Database Issues and a Few Other Things. Department of Mechanical & Aerospace Engineering Michael R. Muller Professor of Mechanical Engineering at Rutgers

Database Issues and a Few Other Things

Department of Mechanical

& Aerospace Engineering

Michael R. Muller

• Professor of Mechanical Engineering at Rutgers• Director of IAC at Rutgers: 1986-1991• Eastern Region Field Manager – IAC 1992 to

present• Eastern region handles database for entire program• My particular interests are:

On-site power generation Supplier development programs Developing Protocols for Industrial “Triage”



Industrial “Triage”

• Strategy for ranking cost saving proposals Replaces list of “good ideas” which preclude ranking

• Requires cost estimates and project impacts Must develop connection to productivity The “soft number problem”

• We do it already – not enough time to go after all of the good ideas at a plant

Need to quickly focus on high yield targets



Program Metrics

• Each year the IAC program’s performance at DOE is determined (GPRA - Government Performance and Results Act of 1993)

• IAC’s are graded on their performance as well Measurable statistics are called metrics (buzz)

• Director’s know about this, but students may not• Students are important parts of a center’s overall

performance You need to track your own metrics



Program Metrics

• East and West regions differ, but details are available

• Examples here are for the East!



Overall Ranking Criteria

• Report Quality• Assessment Performance• Day to Day Operation• Contract Compliance

• Database Metrics



contract compliance

15%

day to day operation

15%

database metrics

30%

report quality20%

assessment performance

20%

Eastern Program Metrics



Report Quality

• Presentation• Clarity• Creativity• Knowledge• Errors

Students do much of the proof reading

• We still see upside-down pages! Lead students will set the tone in the office – will have

great impact with the rest of the team



Assessment Performance

• Based from site visits and client follow ups• Some of the criteria:

Attitude Technical Knowledge Interview Plant inspection

Student participation Faculty leadership

Student safety Instrumentation



Day to Day Operation

• Availability / responsiveness• Database Communications• Extra money handling• Faculty participation• Student Utilization



Contract Compliance

• Timeliness (# of late items submitted) Big student impact here

• Coverage Industry coverage1 (based on # of 2-digit SIC codes) Geographical coverage1 (based on 3-digit ZIP codes)

• Other violations More than 3 exceptions Non-compliant quarters

1 based on last 75 reports



Database Metrics (last 25 reports)

• Implemented Dollar Savings (35%)• Implemented Energy Savings (15%)• Total # of different AR’s (20%)• Recommended Dollars per assessment (15%)• Total # of Energy AR’s (7.5%)• Total # of Non-energy AR’s (7.5%)



Database Metrics

• Students need to track metrics at their own center Should also track their performance against other

centers

• This is very doable, but needs a student to get experienced with databases

• Students already upload most of the data to RU• Database and manuals are online at Rutgers

oipea.rutgers.edu Or call Uncle Fred (Fred Glaser) at 732-445-5540



Training Manuals Online



The IAC Database

• Structure: Two Main Files

• Assessment Database IAC and Report Number, Visit Dates Plant size, Principal products, SIC Number of Recommendations Energy Streams: Cost and Usage

• Recommendation Database A Narrative Description of the Recommendation ARC representing recommendation Resource Use and Costs Avoided Costs to Implement Status of Implementation



The IAC Database (cont.)

• The database contains data from all assessments since 1981

• Data shows changes regionally, and over time – very useful to many groups

• Accessing the Database http://oipea.rutgers.edu Users can:

• 1. Download the data files and perform queries on their own computers

• 2. Use the on-line queries on the web site



Interactive Database Access

• Client - Server structure• Available on RU website• Eliminates need to download database for simple

queries• Current version use MYSQL v. 3.21• Easiest way to check if your data is online• DOE looks at this – their way of keeping track



Database Metrics

• For many of the metrics used to judge center performance, the database must be downloaded and analyzed

• Any database software will let you work with the data

Data is in standard dbase engine (.dbf)

• Most metrics are easy to calculate Normally we sum over last 25 assessments Therefore it crosses contract years



Database Metrics

• Trickiest measure is creativity We count different ARC numbers used in the last 100

assessments Good number is about 100!



Using the database as an assessment tool

• IAC’s develop their own ways of doing things• The IAC database is just one tool• We recommend that students check the database

before an assessment Look for assessments with same SIC code (NAICS) Find recommendations which were made – get ideas Broaden the types of recommendations your IAC makes

• My happiest moments as an IAC director was when students came up with good ideas

• Probably need to use download database



20 Food and Kindred Products 30 Rubber and Misc Products21 Tobacco Products 31 Leather and Leather Products22 Textile Mill Products 32 Stone, Clay, and Glass Products23 Apparel and other Textile Products 33 Primary Metal Industries24 Lumber and Wood Products 34 Fabricated Metal Products25 Furniture and Fixtures 35 Industrial Machinery and Equipment26 Paper and Allied Products 36 Electronic & Other Electric Equipment27 Printing and Publishing 37 Transportation Equipment28 Chemicals and Allied Products 38 Instruments and Related Products29 Petroleum and Coal Products 39 Miscellaneous Manufacturing Industries

IAC Client SIC Code Distribution

0.0%

2.0%

4.0%

6.0%

8.0%

10.0%

12.0%

14.0%

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

2-Digit Sic Code



First Step – Check the interactive database

• Will give top ten recommendations• The IAC program looks at systems which are

common to many industries• There are 22 2-digit SIC codes served by the IAC’s

How many different recommendations appear in the 22 top ten lists

• (max = 220, min 10)

"Industrial Energy Audit/ Assessments: Implications for

Saving Energy in the Manufacturing Sector"

AEE Congress - 1999

Michael R. MullerProfessor of Mechanical Engineering

Rutgers University

0 2 4 6 8 10 12 14 16 18 20

RECOVER HEAT FROM AIR COMPRESSOR

OPTIMIZE PLANT POWER FACTOR

METER WASTE WATER

USE CLOSED CYCLE PROCESS TO MINIMIZE WASTE WATER PRODUCTION

REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES

TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME

INCREASE AMOUNT OF WASTE RECOVERED FOR RESALE

USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR

INSULATE STEAM / HOT WATER LINES

REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS

REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT

INSTALL OCCUPANCY SENSORS

INSTALL TIMERS AND/OR THERMOSTATS

REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED

ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO

INSULATE BARE EQUIPMENT

USE MORE EFFICIENT LIGHT SOURCE

ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES

UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS

INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS

USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS

UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS

Only 21 Recommendations appear in any Top Ten



SIC Searches

• Best to use download database and look for more than the top ten

• Often this will give good ideas• Examples:

Sand recommendations in metal casting Recovery boilers in paper mills Oxyfuel combustion in glass plants High accuracy metering pumps in chemical plants



Understanding the bigger picture

• Another benefit of database is that it shows what plants and industries respond best to IAC services

• How big is the typical plant? How many employees? What industries do we visit most often?

• With IOF industries being the priorities, how are they represented in your region?



Distribution of Gross Sales of IAC Client Firms

0.0%2.0%4.0%6.0%8.0%

10.0%12.0%14.0%16.0%18.0%20.0%

<1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80M

ore

Gross Sales in Millions ($)

Average = $25 millionMedian = $16 million

Characterization of IAC Clients




IAC Client Distribution

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

25 50 100 150 200 250 300 350 400 450 500 More

Number of Employees

Average = 166Median = 125




IAC Client Distribution

0.0%2.0%4.0%

6.0%8.0%10.0%12.0%14.0%

16.0%18.0%20.0%

0.5 1

1.5 2

2.5 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17

More

Yearly Energy Costs ($100k)

Average = $354kMedian = $196k



Some Reminders

• Change from “site to source” for electricity• Electrical energy consumption is not equivalent to

the total energy consumed Losses from power plants and transmission are

considerable Grid efficiency is about 30% Practice leads to 3x undercounting of energy savings on

electrical AR’s

• Before – uploading used MMBtu’s• Now – upload electrical consumption with KWH!



Implementation – what is pending?

• Only three implementation codes are acceptable: I – Implemented must have date that is not greater than 1 year from

implementation interview and not greater than 2 years from assessment

N – Not Implemented with Reason Code• N1 through N22, excluding N12 & N13 • For FY01 we will not accept

– N12 – to be implemented after 2 years – N13 - considering

P – Pending: No date just a ‘P’ • For recommendations over $10,000 use ‘P’ and you then

must call back client within 3 years of audit or recommendation will become not implemented.

• For recommendations under $10,000 – make a decision!

6.1 Implementation Status

The database uses a numerical code to represent the status of implementation. The following table provides details to the coding scheme:

Code Implementation Status I IMPLEMENTED

Was completely implemented at the time of the call, or plans definitely made to complete implementation within 12 months of call ( not exceed 24 months from

the assessment date) P PENDING

This status is for recommendations with implementation costs of $10,000 or more. Delay in implementation should be attributable to large capital investment.

N NOT IMPLEMENTED K DATA EXCLUDED OR UNAVAILABLE

K status may be assigned ONLY by field managers.

Table 4. Implementation Status A list of “pending” implementations will be kept for each center; for each Pending

implementation, a yearly report will be required from the center until the implementation can be identified as either Implemented or Not Implemented.

If, after 3 years, a Pending implementation cannot be identified as Implemented, it shall be changed to Not Implemented.

Pending implementations will not be counted when determining which implementations are Implemented and Not Implemented

Documents

Database Issues and a Few Other Things. Department of Mechanical & Aerospace Engineering Michael R. Muller Professor of Mechanical Engineering at Rutgers