Legacy can help design and implement Real-Time Monitoring & Targeting systems in order to achieve sustainable energy and operational savings.
Legacy offers a tailored and affordable approach to real-time energy use management. The installation of Smart-Meters and Energy Information Management Systems makes it possible to do real-time monitoring and managing of energy consumption.
Granular data can be local or cloud-based so that even enterprise-level monitoring of energy use and distribution per site becomes feasible and cost-effective. The obvious objective is to become more proactive in peak load management, load bench-marking or in addressing specific energy-cost accounting needs such as kWh/Unit of production.
Monitoring and Targeting (M&T) is rooted in the principle that it is impossible to manage what cannot be measured and seen. M&T systems provide continuous feedback on operating practices and results yielded by energy management measures and projects. Budgeting and accurate estimating of expected energy and resource consumption for certain systems, production runs or loads, over any period of time, becomes easy and cost-effective.
M & T System Design
There are a number of important steps in preparation for implementing an M&T System:
- Site analysis and identification of main consumers of energy;
- Identification of variables (production, weather, schedule, etc.);
- To be effective, M&T system design must have the following elements:
- Smart-Metering: Monthly utility bills have limited value other than recording the amount and the cost of energy used in the past. The cost of installing energy and resource-use smart-metering has dropped to the point where the benefits can lead to payback in a few months.
- Real-Time Monitoring: Energy Information Management Systems (EIMS) make it possible and economical to process high volumes of highly granular energy and resource-use data. The same System "Dashboard" can be programmed to display: - Electrical Demand (kW); - Electric Energy (kWh); - Compressed Air Volume, Flow Rate & Pressure; - Water Use (Liters/Hour); - Natural Gas Use (m2/Hour). Establishing baselines and benchmark performance parameters becomes routine and economical in terms of time and money.
- Targeting: Monitor changes and identify reduction targets based on past data and load experience.
- Reporting: Energy and resource-use consumption analysis and accounting to make informed decisions on the measures required to meet targets.
Establishing Key Performance Indicators (KPIs)
Legacy’s assists industrial customers with choosing KPIs to provide the ability to increase energy efficiency and reduce consumption costs, while eliminating unnecessary waste within manufacturing processes.
The following sets of KPIs were built together with leading industrial manufacturing customers. New KPIs can be individually developed and tailored to specific customer needs.
General Energy and Costs KPIs
- Time of Use (ToU) usage analysis – ToU analysis of cost and energy usage associated to any line or machine in the plant;
- Off-hours consumption – Energy waste when no production occurred;
- Schedule Versus Plan – Comparison of machine start time and shutdown vs planned production timing plan;
- Cost per Unit (kWh/Unit) - Cost and Energy associated with unit of production;
- Energy consumption prediction based on production plan – map energy consumption lines and plant-wide energy consumption in advance according to production plan;
- Scheduling - identify machine sequencing and Interdependence issues.
Machines / Lines Performance KPIs
- Reliability – Machines Mean Time between Failures (MTBF) analysis:
(Duration of Run - Duration of Fault / Number of Faults)
- Maintenance efficiency – Mean Time To Repair (MTTR) analysis;
- Efficiency - (Production Hours / Non-Production Hours)
- Idling - Waste associated with non-working or idling machines during production hours;
- Bench-marking – Identify identical machines with performance differences or machines which yield the same production but have a different energy profile;
- Operational performance trend – Machine deterioration over time and preventive maintenance indicators;
- Compliance with Spec – Identify machines that are working out of spec.;
- Pump Performance - Capacity Vs. energy analysis;
- Unbalanced Phases - Motor and compressors unbalanced feed (3 phase).
- Compressors Cycling (Air, HVAC, refrigeration etc.) – Performance analysis based on number and duration of cycles.
Custom-Designed M & T System
We custom-design and install metering, monitoring and targeting (M&T) systems. Our real-time Energy Information Management System (EIMS) makes it possible for managers to identify and monitor Enterprise-Level Key Performance Indicators (KPI) for energy use in order to achieve continuous Operational and Maintenance savings.
These solutions provide real-time granular visibility into energy usage ensuring effective energy management and operational and maintenance cost savings.
Energy Intelligence System Details
Installation of wireless sensors and energy smart-meters can be completed relatively easily on as many loads as required. Data streams and detailed reporting is immediately viewable on any wireless device including mobile phones.
- Real-time data acquisition.
- Main meter readings (electricity, water & natural gas).
- Sub-meter readings (per sector or equipment).
- Easy online access to data via a Web browser.
- Interactive energy consumption tables and charts.
- Powerful management, analysis and programming computer tool tailored to your needs.
- System installed permanently or on a temporary basis depending on your needs.
Main M&T Advantages
- Significant energy savings (between 5% and 15%)
- Very short payback period (less than 2 years)
- Energy cost management
- Greenhouse gas emission reductions
- Quantification of potential savings
- Promotion of financing options for energy efficiency projects.
- Energy savings projections.
Facility energy managers, who regularly oversee and monitor energy usage, will be able to use historical energy consumption performance to analyze and set targets. Typically this gives the ability to identify and reduce variations in energy consumption as a result of operational variability and maintenance issues.Overall Energy Efficiency is typically improved by between 5% and 15%. Monitoring & Targeting Incentives The Ontario SaveON Energy incentive program can provide funding toward 80% of actual eligible costs of up to $75,000 per site to purchase, install and make operational a monitoring and targeting system. back to top