Energy Consumption Overview
(Data covered in this post is highlighted inside the green rectangle)
Each dust collection system is designed with a corresponding fan motor that is powerful enough to provide good ventilation to all workstations. For example, a 50,000 CFM dust collection system will require a 250 HP motor. Without the Ecogate system, the motor usually runs at close to full load.
By changing the speed based on demand, the load on the motor varies. The average fan motor load value shows the average load the fan has during the 3 entire production shifts.
By recording the fan run hours in our database, we also know exactly how long the fan has been running during the entire production time. By multiplying the average load with fan run time in hours, we have the total energy used for that day (kWh).
The Saving % is calculated by comparing two values.
The first value is the electricity consumption of the fan prior to Ecogate system installation, which gives us the baseline.
The load of the fan after Ecogate has been commissioned, Average Fan Load, is the second value.
How to read the data
If the system has been engineered by an Ecogate engineer/technician/dealer, the baseline can be known by the measurement of the fan motor load by the power analyzer. Thus, when you receive the daily summary, you should be able to tell how much reduction in load your motor is performing compared to without any intelligent controls.
Another interesting and important value is Total Energy Used (kWh). Based on this number and facility production schedule, you could estimate the total energy used for one week as well as one month. Therefore, you could also calculate how much money you would have to pay for electricity consumption that month.
Additionally, comparing the data from one day to the next, you can see whether there is an unexpected increase/decrease in the kW load or energy used. This will also help to troubleshoot and better maintain the system. For example if someone accidentally flipped the system to run in Manual instead of Automatic, etc. you will see maximum fan load.
The best way to average the load is to keep track of the average load for 5 consecutive production days. Then, you could use that to estimate the load for that entire month and predict how much energy will be used on dust collection.
Compare the average load of the system on a busy day vs slow day to have a better idea on what your system typically uses. Thus, you can calculate and have a better accurate number for how much energy will be used for a year.
If the savings are low or the fan motor load is high, this could suggest a few things:
High utilization (busy production day)
Too many faulty sensors (sensors stay active the whole entire time)
Fan motor issue
By looking at the data it should be easy to understand what is causing problems.
This article is part of a sequence: Ecogate's Daily Analytics Report. Click Here to start from the top of the sequence.
Authors: Thanh Vu, Ales Litomisky