Energy Consumption Tracking Electricity, Gas, Compressed Air
A standardized program to monitor, record, and reduce energy usage across all utility streams. Defines metering requirements, calculation methods for specific energy consumption (SEC), and accountability structures for continuous improvement.
This program establishes a framework for systematically measuring and analyzing energy consumption of electricity, natural gas, and compressed air. The goal is to reduce specific energy consumption (SEC) per unit of production, identify abnormal deviations, and prioritize efficiency projects. It aligns with ISO 50001 energy management principles and integrates with existing CMMS work orders for meter calibration and leak surveys.
This program applies to all production equipment, HVAC systems, compressed air networks, and lighting within the facility boundary. Every utility meter (electricity, gas, compressed air flow) must be included. All reliability technicians, energy champions, and shift supervisors are expected to follow the recording and reporting procedures. Exclusions: metering for non‑production offices may be sub‑metered separately.
- Specific Energy Consumption (SEC) = Total energy (kWh or GJ) ÷ Production output (units). Calculate separately for electricity (kWh/unit), natural gas (GJ/unit), and compressed air (m³/unit). Monthly baseline required.
- Power Demand – Peak kW drawn in 15‑min intervals. Track to identify load spikes that increase demand charges. Target: ≤ 95% of contracted demand.
- Compressed Air Leak Rate = (Flow with all valves closed) ÷ Total system flow × 100. Target: ≤ 10% of total flow. Conduct quarterly leak surveys.
- Power Factor (electricity) – Real power ÷ Apparent power. Target: ≥ 0.95 lagging. Power factor penalties are applied below 0.90 in most utility tariffs.
- Facility Energy Champion – Owns the tracking program, reviews monthly SEC reports, and coordinates improvement projects. Conducts quarterly energy review meetings.
- Reliability Technician – Reads and calibrates all energy meters weekly (electricity, gas, compressed air flow). Logs readings into CMMS and flags anomalies >5% deviation from trend.
- Shift Supervisor – Ensures daily walk‑down of major energy consumers (compressors, boilers, ovens) and records runtime / standby status. Reports leaks or abnormal operation immediately.
- Maintenance Planner – Schedules preventive maintenance on meters, compressors, and HVAC based on manufacturer recommendations. Integrates energy data into weekly planning.