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Transcript of Industrial EnergyDrivers_web_2013 v1-0
IndustrIal EnErgy DrivErs
Which ones impact your facility?
1. WEATHER
2 INDUSTRIAL ENERGY DRIVERS © CopYRIGhT 2013
When it comes to energy efficiency in an industrial setting, it’s easy to
get lulled into a false sense of accomplishment with an unexpectedly
lower-than-usual utility bill. A temporary reduction in costs might have
you thinking, “I must have done something right last month.” In reality,
you could be mistaken. In fact, you could be headed in the opposite
direction.
EnErgy DrivErs can causE your EnErgy usE to varyGetting at a facility’s true energy performance – or
its energy intensity – doesn’t have to be a mystery.
The first step involves being able to identify your
facility’s energy drivers.
Energy drivers generally fall into two groups:
1 Those you can and should manipulate.
For example, you can (and definitely would
want to) determine the efficiency of the equipment
you purchase, or recognize the positive influence of
operations and maintenance (O&M) actions on the
energy efficiency of the systems at your facility.
2 Those you usually can’t or wouldn’t want to.
For instance, you can’t control the weather and
you likely wouldn’t slow production simply to save
energy.
The point of identifying energy drivers is to remove
the ones you typically can’t or wouldn’t want to
control from your facility’s overall energy-use
equation. In the grand scheme of things, this group
of energy drivers blurs the true picture of energy
consumption at your facility. All of the other drivers
that you can and should control constitute the
purview of energy efficiency.
Factoring out this first group of energy drivers
from your facility’s energy data is done through
sophisticated statistical regression analysis. Don’t
worry; we’re not about to get stat crazy. Our
objective is to help you understand which of the
drivers you can’t control, are in play at your facility.
As you identify them, you’ll be more prepared to
pinpoint your facility’s true energy performance
with the help of statistical modeling (and the data
geeks that do the analysis). Gaining insight into your
facility’s energy drivers won’t make you an expert in
screening every potential variable, but an increased
familiarity could help you save time and money in
building a viable statistical model that accounts for
them.
GAS
WATER
ELECTRICITY
METER 1 - 23kWhMETER 2 - 23kWhMETER 3 - 23kWh
3 INDUSTRIAL ENERGY DRIVERS © CopYRIGhT 2013
common inDustrial EnErgy DrivErsRather than examine an extensive list of all possible hard-to-control energy drivers,
we’ll focus on the four that appear most frequently in an industrial context.
2. ProductionWhen you produce, your facility energy use
typically varies with production volume. Even
your facility’s re-work or scrap-work rates can
have a measurable impact.
1. WEAtHErFor buildings or processes that heat or cool,
weather drives energy use over the course of
the year. Its impact on your energy bill can
be high.
3. ScHEdulEFacility schedules – the normal daily and
weekly patterns of activity when a facility is
in production or idle – may have a stronger
influence on energy use than you might think.
4. rAW goodSFrom a productivity standpoint, differences in
the quality of the raw goods used in production
can impact your processing time as well as the
amount of saleable output. Inconsistent quality
in raw goods can also cause energy use to vary.
Accounting for some (or all) of these four common energy drivers is key to lowering your energy spend
and understanding your true energy performance.
4 INDUSTRIAL ENERGY DRIVERS © CopYRIGhT 2013
1. WEAtHErDoes your energy use vary seasonally, over the course of
the year?
You might guess that thermal systems work harder
to heat in the winter, while refrigeration systems
use more energy to keep product cool during the
summer. If your facility’s industrial process requires
maintaining the temperature of a space, product,
process, or tool, then weather will play a hand in
how much energy the facility consumes. In fact, the
same driver is in play for human-occupied spaces
when an HVAC system keeps office temperatures
comfortable, in spite of the scorching summer sun.
Temperature plus humidity play a role in energy
used for drying processes. Before a lumber mill
finalizes its production of dimensional lumber,
roughly cut wet timber is kiln-dried then run through
a planer to achieve its final dimension. Colder, wet
weather affects how much energy is required to dry
the lumber.
And, wouldn’t you know it—inclement weather (read:
rain and snow) in some climates even determines
how much energy is used to process wastewater.
Precipitation, snow accumulation, storm events, and
saturated ground conditions can increase influent
flow substantially during non-summer months or
a monsoon season. The extra water in the system
means more energy is required throughout the
collection and treatment processes.
Ask Yourself: Is WeAther An energY DrIver?
Check your utility bill history for a pattern of
seasonal peaks and valleys—a strong indication that
weather is an energy driver at your facility.
5 INDUSTRIAL ENERGY DRIVERS © CopYRIGhT 2013
Ask Yourself: Is ProDuctIon An energY DrIver?
Do you have equipment that operates
intermittently, with significant idle time? For
example, do you ever have to fire up additional
equipment at a certain capacity, or use a different
process for a given product line? If the answer is
“yes,” it will be easy to identify how your production
process influences your energy data.
If your operation runs 24-7 with infrequent variance
in production levels, it might be hard to detect
a production influence. You may need to look at
energy data over a much longer time horizon and
compare a 12-month rolling average of production
with energy use in order to determine any long-term
trends.
For all industrials, energy is simply a means to an
end. You’ve got a product to make, and you need
energy to do it. Your business is about converting
raw materials into something that meets customer
needs. Though every facility would love to slow
the rate at which their meter spins, you certainly
wouldn’t turn down orders for finished goods to
do it.
But production as an energy driver isn’t just about
volume or the rate at which product is moving
down the conveyor belt. Energy use per product
will jump if the product doesn’t meet customer
specifications after the initial run and must be
reprocessed. In extreme cases, you could double
the amount of energy that goes into a product by
processing it again. More likely, you might have to
repeat a portion of the process again. For example,
food processors of seasonal frozen products are
often at the mercy of the harvest. As a result, a
facility could be up to its eyeballs in raw goods all at
once. The pressure to process more quickly creates
the potential for inadequately frozen products
that need to be reprocessed. From an energy-per-
finished-product standpoint, maintaining a proven
production process is a more efficient approach.
2. ProductionDoes energy use vary based on long-term production volume?
Does your facility have high re-work or scrap-work rates?
Bonus EnErgy tIpRe-work or scrap work is the bane of efficiency (based
on the amount of energy used to produce one unit of
finished goods). If your “do over” rates seem high or
erratic, consider having staff or third-party experts take
a second look at your facility’s process. You could save
not only energy, but also time and money.
Bonus EnErgy tIpIt’s important to examine energy use when a facility
is idle. This is the “base metabolism” of the facility. If
your facility shuts down on weekends and holidays,
comparing energy data from the two could be beneficial.
Suppose your facility uses 25 percent less energy on
average over the weekends than on weekdays. Now,
what if holiday use is 50 percent less than your average
weekday use? Since you don’t manufacture on either
weekends or holidays, comparing your shut-down
procedures on weekends to your procedure before
holidays could help you save more energy.
6 INDUSTRIAL ENERGY DRIVERS © CopYRIGhT 2013
Ask Yourself: Is scheDule An energY DrIver?
If you have access to energy data, compare your
energy use during week days with weekends or
compare shifts with more personnel on the clock
to lighter shifts. If major differences exist, schedule
could be an energy driver at your facility.
Schedule has to do with the time when a facility is
in production and when it is idle. Because operators
run equipment, the amount of energy consumed
is typically tied to the number of employees on the
floor. Whether you realize it or not, employees make
energy efficiency decisions every day by powering
up and keeping equipment running, or turning it off
when it’s not needed.
If you have an office located within a facility that is
closed while the facility operates over the weekend,
you might notice that the energy per unit produced
(energy intensity) decreases. Since no one occupies
the office on Saturdays and Sundays, overall energy
use at the facility drops. This doesn’t mean that
firing your accounting staff will make you more
energy efficient. (Try explaining the overdue power
bills to your utility!) It does mean, however, that an
energy model created for your facility may need to
account for the missing personnel on the weekend.
3. ScHEdulEDoes your energy use vary throughout the week?
7 INDUSTRIAL ENERGY DRIVERS © CopYRIGhT 2013
Ask Yourself: Is the nAture or QuAlItY of rAW gooDs An energY DrIver?
Pay attention when product yields fluctuate despite
the same per unit input of raw goods or despite
employing the same process. If you don’t have an
indication that this is a driver already, chances
are personnel close to production know which
characteristics of raw goods influence output levels.
Ask them.
Raw goods entering a facility aren’t always of
uniform quality which may cause your production
process to slow down. Since most facilities have
multiple fixed loads that are on when producing,
a slowdown in the process increases the amount
of energy cost per unit of finished goods. At a
lumber mill, for example, when the head rig handles
logs that are comparatively small in diameter, the
process slows and energy intensity climbs. In the
food industry, cold storage facilities often blast
freeze their product. If the temperature of incoming
food products is higher than normal, the process
may take longer and require more energy to get
product down to final temperature.
In some cases, the same amount of energy is
expended with diminishing returns. For example,
in solution mining an underground cave is flooded
with water to dissolve water-soluble mineral
deposits, so they can be pumped out for more
processing. Over time, the concentration of soluble
minerals decreases and the mine realizes less
saleable product for the same amount of energy.
4. rAW goodS [the nAture or QuAlItY of ]
What factors constrain your processing time and/or the amount
of saleable output? Is the same amount of energy used for
operating systems regardless of the rate of manufacture?
dIsEntanglE your drIvErsLooking at your utility bill history to get a read on your
facility’s energy efficiency is kind of like sorting through
a crowded power strip to locate the cord belonging to
a particular device. It’s messy, the cords are interwoven
and indistinguishable, and you might unplug something
important before finding the right cord. Energy drivers
are like the jumbled tangle of cords. By taking the time
to tease them out, you can get a much better sense
for your facility’s overall energy picture. Better still, by
accounting for your energy drivers in order to track your
facility’s true energy performance, you can then turn
your attention to lowering energy intensity knowing that
you now have an accurate measure of progress. And
when you see the resulting cost savings on your utility
bill (or the avoided cost from your energy model), then
you’ll really have cause for celebration.
AGRICULTURE
CHEMICALS
FOOD PROCESSING
HIGH TECHNOLOGY
GENERALMANUFACTURING
MINING & PRIMARY
METALS
OIL & GAS
PULP & PAPER, WOOD PRODUCTS
REFRIGERATED STORAGE &
DISTRIBUTION
WATER & WASTEWATER
FREQUENCY
If process includes evaporative cooling.
Driven by frequent use of pumps to distribute water for irrigation.
When operations shut down for weekends, holidays, or maintenance.
When operations are seasonal, or shut down on the weekend, over holidays, or for maintenance.
When production schedule is not continuous.
When production is not continuous.
When production is not continuous.
If operation is not continuous.
If operation is not continuous.
When operational constraints are imposed by incoming product.
When the type or quality of raw goods varies.
If operational constraints limit throughput or yield.
When ore quality or feedstocks affect processing intensity.
When operational constraints and product quality are driven by feedstock.
When properties or species of wood impose operational constraints.
When storage temperature and incoming product temperature are signi�cantly different.
When changes in in�uent properties impact aeration load.
When shipping/receiving hours are not continuous or if housing seasonal goods.
If refrigeration dominates electrical load.
If space conditioning and process cooling are used.
When space conditioning and chilled water are used in the process.
If process cooling is used.
If evaporative cooling is part of the process.
When space conditioning, process cooling, and kiln-drying are used.
More signi�cant in cold storages that offer blast freezing.
If facility has an open-system design and tighter regulations for summer ef�uent discharge.
MODERATE HIGH NOT OFTEN SOMETIMES OFTEN
INTENSITY
LOW
WEAtHEr Production ScHEdulE rAW goodS
8 INDUSTRIAL ENERGY DRIVERS © CopYRIGhT 2013
What DrivEs EnErgy usE in your inDustry?
AGRICULTURE
CHEMICALS
FOOD PROCESSING
HIGH TECHNOLOGY
GENERALMANUFACTURING
MINING & PRIMARY
METALS
OIL & GAS
PULP & PAPER, WOOD PRODUCTS
REFRIGERATED STORAGE &
DISTRIBUTION
WATER & WASTEWATER
FREQUENCY
If process includes evaporative cooling.
Driven by frequent use of pumps to distribute water for irrigation.
When operations shut down for weekends, holidays, or maintenance.
When operations are seasonal, or shut down on the weekend, over holidays, or for maintenance.
When production schedule is not continuous.
When production is not continuous.
When production is not continuous.
If operation is not continuous.
If operation is not continuous.
When operational constraints are imposed by incoming product.
When the type or quality of raw goods varies.
If operational constraints limit throughput or yield.
When ore quality or feedstocks affect processing intensity.
When operational constraints and product quality are driven by feedstock.
When properties or species of wood impose operational constraints.
When storage temperature and incoming product temperature are signi�cantly different.
When changes in in�uent properties impact aeration load.
When shipping/receiving hours are not continuous or if housing seasonal goods.
If refrigeration dominates electrical load.
If space conditioning and process cooling are used.
When space conditioning and chilled water are used in the process.
If process cooling is used.
If evaporative cooling is part of the process.
When space conditioning, process cooling, and kiln-drying are used.
More signi�cant in cold storages that offer blast freezing.
If facility has an open-system design and tighter regulations for summer ef�uent discharge.
MODERATE HIGH NOT OFTEN SOMETIMES OFTEN
INTENSITY
LOW
AGRICULTURE
CHEMICALS
FOOD PROCESSING
HIGH TECHNOLOGY
GENERALMANUFACTURING
MINING & PRIMARY
METALS
OIL & GAS
PULP & PAPER, WOOD PRODUCTS
REFRIGERATED STORAGE &
DISTRIBUTION
WATER & WASTEWATER
FREQUENCY
If process includes evaporative cooling.
Driven by frequent use of pumps to distribute water for irrigation.
When operations shut down for weekends, holidays, or maintenance.
When operations are seasonal, or shut down on the weekend, over holidays, or for maintenance.
When production schedule is not continuous.
When production is not continuous.
When production is not continuous.
If operation is not continuous.
If operation is not continuous.
When operational constraints are imposed by incoming product.
When the type or quality of raw goods varies.
If operational constraints limit throughput or yield.
When ore quality or feedstocks affect processing intensity.
When operational constraints and product quality are driven by feedstock.
When properties or species of wood impose operational constraints.
When storage temperature and incoming product temperature are signi�cantly different.
When changes in in�uent properties impact aeration load.
When shipping/receiving hours are not continuous or if housing seasonal goods.
If refrigeration dominates electrical load.
If space conditioning and process cooling are used.
When space conditioning and chilled water are used in the process.
If process cooling is used.
If evaporative cooling is part of the process.
When space conditioning, process cooling, and kiln-drying are used.
More signi�cant in cold storages that offer blast freezing.
If facility has an open-system design and tighter regulations for summer ef�uent discharge.
MODERATE HIGH NOT OFTEN SOMETIMES OFTEN
INTENSITY
LOW
WEAtHEr Production ScHEdulE rAW goodS
AGRICULTURE
CHEMICALS
FOOD PROCESSING
HIGH TECHNOLOGY
GENERALMANUFACTURING
MINING & PRIMARY
METALS
OIL & GAS
PULP & PAPER, WOOD PRODUCTS
REFRIGERATED STORAGE &
DISTRIBUTION
WATER & WASTEWATER
FREQUENCY
If process includes evaporative cooling.
Driven by frequent use of pumps to distribute water for irrigation.
When operations shut down for weekends, holidays, or maintenance.
When operations are seasonal, or shut down on the weekend, over holidays, or for maintenance.
When production schedule is not continuous.
When production is not continuous.
When production is not continuous.
If operation is not continuous.
If operation is not continuous.
When operational constraints are imposed by incoming product.
When the type or quality of raw goods varies.
If operational constraints limit throughput or yield.
When ore quality or feedstocks affect processing intensity.
When operational constraints and product quality are driven by feedstock.
When properties or species of wood impose operational constraints.
When storage temperature and incoming product temperature are signi�cantly different.
When changes in in�uent properties impact aeration load.
When shipping/receiving hours are not continuous or if housing seasonal goods.
If refrigeration dominates electrical load.
If space conditioning and process cooling are used.
When space conditioning and chilled water are used in the process.
If process cooling is used.
If evaporative cooling is part of the process.
When space conditioning, process cooling, and kiln-drying are used.
More signi�cant in cold storages that offer blast freezing.
If facility has an open-system design and tighter regulations for summer ef�uent discharge.
MODERATE HIGH NOT OFTEN SOMETIMES OFTEN
INTENSITY
LOW
9 INDUSTRIAL ENERGY DRIVERS © CopYRIGhT 2013
What DrivEs EnErgy usE in your inDustry? [continuED]
DAY WK MO YR
This Year
Last Year
2012
2011
2010
2009
2008
2007
2006
2005
SPLIT BY
TIME PERIODS
Give FeedbackLog Out
JOHN MCCLUDGEYDASHBOARD EXPLORE REPORT ACTUSER
Modify Set-points
Fix Compressed Air Leaks
Repair Sticking Valve
Clean Condenser Coils
LOW-COST ACTION ITEMS
10 INDUSTRIAL ENERGY DRIVERS © CopYRIGhT 2013
A data review performed by reputable industrial energy experts can confirm hunches
or help you unmask drivers you had no idea were influencing your facility’s energy use.
With help, you can determine true energy performance and start down the road to saving
energy and cutting costs.
nExt stEps: hoW to KnoW if you’rE rightEvery set of energy data has a story to tell. Sometimes the impact of drivers you expect
to find could be overshadowed by another variable in your operation, lack of process
controls, or because the driver isn’t variable at all–it’s constant.
123 NE 3rd Ave, Suite 400Portland, OR 97232503.287.8488 main 503.287.8788 fax
LEARN MORE ABOUT SENSEI AND CASCADE ENERGY 866.321.4573
PoWereD bY
energysensei.com cascadeenergy.com
DAY WK MO YR
This Year
Last Year
2012
2011
2010
2009
2008
2007
2006
2005
SPLIT BY
TIME PERIODS
Give FeedbackLog Out
JOHN MCCLUDGEYDASHBOARD EXPLORE REPORT ACTUSER
SENSEI is an energy efficiency platform designed to drive
continuous and cost-effective savings by connecting people to
energy information, actions to results, and projects to measureable
returns. SENSEI allows you to factor in the key energy drivers
you can’t change, so you can see the true results of your actions.
Traditional energy software monitors consumption – SENSEI
encourages action to reduce it.
aBout cascaDe enerGy
Cascade Energy provides corporations
and utilities with the industrial strength
expertise needed to realize their
energy efficiency potential. With a full
complement of services and engineering
know-how based on twenty years of
hands-on experience, Cascade has a
proven track record of reducing industrial
energy consumption and costs.
sEnsEI – your EnErgy roi starts hErE
ebook-006-2 rev 18-oct-2013