Saving $s by Monitoring Electricity Use

A 4-Step Approach to Energy Cost Saving through Power Monitoring Measurements

Sensor Synergy, Inc. 1110 W. Lake Cook Rd.

Buffalo Grove, IL847-353-8200 – www.sensorsynergy.com

February 2011

Goal: Save $’s on Electric Bill

Reduce kW-Hr Consumption

Reduce Peak Demand Charges

Improve Overall Operations through Real-Time Monitoring

Support Sustainability Initiatives

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Power Monitoring Can Impact Your Electric Bill & Save $’s

Monitoring can …

Help Reduce Total kW-Hr Consumption of Electricity by Measuring Where the Power is Going So that better Decisions can be Made

Help Reduce Peak Demand Charges by Measuring When Power is Being Used and Possibly Adjust Operations Schedules

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Monitoring Impacts Sustainability

Monitor key parameters to better track economic and environmental issues

Collect & analyze real-time sensor data to improve maintainability of physical assets

Identify anomalous operations and better characterize normal operations

Extend lifetime of equipment through predictive and condition based maintenance

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4-Steps to Lower Electric Bills thru Electricity-Use Reduction

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1) Monitor Existing Use at the Equipment Level to Identify Power Hogs and Opportunities

2) Determine Cost Effective Equipment Options using Current Measured Power Expenditure in $’s/yr for Target Equipment

3) Seek Best ROI Including Appropriate Utility Incentives & Costs of Equipment Mod/Upgrade Project for Target Energy Hog

4) Monitor Power Use after Project to Validate Benefits & to Collect Utility Company Incentives

Step 1) Identify Power Hogs

Find the Power Hogs – Identify power drain caused by most energy

demanding equipment in your facilities Pumps Air Compressors HVAC units Furnaces and Extruders Other power-hungry machines

Track “Run-Time” and Amount of Power Used

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Step – 1. Monitor Existing Use at the Equipment Level to Identify Power Hogs and Opportunities

Step-2. Determine Cost Effective Options using Measured Power $’s/yr

Consider Options for Improving Energy Efficiency of Target Equipment.

Use Measured Power Costs in $’s/yr to Determine Budget for Options

Select Cost Effective Equipment Upgrade/Modification/Replacement

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Step-3. Seek Best ROI Incentives

Based on Corporate ROI Time Period & Goals, Seek Best ROI for Targeted Energy Hog

Include Incentives from Utility Companies, State, & Federal Programs

Not just Faster, Bigger, Better Also Consider Energy Costs in Targeted

Equipment Upgrade/Modification/Replacement Considerations 9

Step-4. Metrics! Monitor Power Use after Project to Collect Incentives

After Targeted Energy Hog has been Upgraded, Modified or Replaced, Make “Follow-Up” Power Use Measurements

METRICS: Corporate Policies & External Incentive Programs Require “Follow-Up” Measurements after Efficiency Improvement Project in Order Validate Benefits and to Receive Cash Benefits

Before Repeating Process on Next Energy Hog, It is Important to Know Factual Evaluation of Success of Failure of Prior Energy Efficiency Project.

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Applying Watts Aware for SavingsThe 4-Step Process

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Step 1- Measure Energy Costs for Processes &

Equipment

Find the Biggest Energy “HOG”

Step 2 - Determine Options for Reducing Power

Consumption

Step 4 - Measure Energy Costs after Project

Compare Benefits with Project Costs

Repeat 1 – 4. Select Next “Energy Hog”

Process or Equipment and Start Process Again

Step 3 - Select Electricity Use-Reduction Project

with Best ROI

Start HereCollect Savings

$'s

Other Issues for Consideration Regarding Power-Use Monitoring

The Law of Two’s -- Analyze to Determine Power Use Differences for Similar Equipment The Old One – Original, Demonstrating Value of

Equipment The New One – Bigger, Better, More Glitzy Control

and More Electricity Dollars to do the Same Job!

Include Power Costs in Operational Decisions

Identify Power-Use in Operations or Equipment that Should Not Be Using Power at Certain Times of the Day

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Key Features of “Watts Aware” Power Monitoring Product

Tracks Power Use with Watts Aware solution Key Features

Easy to Install (less than 1-hour)

Easy to Move to Other Equipment

Data Delivered to Desks with Wireless

Netbook

Complete Turn-Key Solution includes

All Necessary Hardware & Software

All Cables, Accessories, Manual & Quick Start Guide

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Watts Aware by Sensor Synergy

Power Distribution Panel Switch Box / Breaker Panel

Supplies AC Power to Factory Equipment & Processes

Remote, Real-Time AC Power Usage Monitor

1110 W. Lake Cook Road, Suite 340 Buffalo Grove, IL 60089Voice: (847) 353-8200 www.sensorsynergy.com

Wireless data signals span large areas to

deliver power-use data directly to staff desktop

Inside Power Cabinet “Clip-Around” Current Transformer Senses AC

Wireless Router

Data Acquisition Unit Converts Analog AC

Power Sensor Signals to Digital Info for

Network

Netbook Computer Factory Loaded with All Monitoring/Logging &

Display Software

Power-Use Monitoring – Watts Aware

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Dashboard View from Watts Aware

Monitoring Multiple Watts Aware Units from one small PC

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Example Showing 3 Watts Aware Units Monitored on One Netbook PC Each Dashboard can be Collapsed or Expanded to a Graph, a Gauge or Numerical Display

Opportunities for $ Savings

One Example of Savings Opportunities

Brief project revealed great opportunity for savings at one Chicago-area manufacturing plant.

2 Weeks of automated measurements on one piece of equipment (air compressor) revealed potential savings of >$35,000/year!

Minimal investment of time and energy by plant staff revealed significant $ savings

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Review Data for Selected Time Period.

User Annotated Notes Appear as Vertical

Arrows

Air Compressor Data

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Power-Use Data Delivered Directly to Manager/Stake-Holder’s Desk

02/03/10 02/04/10 02/05/10 02/06/10 02/07/10 02/08/10 02/09/10 02/10/10 02/11/10 02/12/100

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60

70

80

90

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Time

Per

cent

Cap

acity

Compressor Percent Capacity Utilized

Identified Two Operational Modes

Monitoring compressor

operations as a percent of the compressor

capacity from a single air

compressor

Two compressors are used to supply

compressed air to the plant. This data shows only one of

these two compressors. During times with no data on this graph, the other compressor supplied air to the

plant.

Dashed red line highlights two modes of plant demand for

compressed air determined by review of electrical power use

profile for air compressor. Utilization

near capacity while operating during main production shift and

greatly reduced compressed air

demand (<30%) when no production shift

operated.

Costs and Demand for Compressed Air at Different Times of Day

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Costs for Compressed Air Demand for Compressed AirCompared to Maximum Compressor Capacity

Summary of Compressor Use Aggregated During 9 Days of Operation

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Upper bound of tool room and air leak

demand during “off” shifts.

Base load from air leak demand

during “off” shifts.

Electricity Savings for Staged

Air Compressors

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3rd Shift/Weekends.All compressed air can be shut off.

Save $6.23/hr, $37.40/day

2nd Shift.Separate tool room from rest of plant,

and use smaller compressor.Save $6.04/hr, $48.31/day

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Average power-use data calculated for the entire day (12/3/2010) includes 3 consecutive heat treatment furnace runs starting at 7:30am ending at 10:15pm

Consider using 60 HP Air Compressor Less and 40 HP More. Approx. $50/day difference in operatingcosts. Consider reducing set-point air pressure. For each 2% psi reduction, you get 1% cost savings.

Measurements to Find Big Power UsersSample Measurements from In-Plant

Assessments

*Used $0.10/KW hr

$12,000/year Difference in Operating Expenses for Two Machines that Perform IDENTICAL Functions!

Bigger, Newer Vacuum Furnace

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2nd RunAverage Power

208.4 kW$20.80/hr

2nd RunTotal Power995.6 kW-hr

$99.56

Additional Measurements

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Operational Changes from Measurements of Vacuum Furnace

Use older, smaller systems when possible.

Similar short runs can save $10,000 to $15,000 /year.

Similar long runs can save $15,000 to $20,000/year

Similar studies for Air Compressors at same facility showed a total of $25,000 to $30,000 savings.

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HVAC Example of Monitoring Electric Heater at large facility in Spring 2010

Data from heater units One phase from 2 circuit breaker panels

were monitored Data gathered from 3/26/2010 to

5/10/2010 (>45 days)

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A Typical Heavy-Use Day

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Low Temp: 30.3 oF High temp: 47.5 oF

Avg Temp: 37.9 oF Avg Humidity: 75%

Weekdays vs. Weekends

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Q & A – Discuss Electricity Savings

Jamie Wiczer is available for questions, suggestions and more technical information.

Jamie Wiczer, PhD847-353-8200Jwiczer@SensorSynergy.comSensor Synergy, Inc.Buffalo Grove, IL