Analytics Drive Energy Costs Down

“Listen to your Machines and Find Real Savings with Energy Analytics” was one of the first presentations offered at the Siemens 2016 Automation Summit, held June 27 to 30 in Las Vegas. The core of Stephan Ihmels’ presentation was a case history involving a discrete-manufacturing facility in the Chicago area.

Ihmels is business-development manager, Plant Data Services, Siemens Industry Inc. Digital Factory division, Alpharetta, GA.

Management at the Chicago manufacturer was looking to reduce costs. Their goal was a 10% reduction in energy costs, while improving efficiency and productivity. They also wanted to realize a payback of less than 2 yr. and to be able to allocate energy use to different departments.

They decided to reach their goals by using the Siemens Energy Analytics Platinum package, a subscription software and analysis service that carried, for this application, a $3,000/month fee. The service offers custom online dashboards, analytics, and diagnostic support. The payoff is delivery of specific energy-reduction actions and implementation consulting and coaching from Siemens experts.

The system too some planning and setup, but it started making a difference the first month. An analysis of the manufacturer’s compressed-air system showed that 36% of the air consumption was caused by leaks (an ideal level is less than 10%). Tackling that problem resulted in a $16,900 savings the first year.

Electricity monitoring indicated that 14.4% of electricity was consumed during non-productive hours. Now that that is straightened out, they are realizing $45,000 in annual savings.

Overall, they had no problem reaching their 10% utility-reduction goal and have realized an annual energy savings of $70,000. Their ROI for the project was less than a year, way ahead of their 2-yr. goal.

When implementing a system such as this, Ihmel recommended that you focus your initial efforts on applications/processes where savings will be achieved quickly. Also, make full use of the extensive data and reporting generated by the system by making sure the web dashboard is viewed, shared, and analyzed by everyone involved, including management.–Gary L. Parr, editorial director

Learn more about the Siemens Energy Analytics service at siemens.com/energyanalytics.