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Benefits of industry networks include collaboration, knowledge sharing, standards alignment, and vendor partnerships that accelerate innovation in electrical engineering, grid modernization, smart manufacturing, and safety compliance across power systems and automation ecosystems.

What Are the Benefits of Industry Networks?

They enable faster innovation, standards compliance, risk mitigation, and scalable solutions through shared expertise.

✅ Accelerates compliance with IEEE, IEC, UL standards and codes

✅ Improves interoperability across SCADA, PLC, and smart grid systems

✅ Enables supplier benchmarking, risk sharing, and joint R&D

Modern control and business systems require open, digital communications. Industrial networks replace conventional point-to-point RS-232, RS-485, and 4-20 mA wiring between existing measurement devices and automation systems with an all-digital, 2-way communication network. Industrial networking technology offers several major improvements over existing systems. With industry-standard networks, we can select the right instrument and system for the job regardless of the control system manufacturer. Other benefits include:

To understand how device-level buses, controllers, and enterprise systems coordinate, resources like industrial automation communication outline protocol choices, latency tradeoffs, and integration patterns. Selecting between Ethernet, fieldbus, and wireless options benefits from comparing transmission methods for industrial networks with respect to determinism, noise immunity, and distance.

• Reduced wiring -- resulting in lower overall installation and maintenance costs
• Intelligent devices -- leading to higher performance and increased functionality such as advanced diagnostics
• Distributed control -- with intelligent devices providing the flexibility to apply control either centrally or distributed for improved performance and reliability
• Simplified wiring of a new installation, resulting in fewer, simpler drawings and overall reduced control system engineering costs
• Lower installation costs for wiring, marshalling, and junction boxes

Delivering these benefits also depends on choosing switches, gateways, and physical media from a well-architected set of industrial network components that match environmental and reliability requirements. Designers often map sensors, controllers, and supervisory systems across the hierarchical levels of industrial networks to balance real-time control with plantwide visibility.

Standard industrial networks offer the capability to meet the expanding needs of manufacturing operations of all sizes. As our measurement and automation system needs grow, industrial networks provide an industry-standard, open infrastructure to add new capabilities to meet increasing manufacturing and production needs. For relatively low initial investments, we can install small computer-based measurement and automation systems that are compatible with large-scale and long-term plant control and business systems. This standards-based approach aligns closely with how a building automation system aggregates HVAC, power, and security data for unified operations. For teams expanding beyond production into facilities integration, understanding what building automation entails helps frame networking requirements and data governance.

As energy costs and sustainability goals rise, leveraging advanced energy management over the same industrial network can drive measurable efficiency gains and carbon reporting accuracy.

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Energy Management Program optimizes electrical loads via SCADA, submetering, and analytics, driving energy efficiency, demand response, peak shaving, load forecasting, and power factor correction to reduce kWh, cut OPEX, and improve power quality and reliability.

What Is an Energy Management Program?

An engineered method to monitor and control electrical loads, boosting efficiency, reliability, and cutting costs.

✅ Integrates SCADA, submeters, and IoT sensors for real-time visibility

✅ Implements ISO 50001, KPIs, and M&V for continuous optimization

✅ Enables demand response, peak shaving, and power factor correction

An energy management program is increasingly important in industrial, commercial, and institutional power systems due to growing concerns about energy efficiency, costs, and environmental impact. Implementing an effective energy management program (EMP) can help businesses save money, reduce their carbon footprint, and achieve sustainability goals. This article will delve into the key components of an energy management program and discuss how it can benefit businesses in various sectors. To understand the broader scope of best practices, resources on energy management provide context for implementation across sectors.

An effective EMP typically includes energy efficiency measures, energy audits, energy conservation strategies, building automation, energy monitoring, demand response initiatives, sustainable energy policies, and the implementation of EM systems. Facility management plays a crucial role in ensuring the success of such programs. For teams new to these concepts, a concise primer on what is building automation can help align terminology and roles.

One of the primary goals of an energy management program is to increase energy efficiency. This can be achieved by identifying areas where energy is wasted and implementing measures to reduce energy consumption. For instance, energy-efficient lighting, heating, and cooling systems can significantly reduce energy usage in commercial and institutional buildings. Incorporating energy management controls enables precise scheduling and setpoint optimization for measurable savings.

Energy audits are a vital component of an EMP, as they help identify areas of energy waste and provide recommendations for improving energy efficiency. These audits involve a thorough assessment of a facility's energy consumption patterns and equipment performance, which can lead to the implementation of cost-effective energy-saving measures. Audit findings are often operationalized through energy management systems that track KPIs and verify results.

Energy conservation strategies are another crucial aspect of an energy management program. These strategies aim to minimize energy consumption without compromising operational efficiency. Examples of energy conservation measures include optimizing equipment performance, implementing energy-saving operational procedures, and promoting energy-conscious behavior among employees. Modern analytics and automation in advanced energy management support continuous improvement in conservation programs.

Building automation systems play a significant role in energy management programs by allowing for the centralized control and monitoring of various building systems, such as HVAC, lighting, and security. These systems can help optimize energy usage by automatically adjusting settings based on factors like occupancy, time of day, and weather conditions. Selecting an open-protocol building automation system improves interoperability with meters and sub-systems for broader control.

Energy monitoring is essential for tracking the effectiveness of an energy management program. By continuously measuring and analyzing energy consumption data, businesses can identify trends, pinpoint inefficiencies, and implement corrective measures to optimize energy use further. Many organizations centralize this function within building energy management systems to visualize trends and trigger alerts.

Demand response initiatives can help businesses in industrial, commercial, and institutional power systems participate in energy markets by adjusting their energy consumption in response to market signals, such as electricity price fluctuations or grid reliability issues. This can help businesses reduce energy costs and support grid stability.

Sustainable energy policies guide businesses in adopting cleaner energy sources and reducing their reliance on fossil fuels, such as oil and gas. Examples of sustainable energy sources include solar, wind, and hydroelectric power. Integrating these sources into a facility's energy mix can help reduce greenhouse gas emissions and promote long-term sustainability.

EM systems support energy management programs by providing a platform for monitoring, controlling, and optimizing energy usage across a facility. These systems can help businesses identify opportunities for energy savings, improve equipment performance, and reduce energy costs.

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Industrial automation communication connects PLCs, sensors, drives, and SCADA via protocols like PROFINET, Modbus, OPC UA, and Ethernet/IP, enabling deterministic control, interoperability, diagnostics, safety, and IIoT data across electrical systems and networks.

What Is Industrial Automation Communication?

Networked real-time data exchange between PLCs, sensors, HMIs, and SCADA using standardized industrial protocols.

✅ Supports deterministic Ethernet (TSN) and legacy fieldbus integration

✅ Enables real-time control, diagnostics, and predictive maintenance

✅ Interoperates via PROFINET, Modbus, EtherNet/IP, and OPC UA

In the early 20th century, process control systems and the manufacturing systems were designed based primarily on the mechanical technology and with analog devices. After the period, the pneumatic control technology and the hydraulic power were introduced. The pneumatic control technology made it possible to control remote systems by a centralized control system. These technologies are still very common.

At the beginning of 1960, a digital computer was for the first time really applied as a digital controller. The term direct digital control (DDC) was used to emphasize that the computer directly controls the process. In the 1960s, the application of a minicomputer was still a fairly expensive solution for many control problems. In the meantime, programmable logic controller (PLC) was developed and it replaced the conventional, relay-based controller, having relatively limited control functions. In addition, many technologies were developed for machine tools and discrete production processes. The numerically controlled (NC) machine tool became to be controlled by computers and the robot was developed in this period.

With the more widespread use of digital computers and the associated technologies, industrial communication networks became to be developed with or converted to digital transmission. Proprietary digital communication networks for industrial use started in the 1960s as computers for automation systems were first linked together.

In mid 70s, the first distributed computer control system (DCCS) was announced by Honeywell as a hierarchical control system with a large number of microprocessors. Since its introduction in mid 1970s, the concept of the DCCS spread widely in many industrial automation systems such as power plant control systems, manufacturing systems, etc. The installation of distributed control systems in the newly planned plants or replacement of existing analogue or centralized control systems is presently a common decision of enterprise management. In sectors like power generation, advanced energy management strategies leverage DCS data to optimize load balancing and maintenance planning across units.

The use of local area networks to interconnect computers and automation devices within an industrial automation system has become popular since 1980. The high capacity low cost communication offered by local area networks has made distributed computing a reality, and many automation services. The 

As deployments expanded, many organizations realized that the benefits of industrial networks include lower downtime, scalable integration, and improved data visibility across operations.

industrial automation systems are often implemented as an open distributed architecture with communication over digital communication networks. Achieving high availability requires the right mix of industrial network components such as managed switches, protocol gateways, and ruggedized edge controllers.

It is now common for users connected to a local area network to communicate with computers or automation devices on other local area networks via gateways linked by a wide area network. Similar architectures now extend into transportation, where smart city automated level crossings depend on resilient networking to coordinate sensors, barriers, and central oversight.

As the industrial automation systems becomes large and the number of automation devices increases, it has become very important for industrial automation to provide standards which make it possible to interconnect many different automation devices in a standard way. Considerable international standardization efforts have been made in the area of local area networks. The Open Systems Interconnection (OSI) standards permit any pair of automation devices to communicate reliably regardless of the manufacturer. To plan these interoperable systems, designers often reference hierarchical levels in industrial networks to align plant-floor operations with supervisory and enterprise layers.

Industrial networks span many manufacturing applications. Standard industrial networks using digital communication technologies cover a wide range of manufacturing applications. In many applications, the types of devices and performance determine the type of network. Contrast the needs of two devices -- a proximity sensor used on a conveyor belt compared to a control valve used in a petroleum refinery. The proximity sensor has a single function - to transmit a Boolean on/off signal indicating the proximity of an object. We can accommodate this signal in a few bits of data. Diagnostic information from the sensor is probably limited to a single "health" indicator, which again requires very little data. However, we can expect the control valve to provide very sophisticated control functions and diagnostics, such as number of cycles since last servicing, packing friction, and ambient operating temperature. These parameters can be extremely critical in an environment such as a refinery -- failures can result in dangerous situations and costly downtime. Clearly, the proximity sensor and the control valve have different network requirements. Therefore, different types of industrial networks must address a variety of different needs. We must select the right network to address our specific application requirements.

What is an Industrial Network? By definition, an industrial network requires geographical distribution of the physical measurement I/O and sensors or functional distribution of applications. Most industrial networks transfer bits of information serially. Serial data transfer has the advantage of requiring only a limited number of wires to exchange data between devices. With fewer wires, we can send information over greater distances. Because industrial networks work with several devices on the same line, it is easier to add a new device to existing systems. Comparing fieldbus, Ethernet, and wireless backbones, understanding transmission methods in industrial networks helps engineers match latency, bandwidth, and environmental constraints.

To make all this work, our network must define a set of rules -- a communication protocol -- to determine how information flows on the network of devices, controllers, PCs, and so on. With improved communication protocols, it is now possible to reduce the time needed for the transfer, ensure better data protection, and guarantee time synchronization, and real-time deterministic response in some applications. Industrial networks also ensure that the system sends information reliably without errors and securely between nodes on the network.

For the lower level communication network for industrial automation, the industrial local area network solutions such as MAP are too expensive and/or do not reach the required short response times, depending on the application. The fieldbuses have been, therefore, developed to meet these requirements, and many efforts are now being made to make fieldbus standards for industrial automation applications. The same field-level connectivity principles underpin a modern building automation system where HVAC, lighting, and security integrate reliably across facilities.

Read More: Hierarchical Levels in Industrial Communication Networks

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Energy management controls optimize electrical systems via building automation, IoT sensors, BMS/SCADA integration, demand response, and load-shedding to improve power quality, reduce peak demand, and enhance HVAC, lighting, and motor efficiency in industrial facilities.

What Are Energy Management Controls?

Automated systems that monitor, control, and optimize electrical loads to boost efficiency, uptime, and power quality.

✅ Integrates PLCs, BMS, and SCADA for centralized load control

✅ Implements demand response, peak shaving, and load shedding

✅ Meters energy, analyzes power quality, and optimizes setpoints

Energy management controls are conservation tools implemented to control heating, energy consumption, lighting systems, heathing ventilation and air conditioning (HVAC) systems. Modern Direct Digital Control (DDC) systems, which can accurately control building systems, have become very cost-effective in recent years. As a result, they are replacing traditional manual and electromechanical building control systems in retrofitted buildings and being installed in almost all new commercial and institutional facilities. However, maximizing energy efficiency requires strategic facility management control methods for controlling the HVAC, power and communications systems. For a deeper look at modern strategies, the overview at advanced energy management explains integration trends across HVAC and lighting.

Regardless of the technology used, deciding which energy management control mode to apply is important. It is important to understand that these modes can be implemented using many available technology types. In many cases, simple on-off control is adequate and very appropriate. In other cases, the desired effect can be on with modulating controllers. The following are basic control modes. The accompanying diagrams will illustrate typical system performance. Practical frameworks for selecting modes are discussed in energy management systems resources available to facility teams.

The term system capacitance refers to the rate of response of a system to a stimulus. Systems with a large capacitance tend to resist change, and the effects of control are felt more slowly than with systems of smaller capacitance. Comparing the effect to a flywheel or relative mass is a good way to describe this concept. Another useful example to illustrate system capacitance is an instantaneous electric water heater (small volume of water) compared to a standard residential tank-type water heater. Upon energizing the heater elements, the water temperature in the tank unit changes much more slowly because it has more mass, and we say it has greater system capacitance. Understanding capacitance helps in tuning building energy management systems for stability under variable loads.

The term gain is a control term synonymous with sensitivity and is usually an adjustable amplification value used to tune the devices. For example, if a quicker response is desired for a small input change, the gain is increased in a stronger output reaction from the controller. These parameters are typically adjusted within a centralized building automation system interface to synchronize responses across equipment.

On-off Energy Management Controls

Also called two-position control, this rudimentary mode is used with either on or off equipment. A nominal setpoint exists but is only achieved in passing. A range of control values must be tolerated to avoid short-cycling the equipment, and temperature ranges are often fairly wide. In the case of equipment that cannot be modulated, this is often the only choice. The smoothness of control depends strongly upon the system capacitance; systems with very low capacitance can experience short cycling problems using two-position control. In practice, on-off strategies often reflect principles introduced in what is building automation guidance that relates simple control to overall system behavior.

Floating Energy Management Controls

This hybrid combination of on-off and modulating control is also called incremental control. As with on-off control, there is a control range (cut-in/cut out). However, unlike on-off control, floating control systems can maintain a mid-position of the controlled device instead of being limited to full-on or full-off. The controlled device holds its last position between the cut-in and cut-out thresholds. The process variable is not under control within this range, and it floats with the load until it crosses a threshold to get another incremental nudge in the correcting direction. This control is tighter than simple on-off control, and although tight than true modulating control, it is inexpensive and reliable. Equipment items from small HVAC terminal units to 1000 HP water chiller inlet vanes are controlled in this manner with good success. Note that floating control is limited to processes that change slowly, and floating control actuators are usually selected as slow-moving. Selecting floating control as part of a broader energy management approach can reduce wear while maintaining comfort within acceptable bands.

Proportional-only Control (P)

This is the basic modulating control and what most commercial pneumatic and analog electronic systems utilize. It is an error-sensing device with an adjustable gain or amplification. A control output is issued to regulate a process, and the magnitude of the output is directly proportional to the size of the error. This type of control is economical and reliable. However, a characteristic offset (residual error) is natural with this type of controller, and the size of the offset will increase with load. This offset occurs because an error must increase (further off setpoint) before an output increase can occur.

If the proportional energy management controls are too sensitive (gain set too high), the controller’s response will be excessive, and oscillation or hunting will occur. When this occurs, the controller output (and the equipment connected) will oscillate up and down, open and closed, etc., and the control action will not settle out. Training and commissioning within an organized energy management program help operators set appropriate gains and avoid persistent hunting.

Conclusion

Automatic energy management controls are useful for basic regulation and quality control of processes and environments. They can also be leveraged for energy savings through optimization. Properly applied, these systems are reliable and cost-effective. Returning to the chapter's intent, the stated purpose of this chapter was to focus on the application of automatic system controllers as a tool to achieve energy savings. The reader should review the titles of each section, reflect on the key topics taken away, and decide if the stated objective was met. It is hoped that the reader has gained insight into how automatic energy management controls can help achieve energy goals. Therefore, they will endeavour to put these systems to work, optimizing processes and saving energy.

From: Energy Management Handbook, 7th Edition, The Fairmont Press

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PLC training courses build automation skills in ladder logic, SCADA, HMI, and motion control, with hands-on programming on Siemens and Allen-Bradley platforms, diagnostics, IEC 61131-3 standards, safety, and commissioning best practices.

What Are PLC Training Courses?

Programs teaching PLC programming, SCADA, HMI, and industrial automation with hands-on labs and commissioning.

✅ Ladder logic, function blocks, and IEC 61131-3 programming

✅ Siemens TIA Portal and Allen-Bradley RSLogix labs

✅ Fault finding, I/O wiring, safety, and commissioning

Our PLC training courses are designed to help students keep abreast of the latest PLC technologies and techniques available for industrial automation. These courses offer an excellent opportunity for students to ask specific questions and exchange ideas relating to their own applications. For context on modern plant connectivity, see the overview of industrial automation communication standards used in training.

Our PLC training courses are intended for experienced users and will give them greater knowledge of enhanced PLC functionality. Participants also review the benefits of industry networks to understand how network design impacts reliability.

We have three PLC training courses:

Before selecting a pathway, it helps to understand the hierarchical levels of industrial networks that underpin PLC architectures.

PLC Basics Training

PLC Training Basic - Our 12-Hour (2-Day) live online instructor-led industrial automation course is designed to instruct electrical control professionals on how to successfully integrate a PLCs into actual day-to-day industrial electrical processes. The course not only deals with the hardware and software, but all the surrounding systems that must be compatible to achieve a safe and reliable control system. This PLC Training Basic course is generic in nature and applies to all PLC types and manufacturers. We also examine key industrial network components so attendees can better integrate field devices.

PLC Training - Intermediate

PLC Training - Intermediate - Our 12-Hour (2-Day) live online instructor-led industrial automation course is designed to instruct electrical control professionals on how to successfully integrate a PLC into actual day-to-day industrial electrical processes. It not only deals with the hardware and software, but all the surrounding systems that must be compatible to achieve a safe and reliable control system.  The curriculum compares common transmission methods in industrial networks to guide protocol selection.

PLC Training Course - Advanced

In the advanced module, we connect control strategies to advanced energy management concepts for measurable performance gains.

Our 12-Hour (2-Day )Advanced PLC Training Course is designed to give students a basic understanding of Programmable Logic Controllers and how PLCs function. This Advanced PLC training course will not make students PLC experts but rather give them a basic understanding of the PLC, the PLC’s functionality and limitations. The PLC training seminar is generic in nature and applies to all types and manufacturers. Case studies include applications like smart city automated level crossings where safety and uptime are critical.

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Building Energy Management Systems integrate automation, efficiency, and monitoring of HVAC, lighting, and electrical loads. These systems optimize energy performance, reduce costs, and support sustainability goals for smart buildings and modern facilities.

What are Building Energy Management Systems?

Building Energy Management Systems (BEMS) are intelligent platforms that monitor, control, and optimize building energy usage for greater efficiency and sustainability.

✅ Automate HVAC, lighting, and power systems

✅ Lower operating costs through energy efficiency

✅ Support smart building and sustainability initiatives

Understanding Building Energy Management Systems

Building Energy Management Systems are crucial tools for optimizing energy use in industrial, commercial, and institutional facilities. By integrating advanced technologies such as the Internet of Things (IoT), machine learning, and predictive analytics, BEMS enable significant cost savings, improved performance, and measurable progress toward sustainability. The focus of building management systems is on long-term energy efficiency in commercial buildings, reducing consumption while enhancing comfort. Building Energy Management Systems are closely tied to advanced energy management strategies that help facilities optimize efficiency through real-time monitoring and automation.

How Building Energy Management Systems Work

A BEMS combines hardware and software components to monitor, control, and optimize energy consumption. Sensors, controllers, and actuators collect data on power usage, temperature, humidity, and occupancy. The system software utilizes algorithms and analytics to identify inefficiencies, optimize HVAC and lighting systems, and provide facility managers with actionable insights. IoT devices strengthen this process by enabling real-time communication between equipment, ensuring responsive and precise adjustments. A well-designed building automation system integrates HVAC, lighting, and power controls into a unified BEMS platform that improves performance and sustainability.

Generic BEMS Features: Comparison Table

Key Benefits of BEMS

Building Energy Management Systems improve efficiency by identifying waste and optimizing performance. Facility managers can address equipment malfunctions, poor insulation, or inefficient lighting while reducing carbon footprint. These adjustments lead to:

• Lower operating costs through reduced consumption

• Enhanced occupant comfort and productivity

• Long-term sustainability through emissions reduction

Organizations that implement energy management systems benefit from reduced costs, increased operational control, and the ability to meet regulatory requirements.

Case Studies and Industry Leaders

Global companies such as Schneider Electric, IBM, and Emerson offer BEMS platforms that demonstrate measurable returns. For example, AI-driven HVAC optimization has shown reductions of up to 15% in energy use by automatically adjusting based on occupancy and weather conditions. Real-world implementations demonstrate how BEMS not only reduce costs but also extend equipment life and enhance resilience. To achieve maximum value, facility managers often combine BEMS with specialized energy management controls that automate schedules, adapt to occupancy, and respond to changing conditions.

Standards and Certification

BEMS adoption aligns with international standards, such as ISO 50001, which provides a framework for continuous improvement in energy performance. Certification under ISO 50001 enhances credibility, helps organizations meet regulatory requirements, and supports recognition through programs like LEED and ENERGY STAR.

Best Practices for Implementation To maximize benefits, organizations should:

• Conduct comprehensive energy audits to pinpoint inefficiencies

• Set achievable energy-saving targets using benchmarking data

• Establish monitoring and verification systems for performance tracking

• Engage staff in awareness and training programs

• Update BEMS continuously as technology evolves

Sustainability goals are supported by green energy integration, allowing Building Energy Management Systems to incorporate renewable sources into daily operations.

Demand Response and Future Trends

Demand response strategies are becoming integral to BEMS. These involve adjusting consumption in response to grid fluctuations, price signals, or periods of peak demand. Automated demand response enables facilities to reduce their load without compromising comfort, often earning financial incentives and contributing to grid stability. Looking forward, artificial intelligence, predictive maintenance, and data-driven decision-making will further enhance the role of BEMS in creating smarter, more sustainable buildings. Successful deployment requires a broader energy management program that aligns strategy, technology, and staff engagement across the organization.

Building Energy Management Systems are no longer optional—they are essential for organizations seeking efficiency, cost savings, and environmental stewardship. By integrating advanced technology, following best practices, and aligning with global standards, BEMS deliver long-term value while helping to meet the urgent demand for sustainable building operations.

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