Utilize savings potential with intelligent strategies References for more energy efficiency Energy management with SIMATIC Increased energy efficiency in industry is one of the great challenges of the future. And it can be done. All you need for it is our comprehensive range for energy-efficient production. Our portfolio encompasses everything you require to identify, evaluate, and ultimately realize potential energy savings. In other words: everything for systematic energy management. The key lies in the perfect interaction of energy-efficient products and solutions within the scope of Totally Integrated Automation, our open system architecture. Optimize energy consumption with SIMATIC powerrate At plant level, SIMATIC® powerrate for the SIMATIC PCS 7 process control system and the SIMATIC WinCC process visualization system offers a convincing performance. The software records all the energy-related consumption data of the plant, assigns the data to the consumer, visualizes it clearly, and saves it in the archive. In this way, hidden savings potential can be reliably detected – for targeted energy consumption optimization. ci ency con En nt ef f i su lti alu ate I de gy ng er Ev As one of the core components, SIMATIC Energy Management provides support at all levels of automation, as the following references show. The energy management system B.Data thus enables optimized and cost-effective energy operations management at enterprise level – from monitoring, through controlling, right up to planning and energy purchasing. i fy B.Data makes the energy balance transparent in accordance with ISO 50001 Realize The energy management process at a glance siemens.com/simatic-energy-management Energy management in concrete terms Examples from daily practice Load management for cool calculators SIMATIC powerrate at Bürger GmbH required that account for a substantial proportion of the energy consumption of the entire plant. In the food and beverages industry, high quality is the top priority. The key issue here is: Can energy costs be reduced without impairing process quality? Bürger GmbH, a company in Crailsheim in Swabia, Germany has also asked this question. For more than 75 years, it has been producing its Swabian ravioli and potato noodles, popular well beyond the region’s boundaries. To comply with strict hygiene standards, refrigeration systems are Heitec – a Siemens Automation Solution Partner with experience in the area of energy management – recommended SIMATIC powerrate for WinCC for analyzing and evaluating the energy consumption values. For this purpose, 12 consumption meters from the SENTRON family were installed at selected points in the plant. The result confirmed expectations: the load to which the refrigerators are connected contributes disproportionately to overall consumption, with high and expensive power peaks when switching on the systems at the start of each shift. For this reason, the equipment units were adjusted in such a way that the refrigerating compressors switch on in sequence and power up in a controlled manner. The result is impressive: by this means alone, it was possible to reduce both the required maximum power (from 4.2 to 3.7 MW), and the standby values agreed with the power supply utility. This brings down energy costs on a sustained and long-term basis. Reduce power peaks, increase energy efficiency SIMATIC powerrate at Osram semiconductor chips are manufactured under highly automated clean-room conditions. The SIMATIC powerrate energy management system was brought in for energyefficient structuring of the processes. Because even slight reductions in power peaks in energy consumption have a significant effect on energy costs over the whole year. To this end, SIMATIC powerrate at Osram records consumption values, detects trends, and uses the calculated values to automatically shut down loads before the defined limits are reached. This is just an initial step, which can be followed by a further escalation step in the form of connecting internal generators. This is done until the consumption value returns to a level below the limit. Osram is one of the leading manufacturers of LEDs. One of the characteristic features of this innovative form of lighting is low energy consumption during operation. But where there is light, there is also shadow. The manufacture of LEDs consumes relatively high levels of energy. One of the reasons for this is that the extremely complex The tool is only used in the warm summer months because that is when especially high levels of energy are required for refrigerators. But the tool had saved so much energy by the second period that it has already fully paid for itself. Intelligent energy management Seat goes for B.Data In automobile manufacturing, success is decided above all by integrated productivity. Intelligent energy management makes an important contribution here. The path to comprehensive energy efficiency in industrial operations takes you via holistic systems and solutions. This is proved by the Seat central plant in Martorell. This plant is ahead of the pack in Europe in implementing an energy management system in accordance with ISO 50001, and in 2011, Seat became the first company in Spain to acquire this certification. B.Data makes an important contribution here, also in energy controlling. The software enables gap-free monitoring with cost-by-cause checks of the energy and material flows. With B.Data, Seat knows precisely when energy is required at which location, and can thus work out detailed plans for increasing efficiency. B.Data reports falling power consumption in the paint shop, among other locations. To improve energy efficiency, Seat has retrofitted the large ventilators with SINAMICS systems with which it now achieves energy savings of up to 60 %. Lenzing utilizes potential in fiber production B.Data in the textile industry The goal: to extract every last drop of efficiency from all processes, from power generation to the individual production processes. Lenzing AG – a global player in the manufacture of cellulose fibers – was on the lookout for a solution to the problem of systematic analysis of high volumes of data from different energy flows. For this reason, the company decided to introduce the software-based energy management system B.Data. It enables effective energy management at the enterprise level. Whether you’re dealing with electricity, steam, water, high-temperature water, compressed air, cold, inert gas or a vacuum – B.Data acquires energy flows without gaps, and visualizes them on a company-wide basis. In this way, the recorded consumption quantities can be selectively allocated to the individual production processes. At Lenzing, all measuring points can now be monitored and analyzed in real time and used for monthly energy accounting. At home in all verticals Energy-efficient production is increasingly becoming one of the decisive success factors in all verticals. The following extracts from our references shows you where our energy management systems B.Data and SIMATIC powerrate are already in successful use. Or take a look at our Reference Center sometime, where you can always find presentations of examples from dayto-day practice: siemens.com/ee-references Automobile manufacture B.Data energy management system • Plant optimization at the AUDI plant in Ingolstadt, Germany • Information distribution at General Motors Powertrain Austria GmbH in Aspern • Efficient energy management for BMW at their Regensburg plant in Germany • Managing energy data at VW Commercial Vehicles in Hannover, Germany Energy B.Data energy management system • Efficient energy planning for DONG Energy, Denmark • Energy economy database system for E.ON Wasserkraft GmbH (hydro power) in Germany • Transparent operations management at LINZ Strom GmbH (electric power) in Linz, Austria Buildings B.Data energy management system • Cost-by-cause energy billing at Mohn media Mohndruck GmbH, Gütersloh, Germany Industrial parks B.Data energy management system • Powerful energy data management at Infracor in Marl, Germany Steel B.Data energy management system • Quality assurance at voestalpine Stahl GmbH in Linz, Austria Water B.Data energy management system • Energy monitoring for Linz Service GmbH, Austria Plastics industry SIMATIC powerrate • Energy transparency at Dr. Schneider Kunststoffwerke GmbH in Kronach-Neuses, Germany • Efficient load management at Gardena Manufacturing in Heuchlingen, Germany Food and beverages SIMATIC powerrate • Load management at Bürger GmbH in Crailsheim, Germany Siemens AG Industry Sector Industry Automation P.O. Box 48 48 90026 NUREMBERG GERMANY Subject to change without prior notice 04/12 Order No.: E20001-A1100-P200-X-7600 Dispo 06303 MI.AS.EE.XXXX.52.2.02 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 de­ve­lopment 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.