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How Continuous Energy Management Helps You to Realise these Potentials

The goal of an energy management system is the reduction and continuous optimising of the energy consumption of the company. Especially with manufactoring companies the energy costs take a big part in the whole production costs. Energy saving potentials and of the energy consumptions can be shown here as well as energy saving potentials of the costs of continuous energy management. In the following artricle we would like to share our experience with our customers of the manufacturing middle class and show the five typical energy savong potentials that we see on the regular with manufacturing companies.

1. Unnoticed  Standby-Load

Everyone knows that - you turn off the TV and the red standby-light starts to glow. Like this the TV keeps on using energy and costs you a lot of money every year. An identical scenario can be seen in the industries, but the "industrial TV" costs a lot more money than the one at home. When the factory is standing still, you can identify unnoticed standy-loads with a measurement at the transfer counter and avoid them. If you measure an unusual high standby-load, the cause has to be identified in the next step and be reduced through a shutdown or a suting countermeasure. This reduces the energy consumption and the energy costs. 

Mit der Auswertung des Lastgangs am Übergabezähler lassen sich Standby-Lasten sofort erkennen.
Mit der Auswertung des Lastgangs am Übergabezähler lassen sich Standby-Lasten sofort erkennen.

2. Avoidable Peak Loads

Industrial companies that use more than 100.000 kWh a year usually measure not only the energy amount (kWh), but also the power (kW) and settle that up with the network operator. Like that a higher load of the  supply network can be considered from a certain power withdrawal on. In a common tariff the payment depends on the annual peak load, the highest 15-minutes load that occured in the year. This annual peak load is made up of the real load history and the avergaing calculation of this historyin a 15-minutes-window. With the help of highly resoluted data (every 15 seconds) such load history can be anylised precisely and knowledge for the load management can be gained. For example this can lead to a turn on-plan for machines and systems to prevent peak loads and save money with the electricity bill.

This peak load can be seen at the peak load-storage at the transfer counter.
This peak load can be seen at the peak load-storage at the transfer counter.

3. Reduced Transformer Loss

Transformers are often run inefficiently and lead to energy loss at the voltage conversion. Causes for this loss may be old technology, bad configuration, operation in an inefficient operation point or other mistakes. The efficiency of transformers can be easyly checked with an underside-transformer measurement. The measured data is compared at the upstream transfer counter (RLM Counter) and the downstream measurement point. It's especially interesting to compare it to times outside the working hours (e.g. on weekends). If there are significant inefficiencies it can be shown immediately and savings potentials can be realised quickly.

4. System Overload through Harmonics

Harmonics are displayed as a "pollution" of the network and are harmful for devices, machines and highly relevant for the safety of the operation. They can force the production lines and IT systems to stand still and even lead to cable fire. A possibility to avoid such insecurities caused by harmonics is the high frequent measurement of the streams in the company network. This allows the identification and causes and the targeted finding of measurements to prevent harmonics.

5. Avoidable Downtime

With the continuous measurement of the energy consumption of single machines and systems it's possible to discover anomalies of the consumption that point to a defect machine. To do that the measured consumption is compared to the historic data to find unexpected consumption. The connection of energy data  with data bases of the production, for example the produced quantities, allow a conclusion of anomalies through formation of indicators and the comparison with historic data. If there's more energy used apiece as expected it's worthwhile to look at the machine more closely to early anticipate and avoid possible production downtime. 

Energy Saving Potentials Anomaly Detection
Energy Saving Potentials Anomaly Detection

Practical experience shhows that energy saving potentials are hidden in most manufactoring companies and can be relised in the best way by a continuous measurement of electronic parameters. In average our customers safe 8% of their energy costs with the help of the ENIT Agent. The continuous acquisition of highly resoluted energy data is the base for possible savings. Find examples for possible cost saving in detail here:

Our case studies