Implementation of Energy Metering Systems in Complex Manufacturing Facilities–A Case Study in a Biomedical Facility

The continuing inflation of energy costs coupled with the imminent implementation of environmental taxes have placed the manufacturing sector under significant pressure to increase energy performance and reduce emissions. Current state of the art research is focused on reducing the energy consumption of machine tools and process chains. In order to quantify the impact of energy efficient machine and facility optimisations it is first necessary to robustly measure, map, and record the energy requirements of manufacturing facilities. Research projects in the area of machine tool energy performance optimisation are extensive; however, the attention given to the accurate and reliable quantification of machine tool and process chain energy requirements is not comprehensibly addressed in the literature. This paper provides an overview of industrial energy measurement technology and describes a methodology facilitating the effective installation of large scale energy metering systems in complex manufacturing facilities; with an Irish based case study. The aim of the project is to illustrate the benefits associated with absolute energy consumption transparency, only achievable through extensive and continuous power metering. The results of the project, as well as some limitations associated with large scale energy monitoring solutions are also discussed.