Energy Performance Indicators

Liam Tolton

Second Sight Technical

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

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.

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

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….

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……

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

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 …..

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

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

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

A Simple EPI

EPI Graph

Energy Performance Indicator

2400

25002600

27002800

2900

30003100

3200

1 2 3

Month

EPI

EPI kWhrs/tonne forPeriodEPI kWhrs/ tonne Yearto Date

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

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

Example Energy Report

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

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

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

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

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

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

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

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

Summary

• The Concept of EPIs• How to Determine your EPI• The Pitfalls in determining your EPI• Using your EPI

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

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 ?

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

What use will be made of the EPI

• Monthly Reporting ?• Quarterly Reporting?• Annual Reporting ?• Energy Budget Preparation?• Project Evaluation?• Others?

Liam Toltoninfo@secondsighttechnical.com

Tel: 087 2542969

Take Action !

www.sei.ie/energymap

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