Options for Energy Optimization

Options for Energy Optimization

The case for energy optimization is clear: Energy savings are cost savings, energy efficiencies create process efficiencies, and energy reductions cause emission reductions. It is a win-win for all stakeholders. Fortunately, industrial OEMs who are exploring optimization have numerous best-practice opportunities to choose from, all of which are continuously improving thanks to new innovations and unprecedented capabilities made possible by the industrial internet of things (IIoT).

To maximize the return on your efficiency investments, conduct a formal or informal energy survey to learn which assets consume the most energy. Work toward the priorities, but also raise this question whenever a design, rebuild, upgrade, replacement, or capital investment decision is made: How will this affect my energy consumption?

Following are several example technologies and practices that promote electricity optimization. Any combination of these can help to transform a plant’s energy footprint.

Efficient Machine Designs

Electric industrial machines such as motors, pumps, fans, and compressors are rife for energy management. Design and engineering improvements have these machines running cooler and more efficiently than before. For example, replacing inefficient motors with those rated IE3 (premium efficiency) or IE4 (super premium efficiency) can not only slash energy consumption, but they also require less maintenance and have a longer life.

Compressed air system designs are improving to reduce air leaks, heat loss, pressure drops, and utility costs. Flow controller and pressure regulators store compressed air for later distribution. Heat recovery units recover wasted heat and use it for other productive purposes such as heating air or water. Smart wireless sensors enable remote monitoring and predictive maintenance (PdM) to keep the systems operating at peak performance.

Effective Motor ControlsOptions for Energy Optimization motor control

Variable speed drives (VSD) and variable frequency drives (VFD) control the speed of a motor throughout its start, run, and stop cycles. The speed adjusts to the required load instead of always running at full capacity. Running applications at slower speeds significantly lowers energy consumption, and even small reductions in fan, pump, or motor speed can produce sizeable energy savings. Advanced features such as adaptive tuning, permanent magnet motor control, and wireless diagnostics extend the benefits of the drive.

Soft starters are available for equipment where soft starts are necessary but variable speed control is not. Soft starters gradually turn on a power supply to prevent electrical and mechanical strain on equipment from sudden surges or currents. Lowering the peak current required at startup significantly reduces heat buildup. It also helps to avoid spikes in energy consumption caused when plants turn on multiple machines and lights all at once, which can unintentionally trigger peak utility rate charges.

Motor control contactors are available for switching electrical loads, bypassing loads, isolating loads, or switching resistive loads. Compact IEC and NEMA contactors can be used to build smaller energy-efficient panels and enclosures. Contactors with a universal coil can control multiple voltages and operate the same application with a smaller power supply.

Overload relays protect motors against overload as well as conditions such as phase failure and asymmetry, and they can significantly reduce intrinsic power loss. Cloud-connected overload relays enable centralized monitoring and diagnostics for proactive troubleshooting and power optimization.

Power meters measure and transmit power usage in real time. Handheld alternatives include voltmeters for measuring the voltage between two points in an electric circuit, and ammeters (or amp meters) for measuring current in a circuit in amperes. Active power consumption monitoring brings to light conditions requiring attention.

Predictable Power Delivery

Electric power control and quality management devices are many and varied. Uninterruptible power supplies (UPS), surge protectors, power distribution units (PDU), power conditioners, switchgear, circuit breakers, network transient protectors, overcurrent protection devices – each of these plays a role in ensuring reliable, predictable, efficient electrical operation.

Purpose-built Management Systems

Energy management systems with their automated reporting and alerts help to monitor and trend the energy usage of equipment and the plant, show which assets use the most energy, manage power quality and controls, and optimize consumption and efficiency across the plant. For example, providing the ability to monitor and manage peak loads and minimize operations during peak times supports the renegotiation of utility contract rates based on actual energy usage.

Building management systems connect every corner of the plant – from the factory floor and warehouse to the lunchroom and back offices – so that all environments can be centrally managed and optimized. Heating, ventilation and air conditioning (HVAC), lighting, security systems, power systems, fire systems, and access control systems, can all be centrally, intelligently monitored and managed, and issues can be detected and corrected proactively.

Advanced Facility StrategiesOptions for Energy Optimization solar power

Lighting controls automate which lights turn on, and when, based on factors such as occupancy detection, sunlight detection, and integrated scheduling. Swapping incandescent and compact fluorescent lamps with light-emitting diode (LED) lighting also delivers significant and lasting energy efficiencies.

Smart HVAC controls use precision sensors to align the system’s operation with the room’s occupancy and activity, ensuring comfort for the occupants and suitable environmental conditions for the machines.

Thermal or infrared (IR) cameras and systems reveal vulnerabilities in the building envelope such as energy loss from poor insulation or a leaking roof. Indoors, they are effective for detecting conditions such as abnormal heating in an electrical cabinet.

Solar panels and solar power (or photovoltaic) systems have a growing presence at industrial plants. As with other renewable energy sources, solar panels and their balance-of-system components provide an inexpensive alternative or supplement to electricity from fossil fuels. Besides lowering utility bills and emissions, excess electricity can be sold back to the electric grid or stored on batteries for later usage.

Maintenance Best Practices

Several condition monitoring technologies are available for improving asset reliability, performance, and uptime. Whether using smart sensors for online, continuous condition monitoring, or handheld condition data collection tools, detecting early signs of degradation provides time to perform PdM or prescriptive maintenance (RxM) before the asset fails. Vibration analysis, ultrasonic inspections, oil analysis, wear particle analysis, thermal imaging, motor circuit analysis, and multi-sensing solutions are some of the more prominent options.

Many additional options are available, but one thing is clear: The scope, prevalence, and pace of solution innovation reflect the intensity of demand for energy optimization, and there are no signs of it waning.

How helpful was this article? Click a star to rate.
[5 votes so far. Average rating of 4.6]

LEAVE A REPLY

Please enter your comment!
Please enter your name here