Escolar Documentos
Profissional Documentos
Cultura Documentos
Reporting exceptions 04
Precedent-based targeting 06
Activity-based targeting 06
Cusum analysis 10
Visualisation 17
Routine operation 21
Next steps 22
Glossary 23
The purpose of monitoring and targeting (M&T) is to This guide presents M&T from two perspectives. One
relate your energy consumption data to the weather, is routine use (on a weekly cycle, for example). Routine
production figures or other measures in such a way M&T as explained here is quick and simple and requires
that you get a better understanding of how energy is no particular expertise on the part of the user. The
being used. In particular, it will identify if there are signs other perspective is target-setting and diagnosis, an
of avoidable waste or other opportunities to reduce aspect that will appeal to users who wish to analyse
consumption. data in more depth. Although this aspect needs to be
addressed when first setting up an M&T scheme, it then
Data collection may be manual, automated, or a mixture
becomes optional once the system is up and running.
of the two. Once an M&T scheme has been set up, its
routine operation should be neither time-consuming Even for the more advanced aspects, an appreciation
nor complex. An M&T scheme will provide essential of the basic physical principles behind the use of energy
underpinning for your energy management activities, at your place of work and a basic grasp of maths is all
allowing you to: that is needed.
1. Detect avoidable energy waste that might otherwise M&T is an extensive topic and this guide can only
remain hidden. This is waste that occurs at random provide an introduction to the more complex analysis
because of poor control, unexpected equipment faults methods and tools that can be used. Users should
or human error, and which can usually be put right contact the Carbon Trust or an expert consultant
quickly and cheaply (or, indeed, at no cost). Intercepting for more detail or further advice on applying these
and rectifying such problems should more than cover techniques within their organisation.
the cost of operating the M&T scheme. See the next
section for some examples.
The meaning of target Examples of waste and saving that have been identified
by employing M&T include:
Monitoring and targeting can be focused on invoice
checking, contract tariff negotiation and financial • Losses that would have equalled £3,500 a year were
budgeting, or on the physical performance of the incurred when a limit switch came loose at a waste-
organisation’s buildings, processes and vehicles. It is water treatment works, causing some machinery
the latter interpretation that we will use in this guide. that should have been running intermittently to
run continuously.
Often, targets are set without consideration of practical
application or achievability. This guide focuses on • Gas consumption at a council depot doubled when
a maintenance contractor left the heating system
achievable operational targets. An operational target:
running 24 hours a day.
• Is calculated rationally to reflect known • The front steps of an office block were found to be
achievable performance
costing £5,000 a year because the control had failed
• Is discussed and agreed on the de-icing heaters (which the owners did not
• Is applied to individual monitored streams even know they had).
of consumption • Frost-protection systems are a prime cause of waste.
• Is continually amended to reflect improvements One energy manager cut the electricity consumption
of his HQ building by 40% when he found that all the
• Does not need to be widely disclosed
electric frost protection pre-heaters were running on
• Has performance reviewed monthly at most, his air handling units.
commonly every week, or even daily or per shift
• Is beneficial for day-to-day cost and • Hundreds of pounds a year were lost when someone
left a bypass valve open on a steam trap in the
environmental management.
basement of a paper mill.
Hidden avoidable energy loss happens all the time,
usually because of some minor control failure or the
inappropriate action of occupants or maintenance staff. Further information
This guide will help you detect and remedy this waste,
and disclose other opportunities to save energy Fact sheets
and money. Energy management (GIL136)
Understanding your energy consumption (CTL001)
Assessing the energy use at your industrial
site (CTL002)
Assessing the energy use in your building (CTL003)
04 The Carbon Trust
Reporting exceptions
One of the key functions of a monitoring and targeting scheme is to alert
the user to instances of exceptional excess consumption of energy.
This form of exception report has many advantages. Routine monitoring by means of an overspend league
First and foremost, the most significant items are table is so simple that it should take no more than a few
always at the top of the list, so it does not matter minutes a week – unless, of course, additional time is
whether the report contains 10 items or 10,000. warranted by the occurrence of a significantly costly
Second, it will be immediately evident how much problem. Using it is a robust procedure, since almost
remedial effort is warranted; indeed in some weeks anyone can deputise for the principal user in his or
there may be no problems that are sufficiently costly her absence.
to merit investigation. Third, as exceptions are judged
Although this guide goes on to describe various
on cost, non-energy commodities can be included
associated analytical and charting techniques, these
in the same report. By including other utilities and
can be thought of as optional. Once an M&T scheme
consumables such as water, effluent discharge volumes,
has been set up, the overspend league table may be
chemicals and so on, the overspend league table can
all that is needed for simpler examples.
provide valuable benefits beyond energy savings alone.
Methods for calculating expected consumption fall into Generally, however, precedent-based targeting models
two categories. There are those based on precedent can be too simplistic, and organisations may want to
(comparison with previous periods), and activity-based consider activity-based targeting. This is particularly
methods that relate expected consumption to its driving appropriate when there are clear drivers for changing
factors (weather, production throughput, mileage, etc.). energy consumption, for example, changes in production
For the sake of brevity we will refer to any procedure for throughput. See page 17 for examples of how data can
calculating expected consumption as a ‘targeting model’. be compared using automatic meter readings.
1,800,000 500
1,600,000
0
1,400,000 0 20 40 60 80 100 120 140
1,200,000 Cooling degree days
1,000,000
kWh
800,000
600,000
Degree days
400,000 Heating degree days are a measure of the severity
and duration of cold weather. The colder the
200,000
weather in a given month, the larger the degree-
0
0 10 20 30 40 50 60 70 day value for that month. They are, in essence, a
summation over time of the difference between
Heating degree days
a reference or ‘base’ temperature and the
outside temperature.
Further information
Degree days for energy management (CTG004)
www.carbontrust.co.uk/degreedays
1
Limited figures are available free of charge. Commercial data providers can be found on the web and it is also possible to calculate figures from
local measurements.
08 The Carbon Trust
1,800,000 200,000
1,600,000
1,400,000 150,000
kWh
1,200,000
100,000
1,000,000
kWh
800,000
50,000
600,000
400,000 0
200,000 0 200 400 600 800 1000 1200
0 Output (tonnes)
0 10 20 30 40 50 60 70
Heating degree days If a simple straight-line relationship is not applicable,
other methods can be used. However, as there are
operational advantages in being able to represent
Note performance as a straight-line characteristic on a
scatter diagram, methods that manipulate the data
The characteristic line will usually only be needed
to make that possible are generally to be preferred.
for computations within the normal range of data.
The position of the intercept must be interpreted It is beyond the scope of this guide to deal with these in
with caution if it is extrapolated well beyond this detail, but some hints are given below. Suffice to say that
range. Where degree days are the driving factor, any appropriate method can be used to infer expected
the intercept will also be sensitive to the choice consumption from other independent measurements.
of base temperature.
Monitoring and targeting 09
Alternatives to straight-line targets Take a week when production of A, B and C was 400, 500
and 600 units respectively. Expected consumption would
Production processes are often more complex to set
then be given by multiplying the quantity produced by
targets for. One common situation is where several
the kWh per unit:
products with different energy intensities are made
on the same plant. Here, a tabular form of calculation Another way to view these situations is to work out an
is necessary to establish expected consumption. energy-weighted equivalent output. Five hundred units
of Product B, for example, is the equivalent (in energy
Suppose there are three products: A, B and C, which
demand) of 1,000 units of product A (because its energy
respectively require 10kWh, 20kWh and 50kWh per
intensity is double). In the example shown here, the
unit to manufacture. Suppose also that there is a
mixed production is the equivalent of 400 + (500 x 20/10)
fixed overhead of 3,000kWh per week. These values
+ (600 x 50/10) = 4,400 units of Product A. Reducing
would all be constant from week to week, but actual
the week’s bundle of production to a single equivalent
production throughputs would vary.
output in this way enables a straight-line characteristic
to be drawn.
Key M&T charting techniques that users should be Figure 6 Energy consumption related to driving factors
aware of are:
Site E gas – 45 unit
• How to fix straight-line targets at the lowest Performance characteristic line(s)
sustainable level 250,000
• How they can help diagnose abnormal performance.
200,000
In order to apply these techniques, users must be
familiar with cusum analysis. This technique is relatively
simple, but very effective. If the energy performance for 150,000
250,000
200,000
150,000
kWh
100,000
50,000
0
0 200 400 600 800 1000 1200
Output (tonnes)
2
Or other chosen interval.
3
In MS Excel this is termed the x-coefficient.
Monitoring and targeting 11
This then provides enough information to construct Note that the formulae in column D refer to c and m
the cusum calculation. There are six columns (including (the intercept and slope of the current performance
date stamps) in the following spreadsheet: characteristic line) stored in cells $B$2 and $B$3
respectively. These are constants, although possibly
subject to amendment from time to time as the view
of what is achievable changes.
Column Contains
A Input data Date of end of period
B Input data Quantity consumed (kWh)
C Input data Driving factor, such as tonnes or degree days
D Formula Expected consumption (m x col. C) + c
E Formula Difference between actual and expected (col. B – col. D)
F Formula Running total of column E
12 The Carbon Trust
5/03
39/02
33/02
51/02
17/03
23/03
30/03
0
can have limits of expected or allowable variation -50,000
superimposed, as illustrated by the broken blue line. -100,000
It clearly shows whether or not the deviation between -150,000
-200,000
observed and expected consumption is within the
-250,000
normal behaviour of the process.
27/02
33/02
39/02
45/02
51/02
5/03
11/03
17/03
23/03
30/03
-20,000
-40,000
-60,000
27/02
5/03
11/03
33/02
17/03
39/02
45/02
30/03
51/02
23/03
Week
Monitoring and targeting 13
Fixing a ‘tough but achievable’ If we identify the same hand-picked data points on the
scatter diagram (Figure 13), we see that they lie towards
target characteristic the lower edge of the scatter. This is no surprise, but
In order to detect – and thus rectify – accidental energy until we drew the cusum we did not know that these low
waste, target performance characteristics need to consumptions were consistently achievable. In general,
stretch people without breaking them. Set the target just arbitrarily picking low points on a scatter diagram
too leniently, and opportunities will be missed because is not reliable.
some problems will not show up as overspends.
Set it too aggressively4, and everyone will become Figure 13 Best achievable performance on the
demoralised because they will be unable to avoid scatter diagram
adverse reports.
Site E gas – 45 unit
The clue to best achievable performance is in the Performance characteristic line(s)
cusum chart. There may be periods when it slopes 250,000
downwards for weeks at a time, indicating a persistent
tendency to use less energy than predicted by the trial
200,000
characteristic. These favourable periods present an
opportunity for further analysis, as illustrated in Figure 12.
150,000
kWh
0
0 200 400 600 800 1000 1200
250,000
200,000
150,000
100,000
50,000
kWh
-50,000
-100,000
-150,000
-200,000
-250,000
27/02 33/02 39/02 45/02 51/02 5/03 11/03 17/03 23/03 30/03
Week
4
Setting extreme targets is an alternative technique which may be applied in some circumstances, but such methods are outside the scope of this
guide. The Carbon Trust can offer additional advice in this area. Call 0800 085 2005 for further help.
14 The Carbon Trust
By fitting a new performance characteristic line through Figure 14 Finding a new operational target
the points identified as representing best achievable Site E gas – 45 unit
performance, this becomes the new operational target Performance characteristic line(s)
(Figure 14).
250,000
kWh
performance. Figure 15 shows a cusum chart that has
developed a rising gradient towards the end (indicating, 100,000
as previously explained, an adverse change in the way
the monitored plant uses energy). 50,000
150,000
100,000
kWh
50,000
-50,000
-100,000
36/02 42/02 48/02 2/02 8/02 14/03 20/03 26/03 33/03 39/03
Week
Monitoring and targeting 15
By looking at the same points on the scatter diagram, Figure 17 Comparing actual consumption with
compare the adverse characteristic with what is theoretical demand
achievable. This should enable someone with technical
College Q main electricity
knowledge of the process to infer the nature of the Performance characteristic line(s)
fault (in this example, the symptom is fixed extra
70,000
consumption unrelated to production throughput).
kWh
and resulting excess cost and carbon emissions.
30,000
100,000
Figure 18, meanwhile, shows electricity demand in
80,000 a log chipper feeding a pulp mill. The blue line shows
that demand barely changes with throughput. The red
kWh
20,000
Figure 18 Identifying a more rational characteristic line
0 Chipper power
0 50 100 150 200 250 300 Performance characteristic line(s)
Site E rolls production 14,000
12,000
Persistent abnormal performance
The techniques described so far are designed to 10,000
Further information
Advanced metering for SMEs (CTC713)
16 The Carbon Trust
400
350
300 In this false-colour contour plot (above),
Power (kWh)
24:00 24:00
M TW T F S S M T W T F S S M TW T F S S M T W T F S S
Monitoring and targeting 19
As before, by aggregating a week’s worth of theoretical The theoretical heat demand is added up over the
demand, one obtains an estimate of expected course of a week and compared with metered steam
consumption that enables excess consumption to consumption. Again, this is done using an overspend
be included in the overspend league table. league table to detect and quantify any energy losses
that may occur, for example as the plant’s internals
Even more complex solutions can be employed when
begin to foul up or disintegrate.
the risk of undetected loss is sufficiently high. In one
particularly advanced application, process control data To avoid data overload and possible spurious alerts,
such as temperatures and flow rates are being collected do not try to assess performance in real time. Have
from a set of distillation columns and analysed every a weekly review, for example, and then drill down into
20 minutes (during steady-state operation) to calculate the detail of any cases that require investigation. Use
the theoretical heat demand from first principles. data visualisation techniques to help you and your
colleagues find the causes of excess consumption.
Case study:
Chemical works
A chemical works applied M&T to the steam control system, and the more efficient settings were
consumption in some distillation columns, carrying adopted as the norm.
out a weekly assessment of consumption against
The factory’s process managers found the M&T
theoretical demand calculated from 20-minute-interval
scheme useful for comparing the relative thermal
data on material flows and temperatures. It found
efficiencies of their distillation columns, enabling
a number of instances of avoidable waste, such as
them to schedule production on a least-energy basis.
a case where the operators had bypassed a heat
It also gave them the ability to optimise maintenance
recovery unit and another where steam was leaking
shutdowns, as internal fouling and disintegration
through a faulty trap.
can now be detected through a deteriorating energy
In the latter case the fault was already known about, efficiency. They also welcomed the fact that operators
but its cost implications were not. The company also no longer have to try to assimilate dozens of flow
discovered (by chance) that it was possible to operate and temperature readouts, nor guess whether any
slightly outside the stipulated ‘reflux ratio’ and achieve deviations are significant or not; the overspend league
higher thermal efficiency. Manual control was replaced table gives them a simple weekly summary of where,
with an automatic loop by reprogramming the plant if anywhere, waste is occurring.
20 The Carbon Trust
In order to operate an M&T scheme effectively, The required driving-factor data will often include
the following three components must be in place: degree-day statistics, and according to the user’s
circumstances may also comprise production figures,
1. Consumption data
mileages, hours of darkness, or whatever other data
2. Driving-factor data helps to determine how much energy should have
been used.
3. Methods of calculating expected consumption.
Two important points to note are that first, driving-factor
Consumption data may come from meters (manually
data, like consumption data, need to be synchronised
or automatically read), from delivery and stock-level
with the assessment intervals; and second, where
figures, or from proxy measures such as run-hours
production data are used, they should certainly be
counters or ammeters. The critical task is to ensure
gross (rather than saleable) volumes, since it will often
that data are synchronised as closely as possible
take as much energy to produce a unit of unsaleable
with the required assessment intervals. Repeatability
scrap as a unit of good product.
of measurements is more important than accuracy.
Systematic bias in readings is of little consequence: Production volumes may need to be measured at
it will affect the calculated consumption volume, but the intermediate points in the process in order to provide
unexpected change that caused it will still be evident. a meaningful guide to the energy requirements of
different production stages. For example, in a paper-
Meter readings should be read in-house. It is best not to
making machine, the paper goes through a drying stage
rely on invoice data, as suppliers are under no obligation
after dewatering and pressing. The steam requirement
to provide accurate readings. Nor do suppliers read
for a tonne of discarded paper that gets as far as the
private submeters, which are an important source of
reeler is the same as for a saleable tonne, but it is nil
data. Furthermore, in-house meter readings can be
for a tonne of discarded paper that comes off at the
scheduled at appropriate intervals (such as once a week).
wet end.
On half-hourly metered electricity supplies the data
from the supplier will be more reliable, but unless the Finding appropriate indicators of production activity
user makes other arrangements, the data will usually can be a challenge. Avoid complexity at the outset and
only be available monthly in arrears. try a simple approach – it may work. Refine the model
later if necessary. Be pragmatic: if consumption X varies
Automatic meter reading is beneficial when meters are
with driving factor Y, use that relationship as a targeting
inaccessible, too remote, or too numerous for manual
model even if X does not directly depend on Y. Unlike
reading to be an option. Meters with pulse outputs or
with rigorous statistical analysis, there does not need
serial communications interfaces are needed, along
to be a causal link, merely that the relationship between
with additional components such as:
X and Y should normally be consistent.
• Data loggers (when the meter has no recording
capability of its own)
• Data concentrators (when data from multiple logging Further information
devices need to be marshalled)
Metering technology overview (CTV027)
• Gateways (for passing data between networks using www.carbontrust.co.uk/mandt
different protocols or isolated by a firewall)
• Software to interrogate the devices and record results
in a database.
Monitoring and targeting 21
Having secured a supply of consumption and driving- Only in a minority of cases – if at all – will it be necessary
factors data, the final task is to relate one to the other, to carry out further analysis. However, fine-grained data
establishing tough but achievable operational targets. may prove useful where available, and if the problem
These may be precedent-based or activity-based, using persists, it will ultimately become possible to diagnose
straight-line relationships or any other appropriate the new consumption patterns using cusum-assisted
method of calculating expected consumption. However regression analysis.
they are to be done, it is sensible to gather sufficient
From time to time it will pay to look at the foot of the
historical data and set some preliminary targets at the
overspend league table, where all the ‘underspent’
outset. Operational targets can and will be reviewed
streams accumulate. Persistent underspending suggests
and revised as time goes by, and will not be widely
a target that is too lenient. Cusum analysis can then
publicised within the organisation, so it does not matter
be used to identify when the improved performance
too much if they are not absolutely right first time.
started, and a new target can be set accordingly.
Nor does it matter if initial coverage is incomplete.
It is better to have the ability to detect waste in some
areas than to remain in the dark until every single item Choosing M&T software
is covered. Although there are many proprietary M&T software
packages available, not all of them are designed for the
purposes described in this guidance. Some software
Further information supplied with automatic meter reading hardware may
do little more than display demand-profile charts, for
Energy management strategy (CTV022)
example, while energy accounting software may lack the
Practical energy management (CTV023)
analytical and target-setting functions found in products
Advanced metering for SMEs (CTC713)
with more of a bias towards physical performance.
Next steps
Effective M&T provides the basis for energy management. Follow the steps
below to understand the energy consumption on the site and identify where
more information is needed.
Glossary
Activity-based targeting Consumption data
The process of estimating expected consumption Figures, collected at equal intervals, representing
volumes by reference to production throughput, the quantities of energy, water, or other consumable
prevailing weather and other driving factors. Comparison resources used. May be derived directly either from
between expected and actual consumption reveals meters or from stock-level and delivery information;
randomly-occurring accidental avoidable waste. or may be computed by arithmetic combining two or
more flows, or inferred from indirect measurements
Advanced metering such as data-logged electric current.
See Smart meter
Control limit
Assessment interval A tolerance band on the deviation chart indicating the
level of deviation which is considered to be significant.
The period between exception reports; commonly
weekly for industrial plants but often monthly for
dispersed estates of buildings. Daily, per-shift and even Cumulative deviation
‘real-time’ assessments may be worthwhile in some See Cusum
circumstances. Returns of consumption and related
driving factors must at least be synchronised with Cusum
the assessment interval (although more frequent
Cumulative sum of the difference between actual and
measurements may be of some diagnostic value).
target consumption in successive monitoring intervals.
Usually presented as a chart whose most important
Base temperature property is that it manifests a horizontal trend as long
In relation to the calculation of degree days, the as consumption remains close to target.
assumed lowest outside air temperature at which
a particular building can maintain comfort without Degree days
artificial heating (or the highest temperature at which
A measure of how cold (or hot) the weather has been
cooling is not required). In the UK a base temperature
(relative to a stated base temperature) measured over
of 15.5ºC is common for heating assessment.
a regular monitoring interval, usually weekly or monthly.
Benchmarking
Deviation chart
Identifying the things that enable good performance,
A time-series chart showing the difference between
either by critically comparing the performance of
actual and expected consumption in each successive
similar installations, or (if no comparable cases exist)
monitoring period. May have control limits
identifying past periods of better performance.
superimposed. Precursor to the cusum chart which
shows the cumulative sum of deviation values.
Code 5
Code 5 users are sites which already have electricity Driving factor
consumption monitored half-hourly. Sites with peak
An independently measurable factor (e.g. production
consumption exceeding 100kW for three consecutive
throughput, mileage, degree-day value) that determines
months are classified as ‘Code 5’ and suppliers collect
the required quantity of energy or other consumable
actual consumption data into the Balancing and
resource.
Settlement Code for accurate billing. These accurate
data are likely to be available for energy management
Expected consumption
purposes and should be requested from the
energy supplier. Theoretical quantity of energy, water, etc., against which
actual consumption can be gauged. Can be calculated
in various ways ranging from precedent (same period
the year before) to rigorous mathematical modelling
from first principles, but most commonly calculated
using a simple empirical straight-line relationship
between past consumption and corresponding values
of an appropriate driving factor.
24 The Carbon Trust
Appendix A
Constructing a false-colour
contour plot
A false-colour contour plot can be constructed in
Microsoft Excel by one of two methods. Advanced
users can use macro code to colour the spreadsheet
cells according to their relative values. Another method
is to use Excel’s surface chart format as follows:
Step 1
Arrange the half-hourly values in a table, with one
column per day.
Monitoring and targeting 27
Step 2
Highlight the data (including date and time labels) and
from the Excel menu select Insert, Chart. Pick the ‘surface’
option and click Finish.
28 The Carbon Trust
Step 3
The data will be plotted as a three-dimensional surface.
To convert it to a contour map, right-click on the chart
and choose 3-D view. Set both the rotation and elevation
to 90º, and perspective to 0º.
Monitoring and targeting 29
Step 4
Finally, tidy up the display by editing the range-colours
to give an orderly spectrum. You may need to change
the y-axis major interval to increase the number of
steps and you will probably need to increase the size
of the chart, add titles and so on.
30 The Carbon Trust
Appendix B
Performance indicators
Historically, it has been common to express the
performance of industrial processes as specific energy
ratios (SER), kWh per unit of output. A monitoring
and targeting scheme can be programmed to calculate
SERs, but they should be used with caution because
they usually vary with product output (falling as
throughput increases), and are affected by shifts in the
balance between different product grades. They may
also be affected by the weather. In other words, they
cannot be relied upon as a measure of energy efficiency.
They should therefore only be used for summary reports
(if at all) and not for day-to-day management control.
Appendix C
Notes
Go online to get more
The Carbon Trust provides a range of tools, services and information to help you implement
energy and carbon saving measures, no matter what your level of experience.
Carbon Footprint Calculator – Our online calculator will help you calculate your
organisation’s carbon emissions.
www.carbontrust.co.uk/carboncalculator
Interest Free Loans – Energy Efficiency Loans from the Carbon Trust are a cost
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version. See if you qualify.
www.carbontrust.co.uk/loans
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www.carbontrust.co.uk/apt
Case Studies – Our case studies show that it’s often easier and less expensive than you
might think to bring about real change.
www.carbontrust.co.uk/casestudies
Events and Workshops – The Carbon Trust offers a variety of events and workshops
ranging from introductions to our services, to technical energy efficiency training, most
of which are free.
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