Industrial Energy use analysis best practicies and pitfals

Energy Use Analysis:Value, Pitfalls, Mistakes and

Best Practice

By Anatoli Naoumov, GreenQ Partners

Objective

Demonstrate how energy use analysis helps engineers

buy, sell and implement more and better energy projects

Take away message

Proper analysis of energy use will help me Buy/sell energy projects faster and Gain praise, professional satisfaction and good night sleep

Plan

What is the right tool and why?

What’s in it for me?

How to calculate savings by IPMVP?

How to find new projects?

How not to do analysis?

When looking at projects, CFO …

Core business

Energy projects

Knows how it works? Yes Nope

Has done it before? Yes You wishHas reliable numbers to prove results? Yes ?Acceptable return 10% 50%

When looking at projects, CFO …

Core business

Energy projects

Knows how it works? Yes Nope

Has done it before? Yes You wishHas reliable numbers to prove results? Yes ?Acceptable return 10% 50%

Proper tool …

1. Is as simple as possible, but not simpler2. Links results to business3. Delivers much more value than it costs

Goal-oriented Energy Analysis and Reporting -

GEAR

EMs: GEAR assures good night sleep

Common approaches to measuring results: “It’s obvious, just look at the Amps” “Accountants will calculate” “Vendor will calculate”

Proper GEAR:

Pre-agreed result assessment procedure

based on data and linked to key business indicators

Vendors: GEAR helps build business

Win projects on value

Make results count in the Boardroom

Make client happy

Satisfied clients send chequesHappy clients also send referrals

EMs and Vendors:risks and pains with no right GEAR

Frustratingly long sales cycle

Unconvincing Boardroom presentations

At risk: Satisfaction, recognition, career, job

Determine reduction by IPMVP

Before implementation: Identify and measure key consumption drivers and consumption

through the same period Build a statistically valid baseline Record all non-measured factors that affect consumption

After: Measure drivers and calculate Expected consumption Measure Actual consumption Check if factors are still the same, else adjust baseline

Reduction = Expected – Actual ±adjustments

Watch for pitfalls

• Understand accuracy and certainty of statistics-based baseline; agree on them with decision-maker

• Monitor data for human error

• Check dates: production is often recorded later

• Use engineering common sense to validate model

Demand profile shows possible waste

<1% of time demand

exceeded 450kW

25% of the time demand was under 50kW

40% of the time demand was over

almost 300kW

Is there a problem?

1-Jan

-10

1-Mar-

10

1-May

-10

1-Jul-

10

1-Sep

-10

1-Nov

-10

1-Jan

-11

1-Mar-

11

1-May

-11

1-Jul-

11

1-Sep

-11

1-Nov

-11

1-Jan

-12

1-Mar-

12

1-May

-12

1-Jul-

12

1-Sep

-12

1-Nov

-12

1-Jan

-13

1-Mar-

13

1-May

-13

1-Jul-

13

1-Sep

-13

1-Nov

-13

1-Jan

-14

1-Mar-

14

1-May

-14

1-Jul-

14

1-Sep

-14 20,000

25,000

30,000

35,000

15.0

20.0

25.0

30.0

35.0

Nat. gas, m3

Ove

n co

nsum

ptio

n, m

3

Con

sum

ptio

n ra

te, m

3 /ton

CUSUM analysis

April

Baseline

CUSUM analysis and result

April

Baseline

Oven recalibration

Result of calibration

1-Jan

-10

1-Mar-

10

1-May

-10

1-Jul-

10

1-Sep

-10

1-Nov

-10

1-Jan

-11

1-Mar-

11

1-May

-11

1-Jul-

11

1-Sep

-11

1-Nov

-11

1-Jan

-12

1-Mar-

12

1-May

-12

1-Jul-

12

1-Sep

-12

1-Nov

-12

1-Jan

-13

1-Mar-

13

1-May

-13

1-Jul-

13

1-Sep

-13

1-Nov

-13

1-Jan

-14

1-Mar-

14

1-May

-14

1-Jul-

14

1-Sep

-14 20,000

25,000

30,000

35,000

15.0

20.0

25.0

30.0

35.0

Nat. gas, m3

After recalibration in Jan 2014 consumption rate dropped below 2010 level

Value of Energy ManagerNew Plant Manager

$115K per year

CUSU

M, k

Wh

Major retrofit

$240K per year

How useful is this dashboard?

Saved a lot of natural gas in 2016?

m3 per unit

2014 1.39

2015 1.54

2016 1.26

… or not?

2014 (part) 2015 2015 (part)

Take away message

For a copy of this presentation with notes and hidden slides

please contact Anatoli Naoumov anaoumov@greenq.ca

Visit us at www.greenq.ca or call 416-728-7239Subscribe to our blog at www.greenq.ca/blog

Proper GEAR => more business and less hassle

Thank you