EDST (English version)

Co-funded by the Intelligent
Energy Europe Programme of
the European Union 1

Overview
 Introduction
 Manual
 System Requirements
 Analysis
 Results
 Data for EMBT
Introduction – Manual

Distribute consumption by segment and throughout the various production
processes, for both thermal and electrical energy;
The tool assists companies to find answers to the following questions:
Where is energy being consumed?
How is energy being consumed?
Purpose of the ESS-EDST

The Energy Saving Scheme developed in the EU-project SESEC does provide
you with the following tools:
• Overall SESEC Approach
• EBMT (Energy Management and Benchmark Tool)
• EDST (Energy Distribution Support Tool) , based on Excel, described in this
presentation
• SAT (Self Assessment Tool)
• Nine presentations on energy saving best practices:
• Supply Contracts and shifting – Grid
• Utilization - Production machines
• Compressed Air
• Steam and Heat Production
• Renewable Energy and Co-generation
• Lighting
• HVAC I (Heating)
• HVAC II (Ventilation, Air Conditioning)
• Vacuum, Cleaning
For more information consider [1] and [2]
Tools and resources available

Electrical distribution by consumer type. Monthly separation of the total electrical
consumption between Production machines, Heat generators, Compressed air,
Lighting, Auxiliaries and others.
Fuel distribution by consumer type. Monthly separation of the total fuel
consumption between Production machines, Heat generators, Auxiliaries and Others
for each month.
Electrical distribution by process/section (production machinery), all electricity is
distributed by processes.
 Thermal energy distribution by process/section (production), all thermal energy is
distributed by processes.
Full electrical discretization including both consumer type and productive
process/section.
Full thermal energy discretization including both consumer type and productive
process/section.
Data to be used in EMBT.
Note: Due to the fact that in this energy distribution tool calculates based on machine data and estimations, it can be replaced by direct
measurements using portable or fixed energy meters, providing that the inputs necessary for EMBT are observed.
Preview: Results to expect

the European Union 8Introduction – Manual

Steps
1. Set the Scope
2. Setup the Excel
3. Input Technical Data
4. Check Distribution Output, Thermal and
Electrical Energy
5. Data for EMBT (data to be exported and
used in EMBT)

1. Set the scope
What do you expect to get from the ESS-EDST-tool? E.g.:
 Energy distribution within the plant per segment and/or process
Who in your company will work with the ESS-EDST-tool?
 You will need the company machine list with technical data, this list
should also include lighting technical data. If company wishes to be
thorough and include all consumers don’t forget the office equipment
and non productive (e.g. food conservation and confection, etc.)
 Work hours per process and machine workload
What will be the next steps?
 E. g. Attribute energy cost within the plant per segment and/or process

2. Setup the Excel
MS-Excel 2010 or later required
The most current version is available on www.sesec-
training.eu
Macros have to be enabled
The ESS-EDST was developed using macros. You need to
enable macros in order to be able to fully use the ESS-EDST

2. Activate Macros

3. Sheet: Introduction
All sheets are
navigable but tool
use should follow a
left to right order
Read the full intro, it
will help to
understand tool inner
works

Sheet: Introduction
In this module we will use an example of a theoretical company named XPTO. This company produces
two segments:
 Socks that are included in segment “Underwear and Bras” and
 Seamless T-Shirts that are included in segment “T-shirts and related - knitted”.
The main output from the company are socks that represent nearly 100% of the production , T-shirts
represent a very small percentage of production being considered almost as sample production.
The EDST is a tool that’s only able to analyse one segment at a time, this implies that one EDST excel
file must be filled per each segment produced by a company.
In this example, the XPTO company produces two segments, the “Underwear and Bras” segment and
the “T-shirts and related - knitted” segments, this means that two EDST files must be created, one per
segment.
Note: The EDST tools with the examples (one per segment) are also available in SESEC’s website.

The first sheet is the “Start up & Company Data” sheet. In this sheet you’ll be asked to identify the
company, the user and the year that is currently being analyzed.
You will also be asked, in case the company has more than one segment, to perform a first attempt to
distribute electrical and thermal energy trough the various segments based on company's experience.
Finally you will be asked to input the amount of hours worked in each process per month on each
specific segment.
Sheet: Start up & Company Data (1)
Fill company data. All data to be inserted is to
be related to the indicated year

In these tables you must input an estimation of the monthly energy that is used in each segment, the
idea behind this is use the company’s experience to make a first division of energy consumption by
segment. As the user becomes familiar with the SESEC tools, with energy management concepts and
its implementation, this energy allocation will be tuned and consequently closer to reality.
Consider our example of the XPTO company, this company produces two segments “Underwear and
Bras“ and “T-shirts and related - knitted” where the T-shirts segment is regarded as sample
production (read slide 14). The following images show the preliminary distribution in the example.
Table for “Underwear and
Bras“ segment EDST file
Table for “T-shirts and related -
knitted” segment EDST file
As you can see the bulk of energy consumption is allocated to the “Underwear and Bras“ segment
due to the fact that almost all production is related to this segment, also note that in each month
both the electrical and thermal energy adds to 100% (e.g. January electrical consumption is 98% for
“Underwear and Bras“ and 2% for “T-shirts and related – knitted”) also in August there was no T-
shirts production so, inevitably, it appears as 0%. The “Control” cell is there to warn if values are
lower than 0% or higher than 100%.

The final input in this sheet concerns the
hours worked in each process of each
segment.
When filling these tables don’t be
concerned by particular machines, the
objective is to input the monthly work
hours of the process even if only one
machine is working. The fine tune for
hourly attribution is foreseen in
subsequent sheets.
In the example presented by the images
on the left, the monthly work hours are
the same for each segment because in
each segment the work areas are mixed,
meaning that the area where T-shirts are
knitted is the same where Socks are
knitted, same thing for finishing.
Table for “Underwear
and Bras“ segment EDST
file Table for “T-shirts and
related - knitted”
segment EDST file

Sheet: Machinery (1)
In the “Machinery” sheet, user is asked to input all energy consuming machines within the company
except steam/hot water generators and compressed air (consider compressors and dryers), these have
specific sheets for data input. This should be considered as an equipment list so input all machines
regardless of segment, so the same list can be used in multiple EDST files.
... input them here for
process identification.
“Designation” field will
filled automatically.
Use numbers 1 trough
9 from this list, and...
“Observations” and
electrical data are fields
are optional but useful
to input important
information.
Note: All green fields are optional
and are not required by the tool
for calculation.

In the “Equipment/Machine” column (see picture below) user is asked to input each machine, or group
of machines, related to the indicated process. User can either input one machine per cell or group similar
machines that usually work the same hours and have the same electrical characteristics, i.e. similar
consumption. As an example consider a company with 5 knitting machines;
Example 1: Machines are of the same model and/or same electrical characteristics, machine 1, 2 and 3
usually work all production hours and the 4th and 5th usually work half the time. In this example user
should input machines 1,2 and 3 in one row and 4 and 5 in a different row.
Example 2: Machines are of the same model and/or same
electrical characteristics but have totally different work
hours. User should input each machine in a different row.
Example 3: Machines are NOT of the same model and/or
same electrical characteristics but work continuously
trough all work hours. User should input each machine in
a different row. Nevertheless if the electrical
characteristics can be considered the same, meaning they
have similar consumption, these can be grouped in one
single row.
Justification  when grouping similar machines consider
not only the electrical characteristics, i.e. similar
consumption, but also if they have similar work hours.

“Apparent Power”
calculation can be made
by using the support tool
available in the same
sheet.
Retrieve electrical data
from each machine and
follow the tool indication
for kVA calculus

Sheet: Machinery Electrical Energy (1)
In the “Machinery Electrical Energy” sheet, user is asked to input, in a monthly basis, the specific hours
worked and the workload of all energy consuming machines inputted in the previous sheet, the
“Machinery” sheet. Calculus here will convert the “Apparent Power” to “Apparent Energy”. Concerning:
 Work hours  This represents the total monthly work hours of a machine or group of “similar”
machines. Please note that you should NOT add work hours if inputting for a group of machines, i.e.
if the group includes 2 machines and 1 works 185h and the other works 200h do not input 385h,
input an average or a value between 185 and 200;
 Workload  Work load is an
estimate percentage of the
effective work done by the
machine within it's work
hours, i.e. consider a value
between 0% if machine is
stopped and 100% if machine
is at full power/load.
Note that all other fields were
automatically filled based on data
already inserted in the
“Machinery” sheet.

Sheet: Machinery Electrical Energy (2)
Table for “T-shirts
and related -
knitted” segment
EDST file
Table for
“Underwear and
Bras“ segment
EDST file
These two images depict the January month
of both EDST files concerning the two
produced segments of the example, the
“Underwear and Bras“ and “T-shirts and
related - knitted”.
The most important thing to note is that the
values for “T-shirts and related - knitted”
machines in the “Underwear and Bras“ table
are marked as 0 and vice-versa in the “T-
shirts and related - knitted” table.

In the “Lighting” sheet, user is asked to input all lighting within the company. Much like the “Machinery”
this should be considered as an equipment list so input all lighting regardless of segment, so the same list
can be used in multiple EDST files.
Sheet: Lighting (1)
... input them here for process identification. “Area
designation” field will be automatically filled.
Use numbers 1 trough
8 from this list, and...

Sheet: Lighting (2)
... input them here for equipment identification.
“Type” field will be automatically filled .
Use numbers 1 trough 58 from this list, and...
The next step is to input the type of lighting used in the various areas, the
list in the right has 58 combinations of lighting that is commonly used,
cycle trough the list and match each area with its installed lighting types.
In the image below note that for both “Knitting” and “Finishing” the
“Observations” field indicates “Socks & T-Shirts”, this means that both
segments are knitted and finished in the same areas. Because of this, in
both EDST files the “Lighting” sheet has the same data for production
areas.

Sheet: Lighting (2)
Finally, in the same table, user is asked to input the quantity of selected lighting types and their
utilization coefficient. With all data inputted in this sheet the tool calculates the “Apparent Power” and in
the background, using the work hours inputted earlier, calculates to “Apparent Energy”. Concerning:
 Quantity  Always assume “Quantity” as quantity of lamps even if in the company there are double
or triple light fixtures, i.e. there are 10 double light fixtures, when inputting quantity input 20 lamps.
Include all working lamps even if usually they’re turned off.
 Utilization coefficient  Although all were accounted for, not all lamps are turned on during work
time, use "Utilization coefficient" to tune the amount of time lamps are turned on.
In the example (see image below) in the “knitting” area there are 150 fluorescent tube 36W lamps with
electronic ballast that are, in average, turned on 70% of the time.

In the “Compressed air” sheet, user is asked to input the “Apparent power” the “Average work load” and
an theoretical airflow distribution. Concerning:
• Apparent power  this calculation can be made by using the support tool available in the
“Machinery” sheet (slide 20). Retrieve electrical data from each active compressor and dryer and
follow the tool indication for kVA calculus.
• Average work load  the average work load can be seen as the ratio between the compression time
and the total working time.
Although the best way is to proceed with electrical measurements, a practical method can be applied
by only using a watch, imagine a compressor that in an 60 min time frame effectively compresses
during 30 min, the average work load is 30/60=50% (if you have enough patience increase the time
frame for better results). The previous method applies to on/off compressor type, if compressor has
variable speed then the data to retrieve the average work load should be available in the compressor
controller.
• Theoretical airflow distribution  Because it's very difficult, without measurements, to distribute
compressed air consumption the best approach is to estimate consumptions throughout the
installation based on company's experience. The best way to estimate is to identify, in all processes,
where are the biggest compressed air consumers their quantity and average work hours, and
correlate the three, then fine tune the results with the same data but from the less intensive
compressed air consumers.
Sheet: Compressed Air (1)

In the examples both segments have the same theoretical distribution for two main reasons:
• The main concern while analyzing distribution was the “Underwear and Bras” segment because this
is the main segment in the company;
• The weight for compressed air consumption machines concerning Knitting and Finishing is practically
the same in both segments, i.e., ratio for Knitting and Finishing is about 60%-40% regardless of
product.
Sheet: Compressed Air (2)

The “Steam / Hot water” sheet has a similar approach as the “Compressed air” sheet. Here user is asked
to input the “Apparent power” the “Average work load”, an theoretical steam/hot water flow
distribution, and the main difference between this and the compressed air sheet is the introduction of an
reduction coefficient. Also the sheet predicts both fuel and electrical steam/hot water generators
Concerning:
• Apparent power  this calculation can be made by using the support tool available in the
“Machinery” sheet (slide 20). Retrieve electrical data from each active steam/hot water generator
and follow the tool indication for kVA calculus. Remember that this is electrical consumption related
and has nothing to do with thermal power.
• Average work load  the average work load can be seen as the ratio between the effective
burn/resistance activation time and the total working time.
Although the best way is to proceed with electrical measurements, a practical method similar to one
in the the compressed air, can be applied by only using a watch, imagine a steam/hot water
generator that in an 60 min time frame effectively burns/activates resistance during 30 min, the
average work load is 30/60=50% (if you have enough patience increase the time frame for better
results).
Sheet: Steam / Hot water (1)

• Reduction coefficient  Reduction coefficient works basically the same way has the “Utilization
coefficient” in the “Lighting” sheet (slide 25), the work hours were already identified in "Company
data" page but not all generators are turned on during that time, use "Reduction coefficient" to tune
the amount of time generators are turned on;
Note that steam/hot water generators, both electrical and combustible generators, are available for data
input. You can input data in one or both types and if you have more than one equipment in one of type
input “Apparent power” sum and fine tune with “Average work load” and “Reduction coefficient”.

• Theoretical steam/hot water flow
distribution  Because it's very
difficult, without measurements, to
distribute steam/hot water
consumption the best approach is to
estimate consumptions throughout
the installation based on company's
experience. The best way to estimate
is to identify, in all processes, where
are the biggest steam/hot water
consumers their quantity and average
work hours, and correlate the three,
then fine tune the results with the
same data but from the less intensive
steam/hot water consumers.The
main difference between this and
“Compressed air” sheet is a monthly
distribution because heat
consumption is more affected by
season, e.g. comfort heating.

The “Fuel” sheet was created to
differentiate the fuel consumption that is
used to produce steam/hot water via heat
generators (indirect heat production) and
the combustible that is used directly in a
production machine like a dryer, so a
division of the total consumed fuel directly
and indirectly is imperative.
Concerning distribution, a recurrent
problem persists, without measurements
is very difficult to distribute fuel
consumption so the same approach is to
be taken as in "Compressed air" and
"Steam/Hot water" consumption. In the
table input the theoretical distribution all
combustible consumption regardless of
were it is burned (directly or indirectly).
Sheet: Fuel (1)
Based on existing meters or on your perception and experience, input here the % of fuel that is
used directly, i.e., the fuel that is burned directly in production machines like dryers and heaters.

While the previous table, in “Steam/hot water” sheet, only asks for steam/hot water distribution, i.e.,
hot fluid distribution, this one wants to know how the consumption of combustible is distributed.
As an example imagine a company that has processes A and B, in process A only steam is consumed while
in process B both steam and combustible are consumed. Steam distribution is 80% in process A and 20 %
in process B, this is the result for “Steam/hot water” sheet. In this sheet, “Fuel” sheet, the combustible
distribution is 50% for both processes, this happened because there are very intensive machines that
burn combustible directly that shifted the thermal weight distribution between processes.
Sheet: Fuel (2)
In our example sheet (see image) the
company does not consume combustibles
directly but when distributing the entire
combustible consumption all of it is used
for finishing (indirectly trough steam)
Note that also here, similarly to the
“Steam/hot water” sheet, there is a
monthly distribution also because heat
consumption is more affected by season,
e.g. comfort heating.

Results in “Results” sheet are presented both numerically and graphically, the data is divided in 6 pages
with specific results:
• Page 1  In this page you can find the Electrical distribution by consumer type, it separates the total
electrical consumption between Production machines, Heat generators, Compressed air, Lighting,
Auxiliaries and others.
• Page 2  In this page you can find the Fuel distribution by consumer type, it separates the total fuel
consumption between Production machines, Heat generators, Auxiliaries and Others.
• Page 3  In this page you can find the monthly Electrical distribution by process/section (production
machinery). Here, all electricity is distributed by processes, so each process includes its relative
electricity portion of compressed air, lighting, etc.
• Page 4  In this page you can find the monthly Thermal energy distribution by process/section
(production), thermal energy represents the burnt fuel and heat provided by an external source. All
thermal energy is distributed by processes, so each process includes its relative thermal energy
produced in the heat generators and/or from provided by an outside source.
• Page 5  In this page you can find full Electrical energy discretization including both consumer type
and productive process/section.
• Page 6  In this page you can find full Thermal energy discretization including both consumer type
and productive process/section. Note that this is where combustibles are burnt - same principles as
in page 2.
Sheet: Results (1)

Sheet: Results (2)
Some results from “Underwear and Bras” segment EDST sheet (example file)

Sheet: Results (3)
Some results from “T-shirts and related – knitted” segment EDST sheet (example file)

Sheet: Data for EMBT (1)
Results in this sheet are to be used in EDST's sister tool, the EMBT (Energy Management and
Benchmarking Tool) more particularly in the "Energy input“ and “Benchmark” sheets. As you may
remember, this tool only provides the energy distribution of one production segment, meaning that for
multiple production segments multiple EDST's must be built. The same principle applies to
benchmarking, the data in one EDST is only valid for that specific analyzed.
This sheet has three different results provided by three tables, values are available after clicking the
button:
• Table 1, Energy Distribution in Segment  This table represents the energy distribution in this
segment. Just select and copy all the values in this table and paste them in table "Input Energy
Distribution by Process" of the "Energy input" sheet;
• Tables 2 & 3, Benchmarking for Segment  These tables present the necessary data by providing the
energy ratio, both electrical and thermal, on benchmarkable processes in the selected segment. Just
select and copy all the values in both tables and paste them in tables "Electrical energy
consumption" and "Fuel energy consumption" of the "Benchmarking“ sheet.
Click here to retrieve values. These
values are based on the data from
“Results” sheet.

Data to be inserted in EMBT from “Underwear and Bras” segment EDST sheet (example file)

Data to be inserted in EMBT from “T-shirts and related – knitted” segment EDST sheet (example file)

Readings
 [1] CITEVE (2013): Critical Energy Saving Points for the Clothing Manufacturing Process/Factory
Environment, Deliverable D3.1
 [2] CITEVE (2013): O3.2 “Energy Saving Scheme (ESS) Guide for Companies” and O3.5 “Guidance
Document”
 [3] GHERZI (2013): Energy Data, Deliverable D2.2
 [4] DITF (2014): Euratex Overall SESEC Approach, presentation available on www.sesec-training.eu
 [5] CITEVE (2014): EMBT (Energy Management and Benchmarking Tool), presentation available on
www.sesec-training.eu
 [6] ENEA (2014): SAT (Self Assessment Tool), presentation available on www.sesec-training.eu

Pictures
 Slide 8 – Dennis Skley: *grübel* – URI: http://www.flickr.com/photos/dskley/8627475625/sizes/z/in/photostream/
License: CC BY-ND 2.0 (http://creativecommons.org/licenses/by-nd/2.0/legalcode)
 Slide 9 – Carissa Rogers: kid to do list, list, Be happy and go home – URI:
http://www.flickr.com/photos/rog2bark/3437630552/sizes/m/in/photolist-6eLKNh-c1mn5W-9Lcbki-9jeZKu-CdE9B-
6tQG1N-8cuPQg-6oCMfR-5R2t5b-9uCMNF-7WWKna-82Z8Cz-87uSWj-839wC-8QW9Yq-7pHc1U-6qsYHC-gu1Ra-
7Jq5QH-7Mfehz-7VWPxJ-6J37Hp-4QCVn9-8QzzeL-8w3ARY-5JaQRk-5wvNsm-fMnd2-ffgRgs-4yar1X-dr9xUw-dJLTso-
3bLKoc-5sane8-eT8xC-5QjTMr-55xTxK-iYZum-i8xKL-61m8xK-6YzqVs-7JKQkd-5SyRgw-4VSKqq-avZUVo-4ZwxHC-3svSV-
4qU25r-4sCr3S-PVLFS-5rMwqS/ License: CC BY 2.0 (http://creativecommons.org/licenses/by/2.0/legalcode)
 All other pictures (except the logos) are screenshots of the EDST-Tool by SESEC CC BY-SA 2.0
(http://creativecommons.org/licenses/by-sa/2.0/legalcode),

EDST (English version)

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