Brochure Operational Energy Management

8/3/2019 Brochure Operational Energy Management

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Answers for industry.

Identify, evaluate and realize cost-saving potentialin an integrated energy management process

How is energy transformedfrom cost factor to success factor?


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Increasing energy costs, increasingly more stringent environmental regulations or

achieving certification according to the EN16001 energy management standard

there are several excellent reasons that speak for well-functioning energy management

in industrial plants and systems. However, one factor is especially important:

The bottom line is that energy management plays a decisive role in increasing

the productivity of plants and systems, and in turn, significantly increases the

competitiveness of a company and that, in any sector.

System-based higher productivity


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Contents

The energy management processto continually increase the energyefficiency of a plant 4

Identify 5

Evaluate 6

Realize 7

The most comprehensive portfolio for anefficient energy management process 8

Energy efficiency the specifics:Examples from the field 10

Siemens AGIndustry SectorP.O. Box 48 4890026 NRNBERGGERMANYwww.siemens.com/operational-energymanagement

Subject to change without prior notice 04/10Order No. E20001-A20-M117-X-7600DISPO 21505W/26815 GC.GC.HI.EEFF.52.0.01 WS 04103.Printed in Germany Siemens AG 2010

The information provided in this brochure contains merelygeneral descriptions or characteristics of performance which inactual case of use do not always apply as described or whichmay change as a result of further development of the products.An obligation to provide the respective characteristics shallonly exist if expressly agreed in the terms of contract.All product designations may be trademarks or product namesof Siemens AG or supplier companies whose use by third partiesfor their own purposes could violate the rights of the owners.

*Source: VDI 4602 Energy Management Terminology

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Higher energy efficiency ...

Energy management is the predictive and systematiccoordination of energy procurement, conversion,distribution and use with the objective to cover thedemands taking into account ecological and economicdirectives. Put another way: Take planned action withthe purpose of efficiently handling and using energy.*

... using efficient energy management

Functioning energy management is a process, which analog to quality management is used to continuallyincrease the productivity of the energy used. As yourpartner, we can offer you an extensive portfolio, whichsupports you in this process.

Energy management is used to continually monitorthe energy usage of your plant or system, thereforereducing the energy and operating costs and at thesame time reducing the environmental stressing.The key to all of this is the perfect interaction ofour portfolio within the scope of Totally IntegratedAutomation, our open system architecture:

Hardware and software to acquire, visualize andanalyze energy flows

Programs to precisely determine the cost-savingpotential at all levels of production and processautomation

Products and systems that actually reduce theenergy demand


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The energy management processat a glance

Everybody is talking about energy management. However, Siemens is addressing

this topic comprehensively and systematically. We split up the energy management

process into three phases Identify, Evaluate and Realize and support you in

each of these process phases. For this purpose, we can offer you intelligent hardware

and software solutions that allow you to transparently display your energy-related

resources and effectively control them.

Identify

The optimum hardware and software acquire, visualizeand analyze the energy flows in the plant or system:Energy flows become more transparent and this meansthat the process can be optimally configured froman energy-related perspective. The measured dataretrieved allow a first evaluation of the existingcost-saving potential and at the same time, formthe basis for an intelligent and efficient energymanagement.

Evaluate

Based on plant and system parameters, powerfulsoftware tools calculate the precise cost-savingpotential for the specific application and thecost-effectiveness of possible measures for thedrive system at the field level, for the control andsupervisory level and for the higher managementlevel. Financing and leasing options allow energy-saving plant and system components to bepurchased at a favorable price.

Realize

Specific measures allow the existing cost-savingpotential to be fully utilized. In this case, there is aspecial focus on drive technology. Drives represent twothirds of the industrial energy demand. Potential costsavings of up to 70% per drive are definitely realistic.

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Corresponding toEN 16001

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Identify:Make energy flows transparentthroughout the company

In this phase, data can be retrieved that already allow a first evaluation to be maderegarding the energy-saving potential, and create the basis for intelligent and efficientenergy management assuming of course that the energy usage is transparent.Whether for electrical energy or for other energy forms such as water, gas, compressedair etc.: Precise usage values and power data must be available over a longer periodof time so that definitive comparisons can be made as well as practical and realisticoptimization measures defined.

Efficient energy monitoring is indispensable in production and process automation aswell as in the building sector this is especially true for complex tasks. Only then canthe relevant measured variables be precisely monitored and analyzed for instance,power consumption, load profiles, temperatures and flow rates.

We can offer well-conceived and powerful hardware and software solutions for all ofthese tasks.

Product examples

SIMATIC powerrate: SIMATIC energy managementsystem for WinCC and PCS 7 to efficiently acquire,calculate and log all of your energy data for fo-cused energy usage optimization.

SENTRON powermanager software:The energy management software as stand-alone solution is suitable for applications incommercial buildings, smaller or average-sizedindustrial facilities, where there is no automation,or where the automation and power distributionmust be separated.

SENTRON PAC: Compact and powerful multi-function measuring devices. These devicesprecisely and reliably acquire all of the usagedata in the electrical power distribution anddisplay it on a graphic LC display.

SENTRON load disconnectors with integratedmeasuring technology: Combined with SENTRONPAC, they acquire the measured data and transferit to higher-level energy management systems.

Communication-capable SENTRON circuitbreakers: Full transparency by providing energydata from the field level without requiring anyadditional installation.

PROFIenergy: Standard based on PROFINET forfavorably-priced and granular measured valueacquisition directly at the load.he load.


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Evaluate:Precisely determining thecost-saving potential

Product examples

b.data: In addition to seamless energy andmaterial balancing of the energy generatingsystems and loads, energy cost allocationdepending on the particular consumer andtransfer into the ERP system (e.g.: SAP R/3 CO),specific key performance indicators (KPIs) aregenerated using automatic data analysis. TheseKPIs form the basis to increase the energyefficiency of production plants and systems.

SIMATIC powerrate for WinCC and PCS 7 forthe control and supervisory levels: Complete,seamless and integrated power managementsolution to visualize and analyze your completeenergy data to identify energy saving potential.

SinaSave: The software tool for drive technologyat the field level, designed for applications withmotors directly connected to the line supply(fixed speed) and frequency converter operation(variable speed). This tool calculates, based onyour plant characteristic values, the payback timewhen investing in an IE2 or IE3 energy-savingmotor, a direct torque motor or a frequencyconverter. Frequently, these payback times are just a couple of months.

Energy Health Check: This is an integratedservice package to optimize complete plants froman energy-related and holistic perspective, andwhere an optimization measure has a maximumpayback time of just two years. As a consequence,energy costs can be reduced in a focused fashionwith low associated costs.

Siemens Financial Services: Financing andleasing options for investments to increase theenergy efficiency.

Once the energy flows have been acquired, evaluated as well as visualized and thelarge energy consumers identified, the specific energy-saving potential must be cal-culated. The cost-effectiveness of potential measures can be derived for the specificapplication from this result and a decision-making basis created for investors.Across all plant levels from the field up into the management level we can supplyyou with tools that provide you with meaningful results to secure a high degree ofdecision-making reliability.


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Realize:Fully utilize optimizationpotential

Product examples

An extensive range ofhigh-efficiencymotors , which in comparison to standardmotors, have efficiencies that are up to 7%higher.

The most comprehensive portfolio offre-quency converters available in the market,which depending on the application, allowpower costs to be reduced by 70% withrespect to fixed-speed concepts by usingvariable-speed operation. This is especiallytrue for pumps, fans and compressors toprecisely adapt the speed.

Frequency converters capable of energyrecovery with innovative infeed technology,which feed the braking energy back intothe line supply. For instance, for hoistingapplications, conveyor belts and centrifuges,energy costs can be reduced by up to 50%.

Motor starters and soft starters to reducemechanical and electrical peak loads by upto 60% with extremely low intrinsic powerloss.

Intelligent energy management withSIMATIC powerrate for WinCC and PCS 7 to limit load peaks and therefore reduceenergy costs.

The b.data energy management systemensures that your operations and proceduresare optimized by automating all of the pro-cesses relevant when purchasing energy andfor energy supply. By specifically analyzingenergy and production data, you obtaina comprehensive understanding of yourenergy consumption and usage, whichmeans that you can save valuable resources. You continually optimize your cost struc-tures in this way and, on the whole, becomemore efficient.

Dynamic energy management withPROFIenergy , the nonproprietary commu-nication profile from PROFIBUS & PROFINETInternational (PI) reduces energy costs bycompletely shutting down (even briefly)loads that are not used in nonproductiveperiods.

Our Customer Support is there to supportyou when changing over and upgradingexisting drive systems that are no longereconomical to efficient motors and variable-speed drives.

After defining the optimum measures based on an economic feasibilityanalysis, the next step is to tap into all of the potential that has beendetermined as effectively as possible. Within the scope of our extensiveportfolio, we can offer you the appropriate products, systems andtechnologies highly efficient levers that play a role in drastically reducingthe energy requirement of your plant or system.

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The most comprehensive portfolio for anefficient energy management process:

Identify Evaluate Realize More information

PROFIenergyMeasuring functionality

to acquire energy values

Loads specifically shut down in

nonproductive periods

www.siemens.com/

profinet

b.dataSeamless acquisitionand company-widevisualization ofenergy flows.Display of trends andreporting

Transparent energybalancing and determiningspecific KPIs.Energy cost allocationand invoicing accordingto the particular load

Optimization potential by preciselyforecasting energy demand and loadprofile

www.siemens.com/bdata

SIMATIC powerrateVisualization and trans-parency of the energyflows of a plant.Archiving, reporting

Energy-intensive loadsare evaluated

Load management, efficient processconfiguration/arrangement

www.siemens.com/powermanagementsystem

SENTRON powermanager energy management softwareStand-alone software forvisualization for trans-parent energy flows of aplant, archiving, reporting

Provide support for efficient processconfiguration, cost center allocation,monitoring operating states


SIMATIC WinCC and SIMATIC PCS 7Measured value acquisi-tion and archiving of theelectrical and nonelectricalenergies

Trend and curve displays reports and logs of energyusage

www.siemens.com/simatic-wincc

www.siemens.com/simatic-pcs7

SENTRON PAC multifunction measuring devicesPrecise and reliable acquisi-tion of electrical and otherenergy values

Measured values to evaluate the plantstate and the line supply quality


SENTRON switching and protection devicesMeasuring functionalityto acquire energy values

www.siemens.com/sentron

SINAMICS frequency convertersThe power drawn by thedrive system is acquired

Up to 70% energy saving for pump, fanand compressor applications. Up to 50%cost saving when using converters capableof energy recovery in e.g. conveyor andhoisting applications

www.siemens.com/sinamics

SINAMICS and ROBICON medium-voltage convertersThe power drawn by thedrive system is acquired

Up to 70% energy saving for pump, fanand compressor applications. Up to 50%cost saving when using converters capableof energy recovery in e.g. conveyor and

hoisting applications

www.siemens.com/robicon-perfect-harmony

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Identify Evaluate Realize More information

DYNAVERT T frequency converterThe power drawn by thedrive system is acquired

Up to 70% energy saving throughvariable-speed operation

www.siemens.com/loher-dynavert-t

SinaSaveThe cost-saving potential

of energy-efficient drivetechnology and its paybacktime

www.siemens.com/

sinasave

SIMATIC ET 200S FC, ET 200pro FCThe power drawn by thedrive system is acquired

Energy saving using variable-speedoperation.Energy saving using energy recovery

www.siemens.com/et200

SIRIUS InnovationsMeasuring functionality toacquire energy values

Reduced and extremely low intrinsicpower losses result in reduced energyconsumption.Active switching, e.g. for load managementfacilitates cost savings of up to 25%

www.siemens.com/sirius-innovations

SIRIUS motors, starters and soft startersMeasuring functionality toacquire energy values

Active switching. Up to 92% energy savingby using soft starters with integrated powerbypass

www.siemens.com/sirius

SIMOCODE pro motor management systemMeasuring functionality toacquire energy values

Active switching. Higher plant availabilitythrough increased transparency of thecomplete control. Up to 25% energy saving

www.siemens.com/simocode

Low-voltage induction motors and explosion-proof motorsExtensive range of high-efficiency low-voltage motors from 0.09 kW, whichwhen compared to standard motors haveefficiencies up to 7% higher with anefficiency classification IE2 and IE3 in therange from 0.75 to 375 kW. Also explosion-proof motors are available across theboard from 0.75 to 375 kW in the highIE2 efficiency class

www.siemens.com/motors

www.loher.com

HT-direct motorsVery high efficiency through a directdrive up to 3% higher than conventionalmotors. Further, higher system efficiencywith SINAMICS

www.siemens.com/ht-direct

MOTOX geared motorsHigh efficiency across the board,IE2 (or IE3) up to 375 kW

www.siemens.com/motox

Siemens Financial ServicesFinancing solutions with plannable costsfor investments in energy-efficient Siemenstechnology

www.siemens.com/financing

Energy Health Check

Energy optimization for industrial plants and systems integrated and holistic approachto sustainably improve the energy efficiency of industrial plants www.siemens.com/industry-solutions

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Energy efficiency the specifics:Examples from the field

Using the following specific application examples, we will show you the

cost-saving potential that our energy-efficient products, systems and solutions

offer. These examples will also demonstrate how quickly an investment in

leading-edge technology is paid back.

An energy management system for 30,000 energy data trends

For Infracor GmbH managing energy efficiently is a central function when it comes tosupplying energy to the Marl Chemiepark. In this huge facility, the average demand ofall of the plants is approximately 300 Megawatt of electric power and between 700and 1100 tons of steam per hour. Three dedicated power stations with a total of fivegenerating units and three 110 Kilovolt feeder stations from the public grid are usedto supply this facility. Infracor has been using the b.data energy management systemfor eight years now in this remarkable energy environment. b.data is used to acquireand optimize the energy flows. Since it was introduced, b.data has been continuallydeveloped and expanded. Today, approximately 30,000 energy data trends areacquired, and when required, called up. In some cases, the archives go back over15 years. This integrated and holistic perspective creates the basis for extensive opti-mization. Today, b.data is the central control tool for all energy planning processesrelating to supply and disposal and allows the usage of al l of the energy consumedto be optimized.

Soft starters reduce the operating costs by 20 25%

In order to reduce their energy costs, the company operating the Minden-Letelnwastewater treatment plant invested in a control for the new aerator turbines in orderto avoid usage peaks as far as possible. Within the scope of the modernization, theelectric turbine drives were equipped with 3RW44 soft starters and the supervisorycontrol system upgraded to state-of-the-art technology using SIMATIC PCS 7. As aresult of the modernization, the power used in the biological area of the wastewatertreatment plant was reduced by 2025%. In addition, the soft starter solution mini-mized the danger of failures as well as the gear unit service times. This investmentpaid for itself in a very short time and over the next 10 to 20 years, will play a role insignificantly reducing the operating costs.

Efficient drive control saves 70,000 Swiss Franks year in, year out

The Dutch company DSM Nutritional Products AG replaced the fixed-speed pumpsequipped with valve control by variable-speed pumps at their factory located in theSwiss Canton of Wallis. MICROMASTER 440 frequency converters, which are con-nected to the main control room in the factory via PROFIBUS, adapt the flow rate. Thenew solution not only allows the closed-loop control of the plant to be significantlyincreased, but also reduces the usage of primary energy. The expected cost savingsare 70,000 Swiss Franks per annum.

Chemical industry: Infracor GmbH Marl,Germany

Water industry: Wastewater treatment plantMinden-Leteln, Germany

Pharmaceutical industry: DSM NutritionalProducts AG, The Netherlands


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Energy costs slashed by 3000 Euros per month using frequencyconverters

In its large tank farm in Kaiserwrthhafen, Germany, Shell Deutschlandno longer wanted to simply waste energy in mechanical valves. In order toensure that the main diesel fuel pumps always operate at their optimumoperating point, Siemens frequency converters each with a rating of 132 kW

and 1LG4 motors for the redundant pump system were used. The SinaSavesoftware clearly proved that the frequency converters had already paid forthemselves after about 14 months. The plant has slashed its energy costs by3000 Euros per month. An additional advantage is the fact that the variousprocesses have been optimized and the stress on the piping network as aresult of mechanical surges has been reduced. In turn, this has minimizedmaintenance costs and increased the plant availability.

35% energy cost saving through modernization

As a result of the fluctuating demand from the district heating station,the Stadtwerke Chemnitz (public utility in Chemnitz, Germany) planned to

optimize the energy balance in its district heating station that suppliesheating to the local community. The overdimensioned hot water circulatingpump drives with fluid coupling were replaced by variable-speed drive sys-tems based on rugged, high-efficiency N-compact low-voltage motors andthe matching SINAMICS G150 frequency converters. The power costs for thehot water circulating pumps were reduced by about 35% by using variable-speed drive systems and the fact that it was no longer necessary to over-dimension the motors. An additional advantage is the more precise closed-loop flow rate control and operation with lower stress on the mechanicalsystem as pressure surges have been eliminated.

Almost 20,000 Euros of cost savings per month by using frequencyconverters

In its Genk plant, the Belgian Company ALRO investigated the energy-savingpotential of pumps and fans for a painting system for automobile parts.Initially, a stochastic potential analysis was performed for all of the installedpumps and fans with a power rating of 5 kW or more which were previouslycontrolled with throttles and valves. These were then replaced by Siemensfrequency converters. The analysis indicated that 19,870 Euros could besaved annually by using frequency converters for the 12 drives. The paybacktime is less than 1.5 years.

New wood chip heating system: Heating demand is covered 100% usingwaste materials

While renovating the heat and energy supply, the Murimoos, werken undwohnen association were looking for a leading edge control technology thatcould also control a new wood chip heating system with a thermal rating of600 kW. The solution: A SCADA system based on SIMATIC WinCC, which con-trols all of the energy-producing systems and energy users. The optimum en-ergy supplier is used depending on the actual situation, e.g. the availability ofenergy and the actual prices. The advantage of the new wood chip heatingsystem: the wood waste from its own woodworking operations and theregional compost dump completely covers the heat demand without havingto purchase any wood chips. Being able to substitute the heating oil not onlyhad a positive financial impact, but emission values were also reduced.

Oil and gas industry: Shell Deutschland Oil GmbH,Germany

Supply and disposal utility:Stadtwerke Chemnitz, Germany

Automobile industry: ALRO Group,Belgium

Public sector, Murimoos association,Switzerland


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www.siemens.com/operational-energymanagement

Subject to change without prior notice 04/10Order No. E20001-A20-M117-X-7600DISPO 21505W/26815 GC.GC.HI.EEFF.52.0.01 WS 04103.Printed in Germany Siemens AG 2010

Siemens AGIndustry SectorP.O. Box 48 4890026 NRNBERGGERMANY

The information provided in this brochure contains me re lygeneral descriptions or characteristics of per for mance whichin ac tual case of use do not always ap ply as described or whichmay change as a result of fur ther de velopment of the pro ducts.An obligation to provide the respective characteristics shall onlyexist if ex pressly agreed in the terms of contract.

All product designations may be trademarks or product na mesof Siemens AG or supplier companies whose use by thirdparties for their own purposes could violate the rights of theowners.

Documents

Brochure Operational Energy Management