This document outlines a 4-step approach to reducing electricity costs through power monitoring. Step 1 is to monitor existing equipment usage to identify major power consumers. Step 2 determines cost-effective upgrade options using measured power costs. Step 3 seeks projects with the best return on investment, including utility incentives. Step 4 monitors post-project usage to validate savings and collect incentives. Real-world examples from manufacturing plants found potential savings of over $35,000 annually from optimizing air compressor usage. Monitoring a vacuum furnace also revealed $12,000 in annual savings from using older, less power-hungry equipment.

1. 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, IL
847-353-8200 – www.sensorsynergy.com
February 2011

2. Goal: Save $’s on Electric Bill
 Reduce kW-Hr Consumption
 Reduce Peak Demand Charges
 Improve Overall Operations through Real-
Time Monitoring
 Support Sustainability Initiatives
2

3. 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
3

4. 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
4

5. 4-Steps to Lower Electric Bills thru
Electricity-Use Reduction
5
 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

6. 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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7. 7
Step – 1. Monitor Existing Use at the Equipment Level to
Identify Power Hogs and Opportunities

8. 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
8

9. 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

10. 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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11. Applying Watts Aware for Savings
The 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 Here
Collect Savings
$'s

12. 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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13. 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
13

14. 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 60089
Voice: (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

15. Power-Use Monitoring – Watts Aware
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16. 16
Dashboard View from Watts Aware

17. 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

18. 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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19. 19
Review Data for Selected Time Period.
User Annotated Notes
Appear as Vertical Arrows

20. Air Compressor Data

21. 21
Power-Use Data Delivered Directly to
Manager/Stake-Holder’s Desk

22. 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 02/12/10
0
10
20
30
40
50
60
70
80
90
100
Time
PercentCapacity
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.

23. Costs and Demand for Compressed
Air at Different Times of Day
23
Costs for Compressed Air Demand for Compressed Air
Compared to Maximum Compressor Capacity

24. Summary of Compressor Use Aggregated
During 9 Days of Operation
24
Upper bound of tool room
and air leak demand during
“off” shifts.
Base load from air
leak demand
during “off” shifts.

25. Electricity Savings for Staged
Air Compressors
25
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

26. 26
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 operating
costs. Consider reducing set-point air pressure.
For each 2% psi reduction, you get 1% cost savings.
Measurements to Find Big Power Users
Sample Measurements from In-Plant Assessments

27. *Used $0.10/KW hr
$12,000/year Difference in Operating
Expenses for Two Machines that
Perform IDENTICAL Functions!

30. Bigger, Newer Vacuum Furnace
30
2nd Run
Average Power
208.4 kW
$20.80/hr
2nd Run
Total Power
995.6 kW-hr
$99.56

31. Additional Measurements
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32. 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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33. 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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34. A Typical Heavy-Use Day
34
 Low Temp: 30.3 oF
 High temp: 47.5 oF
 Avg Temp: 37.9 oF
 Avg Humidity: 75%

35. Weekdays vs. Weekends
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36. 36

37. Q & A – Discuss Electricity Savings
 Jamie Wiczer is available for questions, suggestions and more technical
information.
 Jamie Wiczer, PhD
847-353-8200
Jwiczer@SensorSynergy.com
Sensor Synergy, Inc.
Buffalo Grove, IL