ON-LINE ENERGY-USE BENCHMARKING SYSTEM FOR INDUSTRIES IN MALAYSIA

Transcription

1 ON-LINE ENERGY-USE BENCHMARKING SYSTEM FOR INDUSTRIES IN MALAYSIA By KAMALA ERNEST Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia, in Partial Fulfilment of the Requirements for the Degree of Master of Science February 2004 i

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3 Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfillment of the requirement for the degree of Master of Science ON-LINE ENERGY-USE BENCHMARKING FOR INDUSTRIES IN MALAYSIA By KAMALA ERNEST February 2004 Chairman: Syed Abdul Rahman Al-Haddad Faculty: Engineering The study is intended to explore the viability of developing a web-based tool to facilitate a holistic approach to energy-use benchmarking management in the Malaysian Industrial sector. Energy-use benchmarking uses the measure of the plant s specific energy consumption to assess its energy performance, which latter can be used as a baseline for future energy efficiency and energy conservation activities. The measures can also be used to chart out future energy policies related to the development of national energy sector. The system developed is a migration of the manual data collection system which has limitations to the number of companies that can use the same. The energy-use benchmarking community which is customarily known as the Industrial Energy Efficiency Community (IEEC) was created as part of the National Productivity Corporation s (NPC) Benchmarking On-line Networking Database (BOND). Currently, the community has a membership of industries from eight energy intensive sectors in Malaysia, and this will be extended to the entire industrial sectors in stages. iii

4 Among others, the on-line tool developed can perform automatic statistical analysis in computing energy-use benchmarks, evaluating performance of the community, and ranking companies performance according to selected indicators. In order to evaluate the usability of the system, a sample of four companies from the wood sector were selected. A survey conducted among the selected factories on the usability of the system showed 83 % favorable. However, there are still opportunities available for enhancement of the tool for better usability that can result in more competitive benchmarking analysis. Further descriptive statistics can be derived from the collected and analyzed data. Analysis shows that there is a performance gap of 59 % among the selected sample companies, which can work together to close this gap through end-use energy efficiency. Through daily monitoring and setting targets for determining slack in energy performance and improving end-use energy efficiency respectively, the participating industries can arrest not only fast depletion of fossil fuel reserves but also the negative impact to the environment due to the excessive emission of greenhouse gasses (GHG). iv

5 Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia sebagai memenuhi keperluan untuk ijazah Master Sains SISTEM PANGKALAN DATA SECARA ON-LINE UNTUK TANDA ARAS PENGGUNAAN TENAGA DI SEKTOR PENGELUARAN DI MALAYSIA Oleh KAMALA ERNEST Februari 2004 Pengerusi : Syed Abdul Rahman Al-Haddad Fakulti : Kejuruteraan Kajian mencadangkan satu aplikasi pengkomputeran antara manusia dengan komputer dibangunkan untuk memudahkan aktiviti tanda aras penggunaan tenaga di kalangan industri di Malaysia. Tanda aras penggunaan tenaga megukur tahap penggunaan tenaga secara spesifik terhadap produk yang dikeluarkan. Ini merupakan salah satu cara untuk mengetahui tahap penggunaan tenaga bagi sesebuah industri dan informasi ini boleh dijadikan rujukan pada masa depan mengambil kira faktor kecekapan dan penggunaan tenaga. Sistem yang dibangunkan ini merupakan peralihan daripada sistem pengumpulan data dijalankan secara manual dan penggunaannya amat terhad untuk sesetengah industri sahaja. Oleh itu, sebuah komuniti Kecekapan Tenaga Sektor Pengeluaran ditubuhkan, sebagai sebuah badan atau komuniti kepada rangkaian pangkalan data benchmarking secara on-line menerusi Internet di Perbadanan Produktivit Negara. Pada masa kini, komuniti ini terdiri daripada 8 sektor yang terlibat secara langsung di Malaysia dan pada masa depan ianya akan merangkumi ke seluruh sektor pengeluaran yang lain. v

6 Sistem yang disediakan di Internet ini adalah percuma. Ianya boleh digunakan untuk mengira analisis statistik dengan cepat. Contohnya : pengiraan penggunaan tenaga benchmark, menilai prestasi komuniti atau sektor yang terlibat, dan tahap/pencapaian industri berdasarkan tanda aras. Dalam menilai tahap penggunaan sistem aplikasi yang dibangunkan ini, satu kajian ke atas satu sub-kelompok komuniti yang terdiri daripada 4 buah industri dari sektor perkayuan, telah dijalankan. Daripada hasil kajian, tahap penggunaan ke atas sistem aplikasi yang diperolehi amat menggalakkan iaitu 83%. Daripada kajian yang dijalankan, analisis dan keputusan yang diperolehi juga berdasarkan daripada data yang dikumpul melalui 4 buah industri yang dinyatakan. Kajian menunjukkan terdapat jurang perbezaan yang besar di kalangan rakan kongsi activiti tanda aras peggunaan tenaga iaitu 59%. Ini menunjukkan potensi yang besar bagi penjimatan tenaga. Sebagai satu proses yang berterusan, satu model perancangan berterusan telah diperkenalkan untuk memastikan dan menggalakkan penggunaan tanda aras penggunaan sebagai satu alat/kaedah untuk mempromosikan kecekapan tenaga dalam sektor industri. vi

7 ACKNOWLEDGEMENTS First and foremost, I would like to express my sincere gratitude and appreciation to the chairman of my supervisory committee, Tn Syed Abdul Rahman, Department of Computer and Communications Engineering UPM for his guidance, assistance and supervision of this thesis study. My appreciation to my industrial supervisor, Mr. R. Ponudurai, Chief Technical Advisor of the Malaysian Industrial Energy Efficiency Improvement Project (MIEEIP) for his guidance, motivation and strong dedication to see that the study attains a highly practical value for future reference. I would like to acknowledge the Malaysia Energy Centre for supporting the research and providing me with a study grant. I would also like to thank the National Productivity Corporation for the excellent collaboration given in enhancing my research work as an online interactive activity for the future. I also wish to convey my heartfelt gratitude to, Mr. Ramvir Sharma, Manager for Energy Efficiency Technology Demonstration Programme of MIEEIP for his constant support and help. To all my lecturers, friends, relatives and associates who have contributed towards my work. vii

8 And last but by no means least, to my beloved mother, Mdm. Leela Somasundram and sister, Shamala Ernest for their continuous love, support and encouragement Thank you viii

9 I certify that an Examination Committee met on to conduct the final examination of Kamala Ernest of her Master of Science thesis entitled On-Line Energy-Use Benchmarking for Industrial Sector in Malaysia in accordance with Universiti Pertanian Malaysia (Higher Degree) Act 1980 and Universiti Pertanian Malaysia (Higher Degree) Regulations The Committee recommends that the candidate be awarded the relevant degree. Members of the Examination Committee are as follows: Prof. Madya Ir. Dr. Norman Mariun Head of Department Faculty of Electrical and Electronic Engineering Universiti Putra Malaysia (Chairman) Syed Abdul Rahman Al-Haddad Lecturer Faculty of Engineering Universiti Putra Malaysia (Member) Ponudurai Rajamanikam Chief Technical Advisor-MIEEIP Malaysia Energy Centre (Member) SHAMSHER MOHAMAD RAMADILI, Ph.D, Professor/Deputy Dean School of Graduate Studies Universiti Putra Malaysia Date: ix

10 This thesis submitted to the Senate of Universiti Putra Malaysia and has been accepted as fulfilment of the requirement for the degree of Master of Science. The members of the Supervisory Committee are as follows: Syed Abdul Rahman Al-Haddad Lecturer Faculty of Engineering Universiti Putra Malaysia (Member) Ponudurai Rajamanikam Chief Technical Advisor-MIEEIP Malaysia Energy Centre (Member) AINI IDERIS, Ph.D. Professor/Dean School of Graduate Studies Universiti Putra Malaysia Date: x

11 DECLARATION I hereby declare that the thesis is based on my original work except for quotations and citations which have been duly acknowledged. I also declare that it has not been previously or concurrently submitted for any other degree at UPM or other institution. KAMALA ERNEST Date: xi

12 TABLE OF CONTENTS Page DEDICATION ABSTRACT ABSTRAK ACKNOWLEDGMENTS APPROVAL DECLARATION LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS ii iii v vii ix xi xv xvi xviii CHAPTER 1. INTRODUCTION General Background Research Problem Current Setbacks in Malaysia Impact Objectives Organization of the thesis Summary LITERATURE REVIEW Introduction Energy consumption trend in Malaysia Overview of Selected Industrial Sectors Wood sector Cement sector Ceramic sector Benchmarking and Data Collection Activities Energy Efficiency Benchmarking in the Thai-German EE 38 Promotion Programme (ENEP) Department of Statistics-Malaysia Benchmarking at National Productivity Corporation (NPC) Development of Human Computer Interaction Principles in Human Computer Interface Usability Engineering Interaction models and Methods for HCI design Linguistic model Seeheim Model PAC-Amodeus Model Model-View-Controller (MVC) Energy Management Information System (EMIS) Requirement of EMIS Components of EMIS 55 xii

13 2.9.3 Designing EMIS Requirement at Different Management 56 Level and area in a plant Using the system Summary -EMIS and User Interface features Typical Benchmarking Model Phase I: Planning Phase II: Analysis Phase III: Integration Phase IV: Action Combining HCI Techniques for Energy-use Benchmarking The Need for an Interactive On-line e-benchmarking System METHODOLOGY Introduction E-benchmark Systems and Industrial Energy Efficiency Community Design Specification Outlook Application of User Interface Architecture Operations of the system Level of accessibility and type of users Creating the community Creating Organization Admin Creating Indicator Administration Types of data collected Energy Consumption data Production data Computation of SEC Role of user Generating the output Scores Report ANALYSIS AND RESULTS Introduction Analysis of HCI application in the e-benchmarking system Recognize diversity and complexity of energy-use benchmarking The Interface Process Evaluating Usability of the system Understandability Learnability Operatabilty Attractiveness Outcome of evaluation Benchmarking Analysis Benchmarking Results Wood sector Cement Sector 108 xiii

14 4.5.3 Ceramic Sector Relationship between energy consumption and production Summary of Results RECOMMENDATIONS AND CONCLUSION Introduction Advantages/ Benefits of the system Weaknesses of the system Constraints of the project Quantum of Data for Analysis Issue of Confidentially Recommendation For A Sustainable Energy-Use Benchmarking For Industries Enhancement of e-benchmark System Monitoring and Targeting System (M & T) Model for Continuous Improvement Conclusion 123 REFERENCES 125 APPENDICES 127 BIODATA OF THE AUTHOR 140 xiv

15 LIST OF TABLES Table Page : Responsibility and level accessibility : User interface Analysis for Organization Administration : User Interface Analysis for Indicator Administration : List of utilities : Conversion factor for electricity and fuel : Matrix for evaluating usability characteristics : Monthly SEC for Wood xv

16 LIST OF FIGURES Figure Page 1.5.1: Organization flow of thesis : Trends in energy demand by sectors :Particleboard production process : Export of Chipboard from Malaysia : International benchmarks for tiles and bricks : Component of Human Computer Interface : Linguistic model : Seeheim Model : PAC Amodeus Model : Model-View-Controller Model : Energy Management Strategies : Energy Accounting Centre : Improving Performance Gap : Plant EMIS operation : Implementing EMIS : Process flow and input for the creation of Industrial Energy Efficiency Community : List of e-communities : Interactive e-benchmark database for Benchmarking Communities : Structure of Benchmarking Community for Industrial Energy Efficiency : Workflow structure of Industrial Energy Efficiency Community : Implementation across cluster/sub clusters : Creating organization administration...80 xvi

17 3.4.4 : Steps in creating Indicator Administration : Creating Indicator Administration : Data Entry Form : Auto calculation to Giga joules : Cluster and Sub clusters of IEE community : System Interface Process : System shortcuts : Successful completion of activity : Competitive Scores for SEC : Results of ranking : Results Overall : Competitive Scores for Cement : Competitive Scores for Cement : Competitive Scores for Cement : Competitive Scores for Cement : Competitive Scores for Ceramic : Competitive Scores for Ceramic : Competitive Scores for Ceramic : Competitive Scores for Ceramic : Relationship between electricity consumption and production : Relationship between fuel consumption and production : Enhancement of Industrial Energy Efficiency Community : Monitoring and Targeting System : Energy-use Benchmarking Model xvii

18 LIST OF ABBREVIATIONS BOND DAS DEDP DoS EC EE EPU EMIS ESCO(s) GDP GEF GHG GoM INEDIS MBS MDF MEC MIEEIP MVC M & T NPC PAC Benchmarking On-line Networking Database Data Acquisition System Department of Energy Development Programme Department of Statistics Energy Conservation Energy Efficiency Economic Planning Unit Energy Management Information System Energy Services Companies Gross Domestic Product Global Environmental Facility Green Houses Gasses Government of Malaysia International Network for Energy Demand Analysis for Industrial Sector Malaysian Benchmarking Services Medium Density Fibreboard Malaysia Energy Centre Malaysian Industrial Energy Efficiency Improvement Project Model Viewer Controller Monitoring and Targeting National Productivity Corporation Presentation-Abstraction-Controller xviii

19 PTM SEC TFP TQM UVM UMIS Pusat Tenaga Malaysia Specific Energy Consumption Total Factor Productivity Total Quality Management User Virtual Machine User Management Information System xix