The Secret to Controlling Excessive Energy Consumption & Cost
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Complex utility rate structures like peak demand rates, low power factor penalties, and time-of-use charges plague industrial owners and operators. Extremely volatile energy usage suggests the management of high energy costs is a necessary evil. Unfortunately, few systems are in place to monitor and control energy usage, which leads to company-wide inefficiency and spikes in operational costs. By examining a manufacturing case study, discover how a modified control sequence allowed operators to initiate automated energy conservation modes to manage consumption and eliminate excessive spikes during peak demand. Learn to implement conservation control strategies through an industrial power management system, identify power quality inefficiencies that lead to additional manufacturing costs, and optimize facility operation by adjusting equipment set points, processes, and production schedules in relation to utility tariffs.
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The Secret to Controlling Excessive Energy Consumption & Cost
- 1. The Secret to Controlling Excessive Energy Consumption & Cost Allan Evora | President | aevora@affinityenergy.com
- 2. Affinity Energy • Control systems integrator • CSIA member • Mission critical energy and distributed generation focus • SCADA, EPMS, PLC, submetering, etc. • Schneider Electric Critical Power EcoXpert
- 3. 30% of energy in industrial facilities is used inefficiently or unnecessarily. EnergyStar
- 4. Manufacturing’s Energy Problem • Plants are energy hogs • Lack efficient systems to monitor quality and control energy usage – Operational costs – Unexpected downtime – Damage to sensitive equipment – Safety risks • Electricity: “just another variable expense”
- 5. Case Study • Drain-waste-vent cast iron and plastic pipe • GE, Schneider Electric, Electro-Industries, Rockwell/Allen Bradley • Massive electric furnaces continuously run with no monitoring or variable control
- 6. CPF Problem • Utility charges about double during summer for on-peak demand • Highest 30 min. demand during on-peak / month • Management challenged operations to reduce utility costs
- 7. CPF Solution • Real-time monitoring of energy consumption • Automated energy management control activated during each 15-min. time block • Dropping autopour and furnace temp once every 15-min,. • Significantly reduced peak demand • System paid for itself within 2 months
- 9. Season Dates Time Rate Summer 5/21 to 9/21 1PM to 9PM $13.66 Winter 6AM to 1PM ~1/2
- 10. “We save approximately $6,000 per month. $12,000 during the summer.” Charlotte Pipe and Foundry
- 11. 6 Ways to Reduce Energy Consumption & Cost
- 12. Understand Your Rate Structure • Peak demand – highest avg. energy use within a month • Low power factor – penalties due to high reactive power consumption • Seasonal – fluctuate when grid is closer to capacity (summer/winter) • Time-of-use – variable increases as grid experiences max demands based on time of day • Real time – published rates based on supply and demand
- 13. Install Submeters and CTs • Independent verification of electric bill (shadow metering) • Track cost allocation – Meter accuracy relates directly to rate structure (e.g., time-of-use rate = submeters support interval data) • Diagnostic tool to root cause power quality issues (e.g., Power Monitoring Expert)
- 14. Track Usage w/ Cost Allocation • Divide utility bill costs based on square footage, energy assessment per device, percentage of total KWH used, etc. • Submeters track consumption and demand by system, process, product
- 15. Start Power Quality Monitoring • Identify potential electrical distribution problems – Harmonic distortion – Phase unbalance – Sags and swells – Transients • Data from submeter helps avoid finger-pointing with utility • PQ meters w/ disturbance direction capabilities on utility service switchgear
- 16. The Electric System’s Invisible Killer • “Dirty" power – Equipment operates less efficiently • Nuisance tripping • Interference – Overheating • Transformers and capacitors • AC motors and generators • Conductors and cables – Premature failure • Bearings • Blown fuses • Sensitive electronics
- 17. Integrate Industrial Power Mgmt System • EPMS (electrical power management system) • One pane of glass visibility into electrical distribution system • Analyzes data to prioritize maintenance and identify inefficiencies • Implement energy conservation control strategies • Alerts on potential equipment failures, electrical faults, and capacity overloads
- 18. Specific Process Control Strategies • For ex: overlooked strategy for compressed air energy reduction- use of base and trim controls • Customized programmable logic controllers (PLCs) execute your most important electrical control sequences • Adjust processes, and production schedules in relation to utility tariffs 140 150 160 170 180 190 SpecificEnergy Year 1 Year 2 14.4% Annual Reduction Impact of Controls Upgrade
- 19. Where are your priorities? • Quickly respond to abnormal electrical conditions • Load profiling or capacity planning • Emergency power system compliance reporting • Power quality analysis (sags, swells, transients) • Load shedding or load management • Energy reporting (cost allocation, tenant billing) • Support engineering studies • Demand response • KPI tracking • Utility shadow billing (verify utility bill) • Equipment/building efficiency verification • Branch circuit monitoring
- 20. Allan Evora – President aevora@affinityenergy.com 704-766-2060 x110
Editor's Notes
- Complex utility rate structures like peak demand rates, low power factor penalties, and time-of-use charges plague industrial owners and operators. Extremely volatile energy usage suggests the management of high energy costs is a necessary evil. Unfortunately, few systems are in place to monitor and control energy usage, which leads to company-wide inefficiency and spikes in operational costs. By examining a manufacturing case study, discover how a modified control sequence allowed operators to initiate automated energy conservation modes to manage consumption and eliminate excessive spikes during peak demand. Learn to implement conservation control strategies through an industrial power management system, identify power quality inefficiencies that lead to additional manufacturing costs, and optimize facility operation by adjusting equipment set points, processes, and production schedules in relation to utility tariffs.
- A little bit about Affinity Energy. We are a specialty control systems integrator. Founded in 2002 We are unique in the fact that we only focus on critical power and energy and distributed generation. Our mission critical portfolio has included not only data centers, but healthcare, airports, infrastructure (such as the Chesapeake Bay Bridge and Tunnel System) and Manufacturing. We are based in Charlotte, NC and have been serving our customers for almost 15 years.
- https://www.energystar.gov/buildings/about-us/facts-and-stats
- Factories and other industrial facilities use a lot of energy. Often there are no systems in place to monitor and control energy usage, which leads to company-wide inefficiency. And when premium fees are charged by local electricity providers, operational costs can spike. Electricity – not a fixed expense. Just like any other variable expense, need to measure and monitor The reasoning isn’t just about energy conservation and cost savings, though. With the heavy machinery running at many plants, the loss of power could jeopardize safety and put employees at risk.
- Drain-waste-vent products Cast iron and plastic pipe and fittings Melt raw iron via massive furnaces drew a lot of electricity
- Engineers previously experimented with lowering furnace temperatures for brief time periods and determined the molten iron would not be affected.
- The Summer On
- More than just total energy consumption component (KWh) and fixed monthly fees Some states, like North Carolina, do not have a penalty for low power factor. Instead, the electric utility works with owners on a case-by-case basis to add equipment like capacitor banks to reduce poor power factor. Time of use: For example, in June-Sept from 1pm - 9pm, Mon through Friday, you might be charged a higher rate. During off-peak months, days, and hours, you will be charged a lower rate. Real time: (Usually the only customers on this type of rate structure are large industrial facilities.) Under certain circumstances, it could be possible to see rates that are 5 to 10 times the normal rate based on conditions influencing electric grid capacity (e.g., a heat wave.) Typically, real-time pricing customers receive lower base rates in consideration for their ability to accept the risk of real time pricing. Generally, customers that negotiate real-time pricing have the ability to curtail or have onsite generation resources.
- There are a few reasons to install submeters and CTs
- Most of today’s electrical switchgear come with metering capability built into the equipment. The same protective devices that tell a circuit breaker when to trip can also communicate the power and energy data to an EPMS system. This provides high level visibility to allow allocation by department, product, or facility system without having to invest in a large number of submeters. Interval Data It’s important to ensure the interval submeter actually records and stores data locally (onboard storage). If your submeter doesn’t have onboard storage and something happens to the network, you’ll have a big gap in your data. (What if peak demand occurred during that gap?) Onboard storage allows you to send the backed up data to fill database gaps. If your rate structure is designed to only charge from the beginning to end of a period, or if you’re a light commercial user, you don’t need a submeter with interval data. Additionally, you need to understand how the utility computes the demand. Is the interval a block calculation or a sliding windows calculation or combination of the two?
- Power quality issues have a huge impact on sensitive electronics, which can’t tolerate spikes in power or large harmonics. Having an EPMS with high-end meters (like power quality meters and power quality analyzers) allows you to determine whether you’ve got potential risk in terms of equipment going offline as a result of poor quality. Harmonics, power factor, waveform capture, sequence of events recording
- It’s difficult for owners to implement energy conservation control strategies without the data gleaned from EPMS. Feedback to reduce inefficiencies related to power delivery and energy consumption Control electrical loads Automate emergency power system tests, reducing manual recording time Advanced analytics to root cause disturbances or identify sources of poor power quality Capacity: An EPMS can tell you if you’re exceeding the capacity of a circuit. This is especially helpful if you’re planning on connecting a new machine to the electrical system. Don’t have to integrate high-end power quality meters into online EPMS Smart devices can store events, extract data on a case by case basis Are you required to have an EPMS system in order to analyze high quality power data? No. But it sure is convenient. Smart devices have the ability to store the last several events within the device, sometimes up to 30 days’ worth of information. This is the way one of our medical campus central energy plant customers has decided to use the high-end Schneider Electric meters built in to their facility. Nobody collects the data from them, and they’re not integrated into the EPMS system. However, if our customer ever had a power quality event and wanted to understand what happened on a detailed level, they could extract the device information by plugging the meter into a laptop. It’s the economical best of both worlds.