Taking steps to maximize energy efficiency

Taking steps to maximize
energy efficiency
Scalable energy management with SIMATIC
Energy management scaled to
suit your needs
The question facing the industrial manufacturing sector is no longer
ci ency con
ef f i
I de
I choose?”. Systematic energy management plays a decisive role in ensuring
i fy
“Do I need an energy management system?”, but rather “Which one should
according to
ISO 50001
the best possible use of valuable energy resources, in cutting energy costs
and in boosting competitiveness. Furthermore, energy conservation legis­
lation is placing ever more stringent requirements on industry.
The energy management process at a glance
Efficient energy management can be implemented
in stages
It is only by knowing where and when how much
energy is needed that we can benefit most from potential
­savings. Siemens can demonstrate that this process does
not have to be complex or cost-intensive.
Our comprehensive portfolio provides you with everything
you need to boost your energy efficiency. Action can be
initiated or expanded by starting with simple energy monitoring and progressing to a comprehensive energy management system. Each step along the way provides more
functionality than the previous stage and can, in most
cases, be fully integrated into the next expansion level.
This safeguards each investment, once it has been made.
Using five example configurations, we can show you how
to set up or expand an energy management system step
by step – starting with simple energy monitoring of individual loads and machines and progressing to a comprehensive energy management system embracing the entire
plant and/or company.
Perfection by combination
Thanks to the ease with which B.Data can be combined
with SIMATIC powerrate, it is possible to build a fully integrated energy management system across all levels, offering outstanding functionality and thus maximum transparency. Supported by this platform you can optimize the
use, distribution and purchase of energy throughout your
company, helping you to achieve maximum cost savings.
Our portfolio is rounded off by a full range of energy
­consultation services as well as support for customers
who need assistance in the practical implementation of
their energy management solution.
The ideal starting point:
Energy monitoring at machine level
HMI device
e.g. Basic or
Comfort Panel
PAC power monitoring device
Further devices ...
Electrical / non-electrical energy
Configuration 1: Compact, low-cost entry-level solution which clearly
displays the energy and power requirements of a machine and its
loads (energy monitoring)
Compact and cost-effective – machine-oriented energy
monitoring is the ideal entry-level solution for anyone
wanting to gain a clear understanding of their energy
data. The concept is based on the PAC 7KM power monitoring devices and does not require a control system.
Energy data such as the power consumption of a machine
and its loads are measured directly at the machine. The
power monitoring devices can be linked up to HMI devices
such as SIMATIC Basic and Comfort Panels and visualized
using SIMATIC WinCC V11 (TIA Portal).
Transparency at the machine
This configuration provides an energy data recording
function or the computation of simple characteristic
­values such as “kWh per unit”. Energy flows and potential
cost savings can be analyzed and optimized and displayed
with simple clarity directly at the machine.
Simply more transparent: Energy management
at visualization / control system level
SIMATIC IPC control or visualization
system with SIMATIC WinCC,
e.g. IPC547D
PAC power monitoring device
Further devices ...
Electrical / non-electrical energy
Configuration 2: Low-cost entry-level solution for energy monitoring via the SCADA system. Capable of expansion by SCADA system
­options which are also suitable for energy management
Our SIMATIC WinCC SCADA software is an innovative and
scalable process visualization system that features numerous functions for monitoring automated processes. It
provides the platform for an equally low-cost entry-level
system for energy monitoring on an industrial PC. Configuration does not require a subordinate control system
and is capable of expansion.
More options available
You can also utilize all plant intelligence options integrated in the WinCC system for the purpose of energy
management. These include, for example, the DowntimeMonitor which records and analyzes downtimes, or the
DataMonitor which displays and evaluates current process
states. In addition, the WebNavigator provides you with a
wide variety of access options. The basic field equipment
for these solutions includes the PAC power monitoring
devices or other components which perform measuring
functions such as frequency converters or circuit breakers.
Machine-oriented: Integrated solution for
energy management and control tasks
HMI device,
e.g. Comfort Panel
SIMATIC S7-315, -317, -319,
... S7-1200
PAC power monitoring device
Further devices ...
Electrical / non-electrical energy
Configuration 3: Compact, machine-oriented energy management
system for combining control system and energy management functions, for example, the correlation of production and energy data at
the machine or process interventions based on energy consumption
This compact, machine-oriented energy management
solution is of interest to anyone who wants to benefit
from a system combining energy monitoring, energy
reporting and energy control in an industrial manufacturing process. In addition to an HMI device and power
monitoring devices, it also includes one or more SIMATIC
programmable logic control systems, thereby allowing
control system and energy management tasks to be
fulfilled within an integrated system. This approach is
generally simpler and more cost-effective than resolving
these tasks individually.
Very close to the machine
This energy management system solution gives users the
opportunity to link production and energy data directly at
the machine and to calculate, for example, “unit costs of
energy”. Current energy consumption data or information
derived from it, for example on maintenance requirements, can likewise be utilized to control processes. This
allows the operator, for instance, to start up or shut down
loads or plant sections depending on energy usage. By
employing WinCC, users can also gain web access to the
visualization system and thus also to their energy data.
SIMATIC powerrate: for capping power
peaks and cutting energy costs
SIMATIC IPC control or visualization system,
e.g. IPC547D with SIMATIC WinCC / PCS 7,
+ powerrate
SIMATIC S7-317, -319, S7-4xx
+ powerrate
Circuit breaker
PAC power mo­n- Further devices ...
­itoring device
Electrical / non-electrical energy
Configuration 4: SIMATIC powerrate is an add-on to the process
visualization or control system which provides specific energy
­management functions, such as load management or energy and
cost reporting.
The SIMATIC powerrate option package offers comprehensive energy management functionality. It is available for
the SIMATIC WinCC SCADA visualization system and for
the SIMATIC PCS 7 process control system. It scales, visualizes and archives mean energy and power values –
and cuts energy costs by capping power peaks.
The package is based on a SIMATIC S7 block library
designed to capture the readings of all energy meters
within a plant and transfer the values to a buffer store
in the SIMATIC system. At the same time, the readings
are archived as 15-minute mean values and the corresponding costs calculated according to the relevant
tariffs. Up to twelve different tariffs can be displayed.
Your energy data manager
Your consumption data are visualized in SIMATIC WinCC
and SIMATIC PCS 7 in a transparent and clear way, stored
in archives and integrated in the operator control and
monitoring interfaces of the basic system. Thanks to
the automatic allocation to cost centers, it is possible
to identify and exploit hidden potentials for savings by
comparing consumer profiles and costs.
The SIMATIC powerrate reporting module provides analysis tools and standard reporting functions. The powerrate
option package also supports simple load management
and automated shutdown of non-essential loads on the
basis of 15-minute mean values, thus ensuring compliance with defined purchase limits. Under ideal conditions,
this means that energy costs can be reduced.
Devices supplied by other manufacturers can be integrated in the evaluation process via the control level.
Moreover, Siemens has developed an interface which
allows the simple exchange of energy data acquired in the
production environment with B.Data, the company-level
energy management system.
B.Data: The management system for a
transparent energy balance
Web client
Energy management
Energy management system WinCC,
PCS 7 or other
PAC power monitoring device
Other sources,
e.g. CSV, ODBC, OPC, ...
Electrical / non-electrical energy
Configuration 5: The B.Data energy management solution provides
the greatest possible clarity as regards energy data, as well as functions for computing key indicators, planning and predicting energy
consumption, as well as interfaces to the ERP system.
Maximum energy data transparency is a key benefit of
deploying the B.Data energy management system at company level. B.Data provides a platform for optimized, costeffective energy management in monitoring, controlling,
planning and energy purchasing.
Energy demands can be planned
The system computes characteristic values (which can be
configured individually on a system-wide basis) to help
users plan and predict their energy requirements efficiently. Calculations are based on the base-load profile
and specific changes to production schedules during the
relevant time period.
Interfaces allow data to be exchanged with higher-level
ERP systems such as SAP. B.Data also helps to handle tariff
models of any complexity.
All energy data in your sights
B.Data is particularly useful to energy managers who want
to store their own, in some cases, complex algorithms, or
formulate and generate reports. It offers supplementary
reporting functions, such as cost center reports, prorata
allocation of consumption costs to cost centers, actual
load demand curves, weekly and monthly profiles, comparison reports and modeling for purchasing optimization,
and even emission reports.
Manage your energy – using B.Data
Another highlight of this system is its modeling functionality. On the basis of existing energy values (history) and
new tariff models, it is possible to compute projected
energy costs with specific reference to your situation.
By comparing existing costs with those which would be
incurred by a different tariff, you can make an informed
choice as to whether to switch to a new tariff model available from your energy supplier.
Siemens AG
Industry Sector
Industry Automation
P.O. Box 48 48
Subject to change without prior
notice 04/12
Order No.: E20001-A1090-P200-X-7600
DISPO 06303
21/37175 MI.AS.EE.XXXX.52.2.02
SB 04122.
Printed in Germany
© Siemens AG 2012
The information provided in this brochure contains me­re­ly general descriptions or characteristics of per­for­m­ance which in case of ac­tual use do not
always ap­ply as described or which may change as a result of fur­ther de­vel­
opment of the pro­ducts. An obligation to provide the respective characteristics shall only exist if ex­pressly agreed in the terms of contract.
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