Taking steps to maximize energy efficiency Scalable energy management with SIMATIC siemens.com/simatic-energy-management Energy management scaled to suit your needs The question facing the industrial manufacturing sector is no longer ci ency con su En nt ef f i lti alu ate I de gy ng I choose?”. Systematic energy management plays a decisive role in ensuring er Ev 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. Implement 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 Ethernet 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 Ethernet 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 Ethernet 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 Ethernet SIMATIC S7-317, -319, S7-4xx + powerrate PROFIBUS DP TCP/IP PROFINET Third-party manufacturer Circuit breaker Frequency converter 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 B.Data Web client Energy management B.Data client B.Data server Internet/ Intranet PROFINET SCADA / DCS 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 90026 NÜRNBERG GERMANY 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. All product designations may be trademarks or product na­mes of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.