MODULE 2

RECORDING & PROCESSING

LEARNING OBJECTIVES
In this module you will learn about:

ENERGY DATA
General Objectives:

L Energy Data Recording and Processing

Specific Objectives:

L Collecting Utility and Fuel Data

L Analyzing Energy Data

Performance Objectives:

After successfully completing this module you will be able

to perform the following:

L Collect the historical energy use of the plant,

L Collect the historical production data of the plant,

L Analyze the collected historical data,

L Record and assess all energy and water inputs on

a daily basis,

L Monitor energy consumption on a daily basis.

SADC Industrial Energy Management Project

Implemented by AGRA Monenco Atlantic Limited for the Canadian International Development Agency
 Module 2
Energy Data Recording & Processing

TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 COLLECTING UTILITY AND FUEL DATA . . . . . . . . . . . . . . . . . . . . . 1

3.0 ENERGY DATA PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.1 Monthly Energy Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.2 Yearly Energy Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4.0 ENERGY DATA ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5.0 WORKED EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.0 ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6.1 Assignment #1 - Historical Audit . . . . . . . . . . . . . . . . . . . . . . 5

6.2 Assignment #2 - Implement Daily Recording Programme . . . 5

7.0 SUMMARY - Module 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

 MODULE 2
ENERGY DATA
RECORDING & PROCESSING
1.0 INTRODUCTION

It is useful to know where we were in order to find where we are going. An analysis
of the past year of production, electricity and fuel consumption can reveal much
useful information about the energy utilization performance of the facility . It is true
that the information is passive since we cannot take any corrective action to
improve the energy use, but it provides us with the following base line data for
future use and comparison:

< annual normalized energy use and cost,

< monthly fluctuations in energy and cost intensities per unit of production,
< presence of seasonal usage variation
< average unit cost of each fuel used,
< gross energy performance between base and current years, and
< cost and energy use trends over the years.

2.0 COLLECTING UTILITY AND FUEL DATA

For the historical data analysis the monthly consumption records for last year or
preferably last two years is necessary. The records consist of utility, fuel and water
bills and monthly production data. In the day to day operation all the bills for
company's operation are sent to and processed by the company's accounting
department. The energy charges for which the plant is responsible are not
generally communicated to the plant manager or plant technical personnel by the
accounting department.This practice is slowly changing and many companies
nowadays will not pay the enegry bills unless they have been verified and signed
by plant manager or other designated technical personnel. The management must
allow the technical personnel to collect and process the production and energy use
data in order to control and improve the energy utilization in the plant.

The plant technical personnel should have free access to the

energy billing and approve all energy bills before payment.

On the other hand, the administrative personnel must be fully

informed about all energy matters in the plant.

The retrieval of the data largely depends on company's filing system. Where
separate files are kept for energy bills, the retrieval is easy. In cases where all bills
are filed chronologically obtaining data takes longer.

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( Don't give up, persevere! (

3.0 ENERGY DATA PROCESSING

What data should you get from the bills ?

Where should you enter it ?

Module 2 incorporates several tables for recording energy consumption data.

3.1 Monthly Energy Data Sheets

The consumption of electricity, fuels (liquid and solid), and water should be
recorded on a daily basis during the course of each month. This information should
be recorded on Monthly Energy Data Sheets. Samples of these tables are shown
in Figures 2.1, 2.2 and 2.3 for liquid fuel, solid fuel and electricity, respectively. A
similar table is also developed in Figure 2.4 to record water consumption.

When the daily data is summarized each month, the Monthly Energy Data Sheets
provide the necessary information for updating the Yearly Energy Data Sheet.

The daily monitoring of energy use and production

output is a very sensitive tool for controlling the
energy use per unit of production.

3.2 Yearly Energy Data Sheet

Figure 2.5 shows a sample of an Energy Data Sheet which is used to record,
normalize and analyze the yearly energy usage in the plant . This process is
sometimes called the Historical Audit.

The top part of the data sheet contains information about the company, production
year, date and person responsible for collecting the data. The spread sheet itself
is divided into columns marked from "A" to "Q" which are used to enter and
manipulate the production and energy data. The rows identify the titles of the
columns, months of the year, total values and averages.

The energy conversion factors and formulae for calculating the values for individual
columns are shown at the bottom of the spread sheet .

After collecting the production, electricity, fuels and water data proceed as follows:

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! Energy Data Sheet Entries

The left hand column shows "PERIOD / Month", listing the months of the year
from January to December. If the company's fiscal year starts at a different
month, change the month's sequence as required.

The monthly data to be entered in each column of the Energy Data Sheet is as
follows:

A production units
B electricity usage in kWh from the utility bills
C convert kWh into Giga Joules (GJ) a standard enery unit by using the
formula
"C" = "B" x 0.0036 GJ/KWh
D cost of energy from the utility bills
E demand in kVA from the utility bills
F cost of demand, either from the utility bills or by using the formula
"F" = "E" x cost per kVA of demand (from utility tariffs)
G total cost of electricity using formula
"G" = "D" + fixed charges + VAT + "F"
H quantity of the fuels in litres, kg, etc from the fuel bills,
I convert fuel energy values into standard GJ using conversion factors
listed at the bottom of the spread sheet.
J cost of fuels from the bills
K quantity of the fuels in litres, kg, etc from the fuel bills
L convert fuel energy values into standard GJ using conversion factors
listed at the bottom of the spread sheet.
M cost of fuels from the bills
N total energy in GJ using formula
"N" = "C" + "I" + "L"
O total energy cost in local currency using formula
"O" = "G" + "J" + "M"
P energy intensity in GJ per unit of production using formula
"P" = "N" / "A"
Q energy intensity in Currency per unit of production using formula
"Q" = "O" / "A"

4.0 ENERGY DATA ANALYSIS

By far the most important performance factors are the Energy Intensity and Cost
Intensity found in the last two columns of the Yearly Energy Data Sheet.

! Energy Intensity

Wide monthly fluctuations in Energy Intensity values may indicate poor

process control, low production rate or simply seasonal variations in production.
In any case these variations should be scrutinized, and an attempt should be
made to identify causes which can be corrected to improve the plant's overall
energy use efficiency and to reduce the cost of energy.

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! Cost Intensity

The Cost Intensity shows the energy cost per unit of production by all inputs.
This factor will vary according to increases in cost of utilities.

! Energy Unit Cost

It is important to recognize the variations in cost per unit of energy for different
fuels and electricity, usually expressed in $/GJ (Giga Joules) . These values
can be readilly calculated from the Energy Data Sheet by dividing total cost of
the individual utilities by total equivalent of energy in GJ . For example, to find
the cost of electricity per unit of energy GJ, divide Total Electricity Cost in
monetary units (Column "G") by Equivalent Energy in GJ (Column "C").

Data processed by computer can produce any number of graphical

relationships between production and any utility desired by the user. Examples
of typical production graphs are shown in Figures 2.6 to 2.12 of this module

5.0 WORKED EXAMPLES

Energy data can be processed manually, using a hand-held calculator and if

needed, individual consumption trends can be plotted on suitable graph paper.
When PC computers are available, the formulae for processing can be fed into any
spreadsheet programme such as Lotus 123, and all the data can be processed in
a very short time. The graphs of any related consumption/production trends can
be readily viewed, or printed and analyzed. Samples of a processed Annual
Energy Data Sheet and a few related graphs are shown in this module. (Although
not shown, water consumption can be processed in the same manner.)

< Figure 2.5 Completed data sheet

< Figure 2.6 Line graph of production / electricity / fuels
< Figure 2.7 Line graph of production / fuel oil
< Figure 2.8 Line graph of production / coal
< Figure 2.9 Line graph of production / electricity
< Figure 2.10 Line graph of production / energy & cost intensities
< Figure 2.11 Pie chart of energy usage ratios
< Figure 2.12 Pie chart of energy cost ratios

It must be remembered that the ratios between production and fuel or electricity
consumption may not be accurate, because the electricity and fuel bills do not
necessarily cover the periods from the first to the last day of the months as the
production records do.

On the yearly basis the values will equalize over the twelve months period . If the
energy consumption data is to be used as a monitoring tool to keep the
consumption to the minimum, it is recommended that daily recordings of all energy
inputs be implemented. Samples of these daily recording charts have already been
referenced in Section 3.

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6.0 ASSIGNMENT

The assignments in this manual are aimed at establishing an Energy Management

Programme in the facility. Each assignment represents a step in implementation
of the energy management process in the company. Energy data recording and
processing is the first step.

The following two assignments must be completed prior to Workshop 2.

6.1 Assignment #1 - Historical Audit

Prepare a complete Historical Audit of energy and water consumption covering the
last two fiscal years of plant operation.

! Collect and record energy usage and production data for each year. Use
Annual Energy Data Sheets as shown in Figure 2.5. (Blank sheet provided.)

! Calculate the Energy Intensity per unit of production, and where applicable,
the Cost Intensity, the Cost per unit of Energy (GJ) for each fuel and
electricity.

! Prepare graphs to illustrate consumption relationships.

6.2 Assignment #2 - Implement Energy Monitoring Programme

Implement an energy monitoring programme by recording on a daily basis all

energy and water inputs to the plant, as well as production data. Guidelines are as
follows:

! Assign one person to take the utilities readings every day at a fixed time.

Use the Daily Energy Data Sheets as required to compile the necessary data
each day, namely:

< Lliquid fuel consumption record (per Figure 2.1)

< Solid fuel consumption record (per Figure 2.2)
< Electricity consumption record (per Figure 2.3)
< Water consumption record (per Figure 2.4)

! Instruct the assigned person how to read the meters, particularly the electrical
meters.

! Oil readings may require special arrangements so that daily usage can be read
with reasonable accuracy from the holding tank. The oil delivery prices and
purchase costs should be recorded separately but note price changes of the
fuel in the daily tables.

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! Check daily records frequently.

! Plot the daily energy use on a chart and display the graphs on the wall in the
office for a quick detection of any unexpected changes in consumption pattern.

! At the end of each month transfer all the data to the Annual Energy Data Sheet
per Figure 2.5.

7.0 SUMMARY - Module 2

In this module you learned about:

L Daily Energy Data Sheets

L Energy Intensity
L Energy Cost Intensity
L Historical Energ Audit
L A Daily Monitoring Programme

You should now be able to perform the following tasks:

L Collect the historical energy usage data of the company,

L Collect the historical production data of the company,
L Analyze the historical data and prepare a brief assessment,
L Collect and record all current energy and water inputs,
L Monitor energy consumption on a daily basis.

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Figure 2.1
DAILY LIQUID FUEL CONSUMPTION RECORD
MONTH: June YEAR: 1994 RECORDED BY: J.H.G.
TANK READING TANK TOTAL
DATE Opening Closing REFILL CONSUMPTION COMMENTS
(litres) (litres) (litres) (litres)
1 9,600 8,070 1,530
2 8,070 6,680 1,390
3 6,680 6,047 633
4 6,047 5,942 105
5 5,942 11,393 6,820 1,369
6 11,393 10,770 623
7 10,770 9,218 1,552
8 9,218 7,942 1,276
9 7,942 6,621 1,321
10 6,621 5,913 708
11 5,913 5,832 81
12 5,832 11,748 7,210 1,294
13 11,748 10,499 1,249
14 10,499 9,425 1,074
15 9,425 7,867 1,558
16 7,867 6,449 1,418
17 6,449 5,741 708
18 5,741 5,645 96
19 5,645 11,833 7,620 1,432
20 11,833 10,410 1,423
21 10,410 9,121 1,289
22 9,121 7,422 1,699
23 7,422 5,891 1,531
24 5,891 5,128 763
25 5,128 4,972 156
26 4,972 11,287 7,960 1,645
27 11,287 9,758 1,529
28 9,758 8,280 1,478
29 8,280 6,749 1,531
30 6,749 5,165 1,584
31
TOTAL 29,610 34,045
COL REF A B C D
Per Column Reference: D = A - B+ C

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Figure 2.2
DAILY SOLID FUEL CONSUMPTION RECORD
MONTH: June YEAR: 1994 RECORDED BY: J.H.G.
INVENTORY READING FUEL TOTAL
DATE Opening Closing SUPPLY CONSUMPTION COMMENTS
(tonnes) (tonnes) (tonnes) (tonnes)
1 28.28.2 24.84.8 3.4.4

2 24.84.8 21.71.7 3.1.1

3 21.71.7 19.99.9 1.8.8

4 19.99.9 19.49.4 0.5

5 19.4 24.7 8.3 3.0

6 24.7 23.3 1.4

7 23.3 19.9 3.4

8 19.9 24.8 7.9 3.0

9 24.8 21.9 2.9

10 21.9 20.5 1.4

11 20.5 20.0 0.5

12 20.0 25.2 8.1 2.9

13 25.2 21.9 3.3

14 21.9 19.2 2.7

15 19.2 23.3 7.6 3.5

16 23.3 20.2 3.1

17 20.2 18.0 2.2

18 18.0 17.3 0.7

19 17.3 23.0 8.9 3.2

20 23.0 19.9 3.1

21 19.9 16.6 3.3

22 16.6 21.6 8.8 3.8

23 21.6 18.2 3.4

24 18.2 16.0 2.2

25 16.0 15.1 0.9

26 15.1 20.2 8.7 3.6

27 20.2 16.8 3.4

28 16.8 13.5 3.3

29 13.5 19.2 9.1 3.4

30 19.2 15.7 3.5

31

TOTAL 67.4 79.9

COL REF A B C D
Per Column Reference: D = A - B+ C

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Figure 2.3
DAILY ELECTRICITY CONSUMPTION RECORD
MONTH: June YEAR: 1994 RECORDED BY: J.H.G.
kWh kVA
DATE Opening Closing Consumed Demand COMMENTS
Reading Reading (kWh)
1 1216394 1221531 5,137 310

2 1221531 1226014 4,483 312

3 1226014 1228418 2,404 312

4 1228418 1230253 1,835 312

5 1230253 1235028 4,775 315

6 1235028 1240478 5,450 317

7 1240478 1245512 5,034 320

8 1245512 1251221 5,709 320

9 1251221 1256203 4,982 320

10 1256203 1258417 2,214 320

11 1258417 1260115 1,698 320

12 1260115 1264411 4,296 320

13 1264411 1269315 4,904 320

14 1269315 1273845 4,530 320

15 1273845 1278982 5,137 320

16 1278982 1283465 4,483 320

17 1283465 1286084 2,619 320

18 1286084 1287905 1,821 290

19 1287905 1293157 5,252 312

20 1293157 1299151 5,994 314

21 1299151 1304689 5,538 319

22 1304689 1310969 6,280 319

23 1310969 1316450 5,481 319

24 1316450 1319269 2,819 319

25 1319269 1321345 2,076 319

26 1321345 1327077 5,732 319

27 1327077 1333622 6,545 319

28 1333622 1339665 6,043 319

29 1339665 1346514 6,849 319

30 1346514 1352495 5,981 319

31

TOTAL 136,101

COL REF A B C D
Per Column Reference: C = B - A

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Figure 2.4
DAILY WATER CONSUMPTION RECORD
MONTH: June YEAR: 1994 RECORDED BY: J.H.G.
METER READING CONSUMPTION
DATE Opening Closing (litres) COMMENTS
(litres) (litres)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
TOTAL
COL REF A B C
Per Column Reference: C = B - A

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 ANNUAL ENERGY DATA SHEET
PRODUCTION YEAR: 1994 - 1995 DATE: June 1, 1995 DATA COLLECTED BY: J.H.G. COMMENTS:

PERIOD PRODUCTION ELECTRICITY FUEL OIL COAL TOTAL ENERGY INTENSITIES

(Prod. Units) Usage Equiv. Cost Demand Cost Tot.Elec. Usage Equiv. Cost Usage Equiv. Cost Energy Cost GJ/Unit Cost/Unit
Month (kg) (kWh) (GJ) ( ) (kVA) ( ) Cost (Litres) (GJ) ( ) (tonnes) (GJ) ( ) (GJ) ( ) Production Production

Jun 2,259.50 136,101 490.0 14,835.01 320.0 13,120.00 27,955.01 34,045 1,420.4 42,215.80 79.9 2,397.0 9,508.10 4,307.3 79,678.91 1.906 35.26

Jul 2,711.40 150,598 542.2 16,415.23 336.0 13,776.00 30,191.23 40,485 1,689.0 50,201.40 55.9 1,677.0 6,652.10 3,908.2 87,044.73 1.441 32.10

Aug 2,485.45 188,248 677.7 20,519.04 330.0 13,530.00 34,049.04 41,406 1,727.5 51,343.44 65.9 1,977.0 7,842.10 4,382.2 93,234.58 1.763 37.51

Sep 2,937.35 169,423 609.9 18,467.14 340.0 13,940.00 32,407.14 46,006 1,919.4 57,047.44 63.9 1,917.0 7,604.10 4,446.3 97,058.68 1.514 33.04

Oct 2,372.48 207,073 745.5 22,570.95 300.0 12,300.00 34,870.95 38,645 1,612.3 47,919.80 59.9 1,797.0 7,128.10 4,154.7 89,918.85 1.751 37.90

Nov 2,033.55 197,660 711.6 21,544.99 332.0 13,612.00 35,156.99 39,565 1,650.7 49,060.60 47.9 1,437.0 5,700.10 3,799.2 89,917.69 1.868 44.22

Dec 1,129.75 150,598 542.2 16,415.23 333.0 13,653.00 30,068.23 29,444 1,228.4 36,510.56 66.3 1,989.0 7,889.70 3,759.6 74,468.49 3.328 65.92

Jan 1,355.70 84,712 305.0 9,233.57 325.0 13,325.00 22,558.57 30,364 1,266.8 37,651.36 53.9 1,617.0 6,414.10 3,188.7 66,624.03 2.352 49.14

Feb 451.90 122,361 440.5 13,337.38 320.0 13,120.00 26,457.38 22,083 921.3 27,382.92 61.9 1,857.0 7,366.10 3,218.8 61,206.40 7.123 135.44

Mar 1,129.75 131,774 474.4 14,363.33 350.0 14,350.00 28,713.33 26,683 1,113.2 33,086.92 55.9 1,677.0 6,652.10 3,264.6 68,452.35 2.890 60.59

Apr 1,016.78 75,299 271.1 8,207.62 310.0 12,710.00 20,917.62 24,843 1,036.4 30,805.32 67.9 2,037.0 8,080.10 3,344.5 59,803.04 3.289 58.82

May 1,807.60 112,949 406.6 12,311.42 315.0 12,915.00 25,226.42 33,124 1,381.9 41,073.76 69.9 2,097.0 8,318.10 3,885.5 74,618.28 2.150 41.28

Total 21,691.20 1,726,797 6,216.5 188,220.91 160,351.00 348,571.91 406,693 16,967.2 504,299.32 749.2 22,476.0 89,154.80 45,659.7 942,026.03

Average 1,807.60 143,900 518.0 15,685.08 324.3 13,362.58 29,047.66 33,891 1,413.9 42,024.94 62.4 1,873.0 7,429.57 3,805.0 78,502.17 2.105 43.43

Col. Ref. A B C D E F G H I J K L M N O P Q

ENERGY CONVERSION FACTORS CALCULATIONS

Electricity: 1 MWh = 3.6 GJ Wood (50% mc): 1 Ton = 10.2 GJ (Density = 738 kg/cu.m) C = B x 0.0036 GJ/kWh J = H x cost per litre
No.6 Oil: 1 Ton = 42.6 GJ or 41.72 MJ/litre (Density = 980) Wood (40% mc): 1 Ton = 12.2 GJ (Density = 640 kg/cu.m) D = B x Cost per unit kWh N = C+I+L
No.2 Oil: 1 Ton = 45.2 GJ or 39.32 MJ/litre (Density = 870) Wood (30% mc): 1 Ton = 14.2 GJ (Density = 541 kg/cu.m) F = E x Cost per kVA of demand O = G+J+M
LPG - Propane: 1 Ton = 50.4 GJ or 25.6 MJ/litre (Density = 508) Bagasse (50% mc): 1 Ton = 9.3 GJ G = D + F + fixed charge + taxes P = N/A
Kerosene: 1 Ton = 46.0 GJ or 33.76 MJ/litre (Density = 726) Bagasse (30% mc): 1 Ton = 13.0 GJ I = H x 0.04028 GJ/litre (HHV) Q = O/A
Petrol (GLN): 1 Ton = 46.5 GJ or 33.76 MJ/litre (Density = 726) OH 2-06
Module 2 - Energy Data Recording & Processing ....

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 DAILY LIQUID FUEL CONSUMPTION RECORD
MONTH: YEAR: RECORDED BY:

TANK READING TANK TOTAL

DATE Opening Closing REFILL CONSUMPTION COMMENTS
(litres) (litres) (litres) (litres)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
TOTAL
COL REF A B C D
Per Column Reference: D = A - B+ C
 DAILY SOLID FUEL CONSUMPTION RECORD
MONTH: YEAR: RECORDED BY:

INVENTORY READING FUEL TOTAL

DATE SUPPLY CONSUMPTI COMMENTS
Opening Closing (tonnes) ON
(tonnes) (tonnes) (tonnes)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
TOTAL
COL REF A B C D
Per Column Reference: D = A - B+ C
 DAILY ELECTRICITY CONSUMPTION RECORD
MONTH: YEAR: RECORDED BY:

kWh kVA
DATE Opening Closing Consumed Demand COMMENTS
Reading Reading (kWh)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
TOTAL
COL REF A B C D
Per Column Reference: C = B - A
 DAILY WATER CONSUMPTION RECORD
MONTH: YEAR: RECORDED BY:

METER READING CONSUMPTION

DATE Opening Closing (litres) COMMENTS
(litres) (litres)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
TOTAL
COL REF A B C
Per Column Reference: C = B - A