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The energy efficiency of things

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When it comes to your plant’s energy efficiency, the Industrial Internet of Things (IIoT) is coming along just in time.

Because these days, you can try cutting consumption across the board - and still have your electricity bill go up. (This is particularly painful in energy-intensive operations such as mining or water/wastewater.)

Maybe you’re consuming less energy, but mostly during times of day when energy prices are peaking. Or maybe there’s something else going on in the complex relationship among your assets, raw materials, and utility costs. All you know is, you’re paying higher prices, while some expensive manufacturing assets are arbitrarily sidelined when you could really use them.

Fortunately, the IIoT presents all sorts of new ways to keep control of your kilowatts, as part of some really cost-efficient energy management schemes. One good example: advanced technology built into the newest programmable automation controllers, or PACs — the successors to PLCs. Their new IIoT-ready capabilities mean that you can be more selective in your asset energy conservation strategies.

IIoT presents all sorts of new ways to keep control of your kilowatts,
as part of some really cost-efficient energy management

Active energy management

These industrial internet-ready controllers come with native Ethernet built in. That allows easy integration within collaborative and integrated automation architectures.

Thus data is visible whenever and wherever it’s needed. You connect these controllers to power meters on machines and other assets - motors, pumps, compressor, evaporators, and so on — across the plant. Their integrated connections make data flows visible to authorized users.

For instance, you can flow relevant data to your site’s IT networks, where, bolstered by cloud-based analytics, it can be used to make highly informed business decisions.

Benchmarking lets you compare the efficiency of different plant areas and operations, or calculate energy consumed per product.

Particularly in conjunction with an overall process expert system, active energy management can be built right into your process. Your managers can take maximum advantage of fluctuating energy costs. And your assets can achieve optimum productive efficiency for any energy consumed.

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Things in the plant suddenly get a lot more energy-efficient with
new super-PLCs — such as the Modicon M580 Ethernet-enabled
automation controller (ePAC) from Schneider Electric. 

High-powered results

Using this advanced controller approach, a typical plant can get 100% controller ROI in under 3 months. And overall, it can cut energy consumption by up to 30% per year!

In China, for example, a large water plant processed 220 million gallons per day. It consumed 1500 kilowatt hours (kWh) per million gallons per day, at $0.05 (USD) per kWH. Annual energy expenditure: $6 million (USD). For its flooding control system, the plant installed advanced controllers using pluggable programming libraries. With transparent data empowering smart decisions, the operation reduced energy up to 30% — cutting more than $1.8 million (USD) a year from its electric bill.

When your controllers are IIoT-enabled, things quickly start looking up in energy management.

For more details on how you can bring all the benefits of the industrial internet to your operation, please select one of the options below.

For related information, click on any of the links below:

[White paper series] Preparing for the IIoT, exploring the impact... 
Seeing the Connections - How the new generation of IIoT-ready controllers reveals value hidden in process data
Facilitating project execution in the connected enterprise 
To learn more about how these new PLC devices can control (and thereby enhance) profitability

New value finder tool helps you discover $$ value hidden in plant assets
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