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Scalable energy management with SIMATIC

Taking steps to maximize energy efficiency

Taking steps to maximize energy efficiency

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 mon-itoring and progressing to a comprehensive energy man-agement 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 indi-vidual loads and machines and progressing to a compre-hensive energy management system embracing the entire plant and/or company.

The energy management process at a glance

Energy management scaled to suit your needs

Perfection by combination

Thanks to the ease with which B.Data can be combined with SIMATIC powerrate, it is possible to build a fully inte-grated energy management system across all levels, offer-ing outstanding functionality and thus maximum trans-parency. 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 question facing the industrial manufacturing sector is no longer

“Do I need an energy management system?”, but rather “Which one should

I choose?”. Systematic energy management plays a decisive role in ensuring

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.

according to ISO 50001

EvaluateIden

tify

En

ergy efficiency consulting

Implement

The ideal starting point: Energy monitoring at machine level

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 moni-toring 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).

Configuration 1: Compact, low-cost entry-level solution which clearly displays the energy and power requirements of a machine and its loads (energy monitoring)

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.

HMI device e.g. Basic or Comfort Panel

Ethernet

Further devices ...PAC power monitoring device

Electrical / non-electrical energy

The ideal starting point: Energy monitoring at machine level

Simply more transparent: Energy management at visualization / control system level

Our SIMATIC WinCC SCADA software is an innovative and scalable process visualization system that features numer-ous functions for monitoring automated processes. It provides the platform for an equally low-cost entry-level system for energy monitoring on an industrial PC. Con-figuration does not require a subordinate control system and is capable of expansion.

More options available

You can also utilize all plant intelligence options inte-grated in the WinCC system for the purpose of energy management. These include, for example, the Downtime-Monitor 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.

Configuration 2: Low-cost entry-level solution for energy monitor-ing via the SCADA system. Capable of expansion by SCADA system options which are also suitable for energy management

SIMATIC IPC control or visualization system with SIMATIC WinCC, e.g. IPC547D

Ethernet

Further devices ...PAC power monitoring device

Electrical / non-electrical energy

Simply more transparent: Energy management at visualization / control system level

Machine-oriented: Integrated solution for energy management and control tasks

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 manufac-turing 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.

Configuration 3: Compact, machine-oriented energy management system for combining control system and energy management func-tions, for example, the correlation of production and energy data at the machine or process interventions based on energy consumption

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 require-ments, 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.

Further devices ...PAC power monitoring device

Electrical / non-electrical energy

Ethernet

HMI device, e.g. Comfort Panel

SIMATIC S7-315, -317, -319, ... S7-1200

Machine-oriented: Integrated solution for energy management and control tasks

SIMATIC powerrate: for capping power peaks and cutting energy costs

The SIMATIC powerrate option package offers comprehen- sive energy management functionality. It is available for the SIMATIC WinCC SCADA visualization system and for the SIMATIC PCS 7 process control system. It scales, vi- sualizes 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 corre-sponding 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 analy-sis 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 compli-ance with defined purchase limits. Under ideal conditions, this means that energy costs can be reduced. Devices supplied by other manufacturers can be inte-grated 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.

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.

SIMATIC IPC control or visualization system, e.g. IPC547D with SIMATIC WinCC / PCS 7, + powerrate

Ethernet

PROFINET

Third-party manufac-

turer

PROFIBUS DP

Circuit breaker Further devices ...PAC power mo n- itoring device

Frequency converter

SIMATIC S7-317, -319, S7-4xx + powerrate

TCP/IP

Electrical / non-electrical energy

B.Data: The management system for a transparent energy balance

Maximum energy data transparency is a key benefit of deploying the B.Data energy management system at com-pany level. B.Data provides a platform for optimized, cost-effective 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 effi-ciently. 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, com-parison reports and modeling for purchasing optimization, and even emission reports.

Manage your energy – using B.Data

Another highlight of this system is its modeling function-ality. 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 avail-able from your energy supplier.

Configuration 5: The B.Data energy management solution provides the greatest possible clarity as regards energy data, as well as func-tions for computing key indicators, planning and predicting energy consumption, as well as interfaces to the ERP system.

B.Data Web client

B.Data client

B.Data server

Other sources, e.g. CSV, ODBC, OPC, ...

PAC power moni- toring device

SCADA / DCS Energy management system WinCC,

PCS 7 or other

Electrical / non-electrical energy

PROFINET

Internet/ Intranet

Energy management

The information provided in this brochure contains me re ly general descrip-tions or characteristics of per for m ance which in case of ac tual use do not always ap ply as described or which may change as a result of fur ther de vel-opment of the pro ducts. An obligation to provide the respective character-istics shall only exist if ex pressly agreed in the terms of contract. All product designations may be trademarks or product na mes of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

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

Siemens AG Industry Sector Industry Automation P.O. Box 48 48 90026 NÜRNBERG GERMANY