Measuring effectively in industry to increase energy efficiency

Optimal data visibility, the central element for increasing energy efficiency

From a pragmatic standpoint, measurement enables tracking consumption at a plant across different time intervals. By providing visibility to field operators, this measurement allows them to:

• Identify the most energy-intensive areas
• Detect consumption drifts quickly
• Manage production and improvement actions more effectively
• Validate the performance of an energy efficiency action implemented

Additionally, measurement also plays a role at a strategic level. It enables comparing results over time at multiple levels:

• Between plants
• Between installations
• Between one technology and another
• Between recipes
• Between a target measurement, a defined trajectory, and the result
• Between theory and practice

Offering the ability to ensure energy and environmental objectives are met, measurement is ultimately the central element for increasing performance.

Measuring is essential, but it must be done accurately and effectively.

Although measurement brings numerous advantages to manufacturers who implement it, one point of caution must nevertheless be considered. Due to their activities, plants generate an infinite amount of data. While it is important to measure in order to act effectively in an energy efficiency initiative, it is not advisable to want to measure everything.

Kristen Quémeneur
Implementation Project Manager

“Manufacturers must have visibility on the data that enables them to conduct a well-structured analysis. Reliable information must be selected, consistent with the objectives set and the installations to be optimized. It’s not enough here to want to collect an astronomical amount of data. This would result in muddled information and no longer knowing what actions to implement to increase performance.”

I want to optimize my measurements

How to collect data effectively?

Today, numerous technologies enable data collection in industry. To ensure effective and relevant information transmission, it is essential to design a coherent architecture, adapted to the operation and needs of the industrial site.

First, the sensors to be used for data collection must be defined. The criteria for making this choice are numerous, but the first question to ask is:
What data do I need to meet my objectives and improve my performance?

Choosing the right technology for measurement.

When adding a measurement within a plant, the challenge is above all to find the best compromise by taking into account all selection criteria (costs, frequency, measurement range, environment, etc.)

Measurement technology is a determining criterion in measurement reliability and accuracy.

Take the example of flow measurement—the technologies are numerous: ultrasonic, differential pressure, vortex effect, electromagnetic, Coriolis, etc. Each has its advantages and limitations, which is why it is essential to implement appropriate thinking in order to choose the right technology, the one that will meet the manufacturer’s specific need. Two examples can be given to illustrate this point:

• For a liquid fluid measurement, intended to regulate production installations with a fine time step (per second), we recommend using an electromagnetic flowmeter. However, for this same measurement, when it comes to tracking daily consumption, installing a volumetric meter would be sufficient. The choice of this technology has a strong impact on other criteria, such as cost and installation constraints.
  
• For a steam boiler with high flow during the week and low flow on weekends, installing a measurement can be complex. Here are different possible solutions:
  • Installing a single vortex flowmeter would only measure the upper part of the measurement range; no values related to the lower range would be collected.
    
  • Installing a differential pressure flowmeter such as an orifice plate (with differential pressure measurement) will measure most of the measurement range but with a fairly significant percentage of uncertainty on the lowest values.
    
  • The ideal solution here is therefore to have a dual differential pressure measurement on an orifice plate, thus able to measure the entire measurement range; however, this represents a significant cost.

For each type of equipment, several technologies are generally available. The manufacturer’s choice depends on several criteria, particularly budget and specific needs (required accuracy, equipment usage, etc.).

Focus on different data acquisition frequencies.

For manufacturers with complex installations, measurements with a high acquisition frequency (per second or in real time) will enable finer measurement analysis and better understanding of drifts.

On the other hand, if the manufacturer wants a more macro and less expensive analysis, data collection can be less frequent (every minute, every hour). In this case, wireless technology such as LoRa is chosen.

The measurement plan, a step not to be overlooked for optimal measurement

The measurement plan is an essential step for defining a coherent, sustainable data collection strategy adapted to energy performance objectives.

Carried out by an energy expert, this measurement plan guides technical teams in understanding existing measurements and advises on implementing new sensors while taking into account surrounding criteria and constraints. Ultimately, it ensures that the collected data can eventually be centralized, analyzed, and effectively utilized by dedicated software for robust energy management.

David Millot
Project Manager

The limitations of installing an EMS software without a measurement plan, focus on a concrete case

“We had the example of a cheese factory that had installed measurement before carrying out a measurement plan. During its implementation, we identified several problematic points.

First, the measurements that had been installed by a service provider were closed to communication, meaning the cheese factory could not utilize its own data without working with that provider’s software. The plant was therefore locked into its choice of tools. For us, it is nevertheless essential that the client retains control of their data and remains autonomous in their choices. This is what enables them to take ownership of and evolve their energy efficiency initiative.”

How does a measurement plan work?

A technical expert visits the industrial site.

Objectives? To best understand the site’s operation, significant energy uses (SEU), challenges, and needs.

At the end of the measurement plan, the following are quickly identified:

• The next equipment/sensors to install to collect new data or optimize the quality of already collected measurements.
  
• The key indicators to collect for effective energy monitoring.
  
• The areas for improvement: Lack of measurement on already equipped installations and measurement inaccuracies are highlighted to be addressed.
  
• The potential for CEE valorization (Energy Savings Certificates), to help finance the EMS software implementation project (only valid when the software is installed).

Once this measurement plan is completed, specifications are built. Measurement tools can then be implemented to optimize energy monitoring.

David Millot
Project Manager

I am calling on experts

Review of the measurement plan carried out at Saint-Gobain

“We started by touring the installations, understanding the site’s needs, and then proposing logical instrumentation.

Saint-Gobain manufactures furnace refractories, so they have few utilities but very large installations, and among them, highly consuming processes (electrode furnaces with auxiliaries: oil cooling, dust collectors, etc.).

The goal was therefore to prioritize measurement of these equipment, primarily electrical. We then placed a second priority on all gas-related uses, namely boilers and heating, as this is an important subject for the client.

Finally, we were able to determine the possible CEE premium for this site, then we launched the instrumentation project that preceded the implementation of our MyDametis software. Now all data is centralized on a single software platform; the client can compare it to optimize their production operation.”

As David specifies, after the measurement plan comes the instrumentation phase. The right sensors must be installed, configured, and monitored to ensure that the data and indicators they collect are consistent with the plant’s operation.

Rémi Pelletier
Measurement Expert

Extra info from our expert!

“To ensure reliable data is maintained over time, it is recommended to perform sensor checks. They are not mandatory but are strongly advised to maintain a sustainable optimization initiative.”

Once we’ve ensured that everything is working properly, software takes over to utilize the data and support the client in their energy efficiency initiative.

However, there are now a multitude of data-utilizing software solutions on the market, and making a choice can prove complex…

Utilizing collected data via software as part of an energy efficiency initiative

Once data is collected, it must be stored and analyzed to benefit from it.
Between simple reporting or implementing EMS or EMOS software, what should be chosen?

Reporting

This method focuses solely on collecting historical data (via invoices, meter readings), most often centralized in Excel.

While this method is simple to implement and inexpensive, it is very time-consuming and unreliable in the long term.

The reason is that energy data in industry changes for the most part by the minute (or even by the second). To perform a reasonably reliable analysis would require constant human presence dedicated to data entry. In addition, historicizing such data via a single file poses problems of unwieldiness, and the manufacturer runs a significant risk of data loss.

How to address this?

EMS software (Energy Management Software)

This tool enables going further than a simple Excel spreadsheet.

Connected to sensors in the plant, this software collects and validates data in real time and then makes it visible via a single interface.

Manufacturers can then visualize their consumption data in the form of dynamic dashboards. By tracking the right indicators across different time intervals, it becomes easier to identify improvement actions to increase performance.

How to go even further?

EMOS software (Energy Management and Optimization Software)

In terms of optimizing energy and environmental performance, EMOS is the most powerful tool. While it builds on the foundations of an EMS, this tool goes further thanks to the artificial intelligence it incorporates. It monitors, controls, and optimizes production, consumption, and storage of energy and water. By transforming data into concrete action plans, it becomes a formidable ally in improving energy and environmental performance. It can be implemented to complement on-site teams or become a true relay for companies that have not designated an Energy Manager.