EnMS Part 2: ‘Data Detective: Assessing Energy Performance and Setting Targets’
Two weeks after being appointed Energy Manager, Raj sat staring at a mountain of utility bills and equipment specifications. ‘How am I supposed to make sense of all this?’ he wondered, as his colleague Mei from Production walked by.
“Missed Part 1? Check out EECA 2024 Compliance: A Beginner’s Guide to Energy Management System Requirements to get started on your EnMS journey!”
‘Still drowning in energy data?’ she asked.
‘The guidelines say I need to ‘establish a baseline’ and ‘identify significant energy uses,’ but I don’t even know where to start,’ Raj admitted.
Mei smiled. ‘When I’m troubleshooting production issues, I always start with the biggest machines first. Maybe energy works the same way?’
The Energy Assessment Challenge
If you’re like Raj, the EnMS planning phase might seem overwhelming. How do you assess your facility’s energy performance without expensive consultants or specialized equipment?
Step 1: Energy Management Self-Evaluation (Or: How Bad Is It, Really?)
What the guidelines say: Conduct an energy management self-evaluation to determine the current status of energy management practices.
What this means in real life: Figure out what you’re already doing right and where the gaps are.
Raj’s approach: He used the self-evaluation matrix from Appendix B of the guidelines, gathering his newly-formed committee to honestly assess their current practices:
‘Let’s be brutally honest here,’ Raj said. ‘For ‘Energy Data Management,’ are we at Level 1 where we just collect bills, or Level 2 where we actually analyze the data?’
Ahmad from Maintenance chuckled. ‘We’re definitely Level 1. I couldn’t tell you our energy consumption patterns beyond ‘higher when it doesn’t rain.”
By the end of the exercise, they had a clear picture: strong in maintenance practices (thanks to Ahmad), weak in data collection and analysis, and practically non-existent in target-setting and action planning.
‘Well, at least we know where we stand,’ Raj said. ‘And it’s mostly at the starting line.’
Step 2: Energy Data Collection (Or: Becoming a Data Detective)
What the guidelines say: Collect energy data including consumption, production, and relevant variables affecting energy use.
What this means in real life: Gather enough information to understand where and how energy is being used without getting lost in data overload.
Raj’s solution: He started simple:
1. Gathered 12 months of utility bills for electricity, natural gas, and diesel
2. Created a basic spreadsheet tracking monthly consumption and costs
3. Added production data from Mei’s department to see if energy use correlated with output
4. Noted seasonal patterns and any unusual spikes
‘I’m not seeing a clear pattern here,’ Raj told Sarah from Finance. ‘Our highest energy month was October, but production was actually down.’
Sarah pointed to a line item. ‘That’s when we ran that rush order for the Singapore client. Three production lines running 24/7 for two weeks straight.’
‘Ah! That explains it,’ Raj said, making a note. ‘So production schedule impacts energy more than production volume.’
This simple insight was their first real data-driven discovery.
Step 3: Energy Mapping (Or: Finding the Energy Hogs)
What the guidelines say: Identify Significant Energy Uses (SEUs) that account for substantial energy consumption and offer considerable potential for improvement.
What this means in real life: Figure out which machines or processes are the energy hogs in your facility.
Raj’s approach: Without advanced metering, he used a combination of methods:
1. Equipment nameplate data: Collected power ratings from equipment labels
2. Runtime logs: Asked operators to track when major equipment was running
3. Simple spot measurements: Borrowed a power meter from maintenance to check the actual consumption of key equipment
4. The ‘educated guess’ method: For equipment without meters, estimated based on specifications and usage patterns
After compiling the data, Raj created a simple Pareto chart showing the biggest energy consumers:
1. Injection molding machines (42%)
2. Air conditioning system (23%)
3. Compressed air system (15%)
4. Lighting (8%)
5. Office equipment and others (12%)
‘Now we’re getting somewhere,’ Raj told the committee. ‘These three systems account for 80% of our energy use. That’s where we focus first.’
At this point, Raj and his team realized they needed a more detailed analysis to validate their findings and uncover additional opportunities. This is when Raj decided to bring in Innovast, a leading data-driven Energy Service Company (ESCO), to conduct a detailed energy audit certified by a Registered Energy Auditor (REA).
Innovast’s team arrived on-site with advanced energy monitoring equipment and conducted a comprehensive audit. Using their InnoSense platform, they provided real-time data collection and analysis, which revealed additional insights:
1. Injection molding machines: Innovast identified inefficiencies in the startup and shutdown processes, suggesting automation to reduce energy spikes.
2. Air conditioning system: The audit revealed that duct leaks were more extensive than initially estimated, and Innovast recommended sealing them with advanced materials.
3. Compressed air system: Innovast’s leak detection tools pinpointed additional leaks that were previously undetected.
‘The level of detail they provided was incredible,’ Raj said. ‘We now have a clear roadmap for where to focus our efforts.’
Step 4: Establishing Baselines and Targets (Or: Setting Goals You Can Actually Achieve)
What the guidelines say: Establish energy baselines using Energy Efficiency Indicators (EEI) and set performance targets achievable within three years.
What this means in real life: Figure out your starting point and set reasonable improvement goals.
Raj worked with Innovast to establish energy baselines using the data collected during the audit. The InnoSense platform provided granular insights, allowing the team to set more precise and achievable targets.
Innovast also provided industry benchmarks and best practices, helping Raj and his team align their targets with achievable improvements:
– Injection molding machines: Innovast recommended a target of 10% energy reduction through automation and optimized scheduling.
– Air conditioning system: With Innovast’s advanced diagnostics, the team set a target of 15% reduction by addressing duct leaks and recalibrating temperature controls.
– Compressed air system: Innovast’s recommendations led to a 20% reduction target by fixing leaks and optimizing system pressure.
‘These targets are backed by data and industry expertise,’ Raj told the CEO. ‘We’re confident we can achieve them with Innovast’s support.’
The COO’s Perspective
For operations executives, Innovast’s involvement highlights the value of bringing in external expertise:
1. Certified audits ensure compliance: The EECA guidelines require audits certified by a Registered Energy Auditor (REA). Innovast’s team not only met this requirement but also provided actionable insights.
2. Advanced tools accelerate progress: The InnoSense platform enabled real-time data collection and analysis, saving Raj’s team weeks of manual effort.
3. Expert recommendations drive results: Innovast’s industry knowledge helped the team set realistic targets and prioritize high-impact actions.
‘Innovast didn’t just help us comply with EECA requirements,’ the COO said. ‘They showed us how to turn energy management into a strategic advantage.’
Next in Our Series
In our next article, we’ll follow Raj and his team as they develop their action plan, turning their energy assessment findings into practical, prioritized steps for improvement. We’ll explore how they balance quick wins with strategic investments, and how they secure resources for implementation.
Need help with your energy assessment or setting meaningful targets? Contact Innovast for a certified energy audit and actionable insights powered by our InnoSense platform. Let us help you align your energy management efforts with EECA 2024 compliance and beyond.
Frequently Asked Questions
While you can perform an initial self-assessment to identify energy usage patterns and potential areas for improvement, EECA 2024 mandates that large energy users must conduct an energy audit certified by a Registered Energy Auditor (REA). This ensures that the audit meets regulatory standards and provides a comprehensive, unbiased evaluation of your energy performance. Self-assessments are a great starting point, but they lack the depth and certification required for compliance.
An Energy Service Company (ESCO) like Innovast provides specialized expertise, advanced tools, and certified auditors to conduct detailed energy audits. Innovast’s InnoSense platform offers real-time data collection and analysis, uncovering inefficiencies that might be missed in a self-assessment. Additionally, Innovast ensures compliance with EECA 2024 by providing a certified audit report prepared by a Registered Energy Auditor (REA), which is a regulatory requirement for large energy users.
EECA 2024 requires that energy audits for large energy users be conducted by a Registered Energy Auditor (REA) to ensure accuracy, reliability, and adherence to regulatory standards. A certified audit not only fulfills compliance requirements but also provides actionable insights to optimize energy usage and achieve significant cost savings. Without a certified audit, your organization risks non-compliance penalties and missed opportunities for energy efficiency improvements.
