Kovara Energy Consultants

dm@kovara.com 045 522866 087 6006829

End