Redefining industrial operations KPIs for more energy savings

In the past, there has been a strong focus on motors and variable speed drives solutions intended to reduce energy consumption. These types of measures often address a few high energy consumers in a plant.

Today, industries have process control systems to control and supervise the main process as well as different utility systems including air, steam and cooling/heating water. In addition, many sites most often operate a substation automation system where electrical energy is controlled and measured. There are great opportunities for industries to further cut their electricity costs and boost their competitiveness by measuring and analyzing the energy flow of the whole plant, and implementing Energy Management programs that focus on continuous improvements over time.

ABB Ability™ System 800xA creates a platform where energy related data is measured, logged and can be analyzed. This gives an understanding of the electrical energy flows and load situations and also allows for the identification of equipment that does not need to be running. Monitoring the quality of the electrical power saves equipment wear and ensures compliance with grid contracts. Additionally, integration with low and medium voltage enables internal plant energy billing - a growing trend seen on larger industry sites.

An integrated system enables operators to understand and easily access power usage. New energy saving opportunities can be explored, while existing energy reduction programs can be enhanced. For example, an increase in power consumption by a unit or an area can indicate equipment malfunction and wear. ARC believes that in many cases, the potential energy savings can equal 10% of the total consumption.

The process draws what power it needs according to operational setpoints from the process automation system, while the electrical control system strives to meet those requirements in a safe, reliable way. This makes electrical energy the most important input to process manufacturing operations after raw materials.

The importance of energy as a process input has redefined the industrial operations’ key performance indicators (KPIs) in terms of unit energy consumption, rather than overall production rate: in tons of product per kWh rather than in tons of product per day or year. This KPI has a more direct correlation with plant profitability than does overall production rate. Energy consumption visibility, enabled by the integrated approach of System 800xA Electrical Control, is making this possible.

Every process industry has a substation that provides the necessary energy. ABB Ability System 800xA Electrical Control monitors and controls the substations in an industrial facility and ensures full availability with real-time applications. Users can control a process, manage a field crew and deliver outstanding operational efficiency with a single system.

ABB Ability System 800xA supports all major communication protocols which allows several ways to integrate both power distribution switchgear and intelligent low voltage equipment. More accurate and effective operations and monitoring of equipment like motors, drives, switchgear contributes to savings on energy costs.

800xA Personalized Workplace concept gives plant owners a dedicated workplace with one single view to analyze the plant electrical energy flows and, more importantly, work on potential solutions for energy savings.

ABB also offers the Energy Monitor app - a modern software system solution developed for industrial use in energy intensive industries according to DIN EN ISO 50001.