Energy management education

/Energy management education

5 golden rules of energy data analysis

  1. In metering we trust :)    Data is only reliable if it has been collected through routine automatic metering, which has been validated.  All claims like 'we always keep this operational schedule', 'compressor/boiler/light is off on weekend' or 'current never exceeds X Amp', all of them have exactly zero value to energy [...]

Are energy meters like birdhouses or like screws?

It occurred to me that meters relate to energy monitoring in the same way as screws relate to birdhouses. How is that? Some manufacturing plants start energy management from installation of meters. Too often the process ends with meters too. However costly, this result is predictable. I will explain why on an example of [...]

#11. How to estimate possible energy savings in 25 minutes and at no cost?

Energy audit takes time and costs money, is it worth the effort?  How do I know if it will uncover enough saving opportunities? To quickly estimate how much money can be saved on utilities, we have devised an express tool - Energy Management Score assessment™. EMS is based on a premise that the way [...]

3 lessons and 5 mistakes of IIoT projects

Sam Hoff, president of Patti Engineering. suggests to start collecting data only after one has identified the problem. See IIoT project success: First identify the problem, then begin collecting data. I think he meant to say "problem area", because if you know what the problem is - you do not need more data, you need [...]

#9. Energy audit finds $20,000 in energy savings at a cost of a 30 ft pipe.

A perfectly efficient machines can still waste lots of primary or secondary utilities. A complex utility audit routinely uncovers how water, heat or 'cooling' can be reused. Hot water reuse at poultry slaughter house Two industrial poultry processing procedures were set in adjacent production space - vacuum pump and scalding. [...]

How much money is at your ‘energy waste’ account?

Situation Doing nothing is an investment decision too. Investment with a guaranteed return of nothing. Here is a common conversation at a manufacturing plant: Me: … Implementation will cost you $5K and save $15K within 12 months. Maintenance manager: So we save $10K?  Not much for our plant. Besides, I do not make investment [...]

#8. Energy audit busts ‘Nothing to save, Everything is automated’ belief

A common objection to doing an energy audit is that 'Everything is fine'. This is rarely the case. Here are two examples when audit uncovered saving opportunities that clients did not know existed because they believed everything was in perfect state already. Efficient equipment does not equate to efficient operation. Sanitation staff turned [...]

Energy waste is invisible, until you measure it

A prospect informed about a possible massive cost of compressed air leaks responded: “What leaks? I do not hear hissing noise from compressed air leaks on the floor.” Plant manufactures gravel. Production noise is deafening.  To hear compressed air leak would be a disaster, not only for energy bill, but likely for the whole [...]

#7. 4 sources of energy waste at plants with efficient machines

A common belief is that if plant is equipped with efficient machines it runs efficiently. Unfortunately, this is not always true. Efficiency of components does not equate to efficiency of the whole plant. Common reason for utility waste by efficient machines: Misuse: compressed air used instead of blowers or for cooling, oversized motors, excessive [...]

#6. 6 beliefs about energy efficiency busted by energy audits

We often hear: "Our plant runs at top energy efficiency because we use these procedures and settings and our efficient equipment is fully operational." Just how often is this true? With all due respect to maintenance and operational staff, recommendations of a proper energy audit are based on direct observation of operations and lots [...]