5 energy monitoring systems you must know

Hey, are you reducing the cost of energy at your plant and in your home? Let’s have a talk about energy consumption and how you can save money in your plant. Maybe in the near future, I can bring you solutions for your home as well.

We have plenty of articles related to energy management, so you can find content on the basics and examples of solutions for your processes. We all need to think about energy and how it relates to the Internet of Things (IoT), Industrial Internet of Things (IIoT), and Industry 4.0. So most companies have begun adding energy concepts to their IIoT solutions.

IoT, IIoT, and Industry 4.0

We could have navel-gazing chats about these concepts for the next decade, and some of us will. Fortunately, vendors want to make money, so they act instead of just talking. Some companies provide remote solutions, where their experts analyze your data to send relevant reports. Others offer platforms with clear dashboards to help you develop your own reports and insights.

These solutions tackle issues such as energy monitoring system, process improvement, and condition monitoring with a variety of methods. Some use the control system to monitor and analyze the process energy, and others use gateways to send data to the cloud or platform, bypassing the control system altogether.

As with anything, these systems have their pros and cons. I like solutions that run outside the control system rather than through it. With remote access, you can focus on the data related to the specific application, instead of getting everything. Plus, you can limit access to reduce security issues.

Below, I created a list of outstanding solutions in different fields. Here you’ll see traditional systems from ABB, Eaton, and Endress+Hauser. Beyond that, you’ll find companies such as Emerson and Beckhoff using clouds and remote access. Take a look to get some ideas – and possibly solutions – for your process.

Gas optimization – ABB

ABB’s cpmPlus Energy Manager offers a flexible and complete system, with three modules for energy monitoring system. The first conducts energy efficiency monitoring and gives you a visual report to find the areas in your process that need improvement.

energy monitoring
Courtesy of ABB

The second calculates the predicted energy use and sends plans for the energy supply. The last gives you all your data for your energy demand and supply.

ABB has a white paper with information on how the cpmPlus can improve efficiency in the iron and steel industry. Although it explains how the system can improve your process, it reads a bit like a sales pitch. Still, it gives details about the economic flow network, the dashboard, and other features.

Learn more about ABB energy solutions with the video below:

And check out ABB’s specs and details on the cpmPlus here.

Electrical monitoring – EATON

EATON’s package can help you develop an energy monitoring system plan for your plant. It starts from strategy and planning and goes all the way through continuous improvement.

energy monitoring
Courtesy of EATON

It too has three levels. The entry-level system is a low-cost solution made up of metering devices, gateways, and web solutions. The second level can identify power anomalies in your system such as voltage or current distortion, harmonics, and more.

Finally, you can add an advanced power quality level that includes web tools and graphics. This level allows you to capture waveforms, trend data, and more. All the data for these levels can combine into a visual report.

Here you can see how the web interface works:

You can read more about the EATON solution here.

 Wastewater treatment – Endress+Hauser

Endress+Hauser also has packages for different applications, although the company takes a traditional route, with no cloud to run the functions. All gathered data goes through a 3G connection to Endress+Hauser’s management service and the local plant operator.

For example, the Liquicontrol CDC80 uses field devices to measure oxygen, nitrate, flow and more in wastewater treatment, with a focus on energy and cost savings. This system provides automatic control through an integrated engineering panel.

energy monitoring
Courtesy of Endress+Hauser

It monitors and maintains stages such as nutrient breakdown, phosphate elimination, and process reliability. It also offers seamless integration and remote monitoring by Endress+Hauser specialists.

Check out this video for more:

If you want to learn more about Endress+Hauser’s wastewater management, click here.

Steam monitoring – Emerson Automation Solutions

Emerson has a clear strategy for IIoT, with energy as only one piece of the solution and this steam system as a good example. A transmitter monitors the steam traps and sends all its data through a 3G network to a Microsoft Azure cloud, which creates performance reports. Emerson’s experts can remotely analyze all the data and provide a complete report as well.

The devices run wirelessly in the field on wirelessHART with a MESH network, which requires less structure than a cable solution. Emerson also employs IIoT service, with a good example of this concept in Denka Singapore.

energy monitoring
Courtesy of Denka and Emerson

Denka spent nothing on the structure and devices; Emerson installed it all, and Denka Singapore pays a monthly fee for the service. This model has 148 devices on a 3G mobile network, Microsoft Azure cloud server, and SteamLogic software. According to Ng Hock Cheong, the maintenance manager of Denka Singapore, it has already reduced steam use by seven percent.

Watch the video for more about the Denka’s solution from Emerson:

You can read more about this success case here.

Energy optimization – Beckhoff

At Hannover Messe 2017, we had a chat with the reps from Beckhoff. Better still, we could see Beckhoff’s Azure-based system and learn more about how it works.

So we found out that it collects and analyzes data from your process through its TwinCAT analytics. You can also get predictive maintenance, machine optimization, and condition analysis.

energy monitoring
Courtesy of Visaya Solutions

You can connect the field devices through the EK9160, an IoT bus coupler certified by Microsoft Azure. It doesn’t need a control program, finding its parameters through a web server that you can access with any browser. You can also use the IoT controller, giving you more ability to use your data.

It all goes into the Azure Ecoystem through OPC UA over advanced message queuing protocol (AMQP) or MQ telemetry transport (MQTT) protocol. Then, within Azure, you get options such as IoT data agents or analytics loggers and workbenches.

Watch this video for more about Beckhoff’s solution:

You can also check out more on Beckhoff here.


So if you need an energy monitoring system, then you can find a  solution to fit you, from Emerson’s steam traps to Endress+Hauser’s wastewater treatment and beyond. Best of all, these systems can apply in various processes throughout your plant.

Save energy!

energy monitoring
Courtesy of Giphy
Reference articles
– Sounding Out an IIoT Application in Asia

Someone in this list may have your next energy monitoring system:

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