ABB’s buildings and utilities data analysis platform ABB Ability™ Building Analyzer has been installed at the company’s Stonehouse manufacturing facility in the UK, as part of a broader energy management system implementation that aims to improve energy efficiency by 20 percent relative to a 2019 baseline.
ABB Stonehouse produces flowmeters and other devices for the continuous analysis of gas and water treatment. It features a dedicated flow calibration facility, with both a large and a small flow laboratory. The facility is accredited by the United Kingdom Accreditation Service (UKAS) for flow rates ranging from 0.1 to 2,800 liters per second (0.03 to 740 US gallons per second).
ABB’s expertise in flow measurement and calibration, and in the specification, operation and maintenance of flow metering equipment at the site goes back 50 years.
ABB has pledged to the EP100 initiative with the goal of establishing an energy management system throughout its worldwide facilities by the year 2030. In 2024, two PAMA (Process Automation Measurement and Analytics) sites, in Stonehouse and Quebec, with another five planned, set precise targets to install ABB technology to help monitor, analyze, improve, and control energy efficiency, and to adopt the ISO 500011 standard.
ABB Ability™ Building Analyzer: Driven by data
The strategy at ABB Stonehouse includes the deployment of ABB Ability™ Building Analyzer as part of a broader energy management platform strategy. Building Analyzer offers comprehensive tracking of energy consumption, encompassing various points of electricity, gas, and water usage throughout the factory. The implementation of this system marked a significant step towards the goal of improving energy efficiency and sustainability and reducing operational costs on site.
The solution consists of multiple devices and systems that are connected to the Building Analyzer. The digital solution displays data from an unlimited number of data points of almost any source and type in one intuitive and easy-to-use interface – enabling personnel to monitor and analyze electricity and utility consumption in real-time and apply actionable insights to save money while improving energy efficiency, sustainability, and occupant awareness.
The following devices were added on-site:
- 29 electrical sub-meters – ABB M4M Power Meters
- Additional two M4M power meters were utilized for the overall site load monitoring to match the data provided by the utility electric meter- API connection.
- The M4M power meters are fitted in an ABB electrical cabinet, ArTu. The ABB Building Edge device is also fitted in this cabinet and connects to the M4M meters over Modbus TCP protocol. The building edge then sends the data to the Building Analyzer.
- 7 gas meters
- 1 water meter – ABB Aqua Master 4 (manufactured in Stonehouse)
- 1 utility gas meter – API connection to utility data provider
- 1 utility electric meter - API connection to utility data provider
All gas and water meters are connected to a programmable logic controller (PLC). The building edge also connects to the PLC over Modbus TCP. Following the installation of the Building Analyzer system, data began to flow in, providing valuable insights for the team. After thorough analysis, five critical areas were identified as major contributors to overall energy consumption, accounting for 47 percent of the total energy usage at ABB Stonehouse. By focusing on these high-impact areas, the team was able to drive substantial energy savings and contribute to sustainability efforts.
We wanted to make significant improvements in factory energy efficiency and agreed that having accurate data was key. ABB Ability™ Building Analyzer was straightforward to install and the interface easy to use. What surprised us was how quickly we could use the data to make step changes in energy usage. To be able to see the 15-minute usage data gives a clear indication of where and when energy is used, enabling usto make targeted changes that can be easily verified. Our actions in the first year will save 20 percent in electricity usage alone.
John Whitbread, PAMA Division Manufacturing Manager
Building Analyzer helped identify several important opportunities for improvement:
Hot water heater optimization
ABB Ability™ Building Analyzer flagged an anomaly – energy usage was consistently higher on Sundays compared with Saturdays. After investigation, it was discovered that the Sunday timer settings were identical to those on weekdays. To address this, the timer settings were reviewed and optimized for the water heater.
By optimizing the water heater’s operation, not only has energy consumption been reduced, but significant utility cost savings have been realized.
Canteen heating settings
Upon reviewing the gas heating settings, ABB Ability™ Building Analyzer indicated an inefficiency in the canteen area. Despite the canteen being unoccupied after lunch, the heating timer was set to operate until 3 pm. This extended heating period resulted in unnecessary energy consumption. The canteen’s heating timer was promptly updated to align with actual occupancy hours. Now, the heating system turns off shortly after lunch, eliminating energy wastage. Since implementing the changes, the canteen now saves approximately 10 hours of gas heating per week.
Optimizing air compressor usage
Despite no production occurring on Sundays, the air compressor was needlessly running during those hours. Thanks to data insights provided by ABB Ability™ Building Analyzer, the timer configurations for the air compressor have been adjusted to ensure that it remains inactive on Sundays, except when production demands necessitate an override. This modification is expected to lead to a considerable decrease in energy consumption when the facility is not in operation.
Large calibration pump operation
Energy usage patterns related to pump operation revealed higher energy consumption in the afternoon than in the mornings. This highlighted a lack of formal operating procedures for running the pumps, as the two operators handled the pumps differently. One adjusted the pump speed to vary the flow, while the other ran the pumps at full capacity and controlled the flow using the bypass valve.
Initial results from the late shift following corrections to the way the pump is operated indicate a reduction of 500 kilowatt-hours (kWh) per day, which extrapolated over a year, amounts to substantial savings.
By standardizing pump operation and leveraging automation, significant energy savings were achieved while maintaining optimal performance.
Christmas deep shutdown: A smart energy-saving strategy
Recognizing the opportunity to reduce energy consumption during the holiday season, a planned 10.5-day shutdown was implemented. Many devices in the ABB Stonehouse factory operate on seven-day timers. Despite the shutdown, these devices would still activate during this period, even though no one would be present. Some equipment runs continuously but is unnecessary during a shutdown. To correct this, the facilities manager manually turned off the in-scope equipment (including ovens, HVAC, water heaters, gas heating, air compressors, computers, demineralization plants, conveyors, and vending machines).
By strategically managing equipment usage during the holiday shutdown, substantial cost savings coupled with a more sustainable operation were achieved.
In addition to the primary energy-saving measures outlined above the factory implemented several supplementaryinitiatives to further reduce energy consumption.
All non-LED light fixtures were promptly replaced with energy-efficient LED fittings, not only improving lighting quality but also significantly reducing electricity usage. Furthermore, the installation of PIR (Passive Infrared) sensors in the warehouse and flat roof areas ensured that illumination was only active when needed, minimizing unnecessary energy expenditure. The cumulative effect of all the energy-saving initiatives will result in a remarkable 20 percent improvement in annual electricity consumption. This reduction translates to the equivalent energy needed to power 91 households in the United Kingdom for an entire year. Implementing these measures not only contributed to environmental sustainability at ABB Stonehouse but also significantly reduced the strain on wider energy resources.
The project at Stonehouse is just one example of how Building Analyzer is empowering operators in the UK and worldwide to take the first step on their building decarbonization journey, turning data insights into opportunities for improvement – quantified and prioritized in terms of energy consumption, carbon emissions and ROI – helping businesses and wider society on their journey to net zero.
1 ISO 50001 is a globally recognized standard issued by the International Organization for Standardization (ISO), which outlines the necessary steps to design, implement, sustain, and consistently advance an energy management system (EnMS).
2 Average annual household consumption inthe UK is 2700 kWh, source – Ofgem
