atcetera gruppe - manageENERGY

atcetera managENERGIE
Energy monitoring

ISO 50001 – ENERGY MANAGEMENT

ManagENERGY is an eligible energy monitoring system according to ISO 50001!

The energy monitoring system manageENERGY according to ISO 50001

With structured energy monitoring, you reduce costs and use resources sustainably.

With the energy monitoring system managENERGY, energy costs of electricity, steam, water and heat can be permanently reduced. Our versatile energy monitoring system managENERGY according to ISO 50001 is adapted to your needs to identify energy and process-based potentials. You get maximum transparency about your energy consumption and CO2 emissions. Transparency leads to more efficiency and more productivity. We accompany you throughout the entire optimization process for continuous cost reduction.

Energy management is the basis for efficient and careful use of environmental resources.

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Extensions of the energy monitoring system managENERGY

The extension of our existing energy monitoring system managENERGY specifies the reduction of energy demand in the production process.

Continuous processing of energy key figures enables companies to transparently monitor, analyze and optimize all energy-relevant processes. Thus, energy saving potentials can be exploited more efficiently.

Innovations of the existing energy monitoring system managENERGY

Based on the existing data structure, the following main innovations were developed:

Dashboard

On the visualization, each production section is colored according to its current energy rating in a graphical plant overview. Thus, it is visible at a glance if there is a change in SEUs in an area.

The press monitor in energy monitoring

In feed production, the pressing of the feed (pelleting) represents the process with the highest energy demand.

With the press monitor, the current energy consumption in the form of electricity and steam, the relevant machine data and thus the live energy key figures of the pressing process are continuously determined in real time and compared with historical data from the system database. The result is displayed live to the operator in the machine control system as key figures, cost factors and also as a traffic light function.

He can thus continuously adjust the machine parameters optimally during the process in order to proactively produce more energy-efficiently. This function can be transferred to other energy-intensive processes in automated production. The press monitor in particular has already been tested in several feed mills and led to a significant stabilization of the key figures during operator changes and thus also to energy savings. Several plant managers spoke of the awakened “play instinct” of the millers to produce as efficiently as possible.

The additional historical evaluation that is available also enables the mill management to react to tendential changes in the plant.

The mill monitor in energy monitoring

Grinding is another energy-intensive process in feed production.

This process is automated to the greatest possible extent. By continuously determining the relevant key figures, by means of energy measurement technology, the machine data and the historical data on the current product in the plant, predictive maintenance can be derived. Attention can be drawn to signs of wear, such as clogged filters or worn beaters, in order to prevent negative effects on the efficiency of the plant. This feature provides mill metrics that indicate the optimal time for maintenance. Phases of inefficient grinding with worn tools or too early tool changes are thus avoided.

The compressed air monitor in energy monitoring

Compressed air represents a significant cost factor in almost all industrial plants. Modern, efficient compressed air systems have already been installed in many plants. However, there is a need for clarification on the factor leakage losses and the associated cost trap “compressed air waste” due to leakage. Continuous monitoring by the energy monitoring system managENERGY can prevent this cost trap efficiently and without time-consuming searching. In adjustable intervals during the plant shutdown, the customer’s plant is pressurized in order to record the energy consumption at the compressor and the compressed air volume flow to the individual plant parts.

The following can be derived from the measurement results of our energy monitoring system:
Occurrence of a new compressed air leak
Local containment of the leak
Extrapolation of the leakage loss
Automated fault reports

The base load monitor in energy monitoring

The base load accounts for a not inconsiderable share of the energy costs. All plant components that consume energy even when the plant is inactive make up the base load. Since these plant components are in operation 24 hours a day, 7 days a week, they quickly represent a considerable cost factor. In new plants, this factor has already been minimized by modern automation. In older plants, energy consumption continues to add up to over 100 kw due to rebuilds, expansions, and only partially automated areas.

The base load monitor determines the energy consumption of all plant sections during each plant shutdown and automatically sends a report to the responsible authority.

The following can be derived from the results of the energy monitoring system managENERGY:

Energy consumption of all plant components
extrapolated costs
changes in the base load

The plant management is thus able to recognize any continuous consumption and to counteract it with appropriate measures. Misbehavior in non-automated areas can also be quickly detected and avoided by the manageENERGY energy monitoring system.

Peak load management in energy monitoring

The peak load management in manageENERGY 2.0 provides the following additional modules to the conventional systems:

a static load cut-off in stages
a grid-dependent management with configurable location-relevant blocking and free times
an interface to plant automation for process-dependent load control.

In case of need, the first area to be throttled is the one that currently has the least influence on the output of the production process. The available load window can thus be optimally utilized without having a significant negative impact on the process chain.

Alarming

Based on the realization that in production plants the focus is always on the product to be manufactured, its quality and the performance of the plant and not primarily on the energy efficiency, a comprehensive evaluation and alarm system was developed.

In the background, key figures are continuously determined from all the data obtained from the energy measurement technology, the plant control system, the ERP system and other measured variables, and compared with historical data or other dynamic limit values in order to automatically notify the defined person responsible for the relevant area if action is required. This always ensures that changes in the plant that result in a reduction in efficiency can be dealt with promptly. Faults in the measurement infrastructure are also detected and alerted immediately.

Reporting

In addition to reports that support the work of the energy management team according to ISO 50001, the main focus is on providing production with a tool to determine the optimal configuration of the individual production sections for each article.

In the production report, the energy consumption is shown for each individual batch in each individual production section, the corresponding key figures under the corresponding machine parameters. This makes it possible to show for each article under which parameters in the individual processes the highest efficiency can be achieved.

The energy cost shares of each product can thus also be determined for each part of the process chain.

Why invest in energy management?

Customized solutions

When implementing an energy management project in your company, the energy controlling system manageENERGY offers you customized solutions in conception, establishment and permanent implementation.

It takes into account existing operational systems or structures and is flexibly designed and structured so that specific requirements can be individually taken into account. The system can be expanded and upgraded at any time.

Translated with www.DeepL.com/Translator (free version)

Why energy controlling?

Automatisierte Auswertung

Zahlen und Daten werden vollautomatisch, live und jederzeit zur Verfügung gestellt. Mittels entsprechender Sensorik werden alle Daten der definierten Energie- und Materialeinsätze sowie der Prozesse zuverlässig erfasst, ausgelesen, in der Datenbank gespeichert und visualisiert.

Transparenz von Energiedaten

Die Transparenz des Energieflusses und der Produktionsprozesse sind gesichert. Sämtliche Informationen und Einzelheiten werden numerisch und graphisch aufbereitet. Sie lassen sich in Tabellen, Diagrammen und Schaubildern darstellen.

Alle Daten können präzise untereinander korreliert und mit Maschinen- und Anlageverhalten etc. verglichen werden. Genaue Analysen ermöglichen Soll-Ist Vergleiche und die Entwicklung von Kennzahlen. Mittels der Transparenz ist die exakte Anpassung von Leistungsaufnahme und Leistungsabgabe an den tatsächlichen Leistungsbedarf zu jedem Zeitpunkt möglich.

Testimonials

“For us, sustainable work processes and energy-efficient production processes have top priority. The Manage Energy energy controlling system from atcetera gruppe supports us in optimizing and expanding our innovative environmental policy. A sensible investment for anyone who wants to uncover energy saving potential in their company.”

Volker Ollmann Process optimizer and energy manager ATR Futtermittel–ATR Landhandel GmbH & Co. KG

“Our guiding principles in the area of environmental protection are environmentally oriented and forward-looking action and energy-efficient production conditions. In this context, our innovative corporate management attaches great importance to environmentally friendly and responsible work. The establishment of the eligible energy controlling system Manage Energy of the atcetera group supports us in continuously developing and optimizing our production processes in line with our environmental policy.”

Daniel EibischMaintenance & Project Manager–Radsystem GmbH

atcetera managENERGIE