Energy Management : 2014/2015

Energy Efficiency in Industry and Energy audits

Prof. Paulo Ferrão

 Energy Management

SGCIE

Sistema de Gestão dos Consumos Intensivos de Energia,

Management System of Intensive Energy Consumption
The PT National Strategy for Energy, by the Decree-Law n. º
71/2008 of 15 April, regulates SGCIE.
SGCIE é uma das medidas constantes do PNAEE – Plano
Nacional de Ação em Eficiência Energética.
SGCIE is a measure included in the PNAEE - National Action Plan
for Energy Efficiency.

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SGCIE

The Plan for the Rational Use of Energy (PREn) is

developed based on the energy audits and should
identify identify measures with a payback period of the
investment (PRI) less than 3 years, or less than 5 years
in the case of facilities with power consumption less
than 1000 toe / year.
The PREn must also establish targets for energy and
carbon intensities and Specific Energy Consumption,
where applicable, based on measures provided in the
preceding paragraph, taking into account the following
indicators:

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SGCIE

1. Energy intensity, measured by the ratio between the total

energy consumption (considering only 50% of the energy
derived from endogenous waste and other renewable
fuels) and Gross Value Added (GVA) of business
activities directly linked to these sites;
2. Carbonic intensity, measured by the ratio between the
amount of emissions of greenhouse gases resulting from
the use of various forms of energy in the production
process and its total energy consumption;
3. Specific Energy Consumption, measured by the ratio
between the total energy consumption (considering only
50% of the energy derived from endogenous waste and
other renewable fuels) and the volume of production.
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SGCIE

The goals referred to in the preceding paragraph are subject

to the following values​​:
a)At a minimum, an improvement of 6% ​of the indicators
referred to in 1 and 3 above, in six years, in the case of
facilities with energy-intensive less than 1000 toe / year, or
4% improvement in eight years for other facilities;

b)At a minimum, the maintenance of the historical values ​of

carbon intensity.

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SGCIE

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SGCIE

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 Energy Management

ENERGY AUDIT

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Energy audit – key goals

• Detailed analysis of the energy use in a certain equipment,

activity, installation , building, campus:

– Where energy is used

– When energy is used

– How energy is used

• Through an audit it is possible to:

– identify/model the required energy services

– Design a solution to improve the energy use and supply

• Equipment replacement, process change, user

behaviour change
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Energy Audit Phases

• Preparing and Planning

• Facility inspection

• Field Work

• Data analysis

• Energy audit reporting

• Energy Action Plan

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PREPARATION AND PLANNING

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Tasks

• Collect data regarding energy use and production

– Energy bills (at least 1 year)

– Production (at least 1 year)

• Collect data regarding building envelope and equipment's

– Location and weather data

– Building description (blueprints, bill of materials, etc.)

– Characteristics of the main equipment's

– Functional organization, analysis of

• Preliminary data analysis

– Find any awkward result…

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Preliminary visit

• Visit together with the facility manager to see

how the facility operates

• Collect other data (if available)

• Observe the building envelope

• Identify “low-hanging fruit” savings

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 Energy Management

Forma de energia E.Eléctrica Propano

Unidade fisica MWh Ton
Gcal/unid. fisica 0.86 11.39
GJ/unid. fisica 3.60 46.30
Tep/unid. fisica 0.29 1.14

1998 1999
Mês 1998 1999
Mês E.Eléctrica Propano E.Eléctrica Propano
(fx) (fx)
MWh Ton MWh Ton
Jan 33,324 56,894
Jan 266.5 176.3 374.0 150.3
Fev 37,658 51,774
Fev 285.3 152.6 435.7 171.6
Mar 40,846 58,383
Mar 270.8 169.1 397.3 194.3
Abr 35,727 43,010
Abr 385.4 165.2 410.0 123.6
Mai 41,889 45,421
Mai 322.8 158.7 416.7 180.2
Jun 45,167 48,938
Jun 368.6 157.9 468.8 185.7
Jul 45,463 52,463
Jul 367.0 151.1 464.1 194.1
Ago 36,083 35,180
Ago 336.1 115.2 292.0 156.9
Set 63,351 51,809
Set 315.4 189.0 494.1 187.9
Out 60,443 48,316
Out 410.5 188.7 398.8 199.1
Nov 67,612 51,692
Nov 398.7 196.6 493.4 209.2
Dez 53,611 30,666
Dez 431.2 162.8 422.8 158.3
Total 561,174 574,546
Total 4,158.4 1,983.1 5,067.8 2,111.3
Média 46,765 47,879
Média 346.5 165.3 422.3 175.9

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Factura Especifica ($/(fx))

700

600

500

400

300

200

100

0
0 10000 20000 30000 40000 50000 60000 70000
Produção Mensal

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600

500
Energia Eléctrica (MWh)

400

300

y = 0.0025x + 303.13
200 2
R = 0.1322

100

0
0 10000 20000 30000 40000 50000 60000 70000

Produção Mensal

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16

14
Consumo Específico Eléctrico

12

10
(kWh/Ton)

0
0 10000 20000 30000 40000 50000 60000 70000
ProduçãoMensal

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450

400
Energia Primária (Tep/mês)

350

300

250

200

150 y = 0.0023x + 214.46

2
R = 0.2301
100

50

0
0 10,000 20,000 30,000 40,000 50,000 60,000 70,000
Produção Mensal

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12

10

0
0 10,000 20,000 30,000 40,000 50,000 60,000 70,000
Produção Mensal
Consumo especifico de Energia Primaria (kgep/(fx))

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FACILITY CHARACTERIZATION

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Objective

• Detailed analysis of the collected data

– Evaluate energy consumption baseline (normalize
climate data)
– Prepare energy balance
– Identify energy services
• Characterize equipment's performance
• Heating and cooling • Elevators and other mechanical
– Hot water and steam boilers transportation systems
– Chillers and cooling towers • Specific equipment's of the building
– Ait treatment units – Monitors in hospitals, TVs in restaurants
– Ventilation units
• Refrigeration equipment's in kitchens ,
– Pumps and pipes
laundries, pools
– Air conditioning units
– Air conditioning controllers
• Energy generation systems (solar, co-
generation)
• Hot Water
• The efficiency of every heat generation
– Tankers
system should be verified
• Lighting
– Lights
– Ballasts
– Controllers

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Field Work Plan

• With the collected data and the characterization of the

facility, prepare the field work:
– The list of equipments that will be measured
– The list of equipments that needs to be used for
measurement
– The measuring procedure (one point measure, long data
collection)
– Interviews to be done to complete information

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FIELD WORK

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Main activities

• Measure energy consumption of main sectors/equipments

– Productive systems, hot water, heating and ventilation

– Identify lack of maintenance

• Verify electric installations

• Verify HVAC and lighting controllers

• Continuous monitoring or main consumption points of

energy to obtain load diagrams

– One day

– One week

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Complementary activities

• Complementary measurements to collect information

– Room temperatures
– Room luminance
• Characterize schedule of main equipments (interviews,
observations)
• Characterize the envelope in detail and how users interact
with it (interviews, observations)
• Characterize utilization patterns

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EQUIPMENT

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Physical entities Equipment

• Electricity • Electrical analyzer
• Mass flow • Anemometer (turbine, Pitot)
• Temperature • Thermometer
• Humidity • Humidity meter
• Flue gases composition • O2, CO2, CO analyzer
• Luminance • Luximeter
• Total dissolved solids • TDS meter

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450

400 4ª feira 5ª feira 6ª feira Sábado Domingo

350

300
Potência (kW)

250

200

150

100

50

0
0:00 12:00 0:00 12:00 0:00 12:00 0:00 12:00 0:00 12:00 0:00

Potência Média Potência Instantânea

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50

45

40

35
Potência (kW)

30

25

20

15

10

0
12:00 15:00 18:00 21:00 0:00 3:00 6:00 9:00 12:00

P. Média P. Instantânea

Medições no compressor 793

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Energy balances in energy audits

The energy balance in EAs differs from current

thermodinamic energy balances because some
unknowns are obtained by measurements.
Unknowns obtained from measurements have an error
of measurement

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Energy audit objectives:

1 - Energy accountability (data)
2 - Energy consumption (measurements)
Direct measurement
Energy balance (equation + measures)
3 - Energy savings

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Energy balances in energy audits

The energy balance in EAs differs from current

thermodinamic energy balances because some
unknowns are obtained by measurements.
Unknowns obtained from measurements have an error
of measurement
Oftenly we do also need to assume the values of certain
parameters and then to check the balances.

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HOT WATER

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Hot Water

• Water used for

– Showers
– Washing (dishes, clothes, house cleaning)
• Important Variables
• Litters of water
• Final temperature (Hot)
• Initial temperature (Cold)
• Energy

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Water usage

• Reducing water usage reduces energy water consumption

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Water Temperature

• The Final Temperature has two conflicting constraints

– Skin scalding (5s at 60ºC)

– Bacterial Contamination (e.g. Legionella)

• The European Guidelines for Control and Prevention of Travel Associated

Legionnaires’ Disease recommend that hot water should be stored at 60
°C (140 °F) and distributed such that a temperature of at least 50
°C (122 °F) and preferably 55 °C (131 °F) is achieved within one minute
at points of use

• The Initial Temperature

– Depends on the ambient temperature

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Pipes losses

Typical values in
Portugal

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Energy balance sequence:

Frontier definition
Characterization of mass and energy flows
Equations identification
Definition of measurement plan
Equipment selection
Measurements
Validation

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Example: Industrial heat generator

Wall
Losses
3

Electrical
resistance

Qelec

1 2

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Equations and unknowns:

Mass and energy balance:
m1  m2  m3
m1C pT1  m2C pT2  Q  m3C pT3  H .Loss

Unknowns - measurements:
Good confidence: Q, T1, T2, T3
Less confidence: m1, m2
No confidence: m3, Heat loss
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Case 1: Equilibrium
2 Equations = 2 Unknowns
Measurements accepted:
Q, T1, T2, T3, m1, m2
Unknowns obtained by 2 eq. System:
m3, Heat loss

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AUDIT REPORT & ACTION PLAN

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Objective

• Describe the energy demand of the installation

and the costs
• Describe the equipment status
• Identify energy efficiency measures, the
investment and its potential payback
– Substitution or retrofit of equipment
– Use of more efficient controllers
– Installation of energy management systems
– Introduction of renewable resources
generation
• Identify upcoming changes in regulations that
may impact on the current energy use

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Action Plan

• From the different measures proposed in the

energy audit, identify an implementation plan
– Investment plan
– Schedule
• Low cost measures should be the first to be
implemented
• The return of investment period should be
the indicator used to prioritize the measures
in the plan
• This should be done closely with the energy
manager and the board

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KEY ENERGY SYSTEMS

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SPACE HEATING (AND COOLING)

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Thermal Balance (1)

Applying the 1st law of thermodynamics

– Balance between all the gains and
losses
• Solar (S)
• Internal(I)
• Conduction, convection and
radiation through envelope (T)
• Air mass balance/ventilation (V)

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• Electric appliances
– Computers
• Heat generation in power sources, processor
– Lighting
• Radiation and convection
– Occupants
• Radiation, convection, latent heat (water
vapour)

We do not consider here the heat generation from radiators, fireplaces, AC

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Energy generated by occupants

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Air exchanges and leakages

• Air Exchange between the interior and the exterior

originates changes in the internal energy (and thus
temperature)

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Dynamic simulation

• It allows to Design Builder

evaluate all heat
exchanges and
calculates heating
and cooling needs

Open Studio

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THE INFLUENCE OF CLIMATE

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Degree Days

• Simple and direct method (though incomplete) to

characterize the climate of a certain region
– It measures the product between the number of days
and the number of degrees that the interior temperature
is lower (heating) or higher (cooling) than a certain
comfort temperature
• Heating degree days (HDD)
• Cooling degree days (CDD)

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HDD and CDD in Europe

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THERMAL COMFORT

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Comfort temperature

“mind state that expresses satisfaction

about the thermal environment”
•Human comfort depends on the ability to
control the body temperature between 36
and 37ºC
•It depends on the balance between heat
exchange
– It is not only about air temperature
• It depends on the humidity
(evaporation/transpiration)
– It depends on the activity, clothes, etc…

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Comfort conditions

• Temperature: 20 to 27ºC
• Relative humidity: 30 to 60%

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INSULATION

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Thermal and air leakage insulation

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Thermal bridges

• It describes the disruption of the thermal

insulation due to the existence of a
material with high conductivity
• They can represent up to 20% losses

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Green roofs and facades

• Adds width (L) with a fairly good insulation

– k: 0.18 a 0.41 W/mK
– Concrete roof k=1.4 W/mK
• Has impact on radiation and convection through latent heat

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