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Industrial network components enable reliable Ethernet, fieldbus, and IIoT connectivity across PLCs, HMIs, drives, and sensors, using managed switches, routers, protocol gateways, and cybersecurity firewalls for real-time control, redundancy, and deterministic data.

What Are Industrial Network Components?

Hardware like switches, routers, gateways, and I/O modules that link PLCs and sensors for secure, deterministic control.

✅ Managed Ethernet switches enforce VLANs, QoS, and ring redundancy

✅ Gateways bridge Modbus, PROFIBUS, and PROFINET protocols

✅ Industrial routers add VPN, firewall, and IEC 62443 security

Industrial Network Components

In larger industrial and factory networks, a single cable is not enough to connect all the network nodes together. We must define network topologies and design networks to provide isolation and meet performance requirements. In many cases, because applications must communicate across dissimilar networks, we need additional network equipment. The following are various types of network components and topologies:

For an overview of how devices exchange data across varied protocols, see the guide on industrial automation communication best practices for plant networks.

• Repeaters -- a repeater, or amplifier, is a device that enhances electrical signals so they can travel greater distances between nodes. With this device, we can connect a larger number of nodes to the network. In addition, we can adapt different physical media to each other, such as coaxial cable to an optical fiber.
• Router -- a router switches the communication packets between different network segments, defining the path.
• Bridge -- with a bridge, the connection between two different network sections can have different electrical characteristics and protocols. A bridge can join two dissimilar networks and applications can distribute information across them.
• Gateway -- a gateway, similar to a bridge, provides interoperability between buses of different types and protocols, and applications can communicate through the gateway.

In planning placement of routers, bridges, and gateways, it's useful to map the hierarchical levels of industrial networks across field, control, and enterprise layers.

Network Topology

Industrial systems usually consist of two or more devices. As industrial systems get larger, we must consider the topology of the network. The most common network topologies are the bus, star, or a hybrid network that combines both. Three principal topologies are employed for industrial communication networks: star, bus, and ring as shown in Figure 3. Understanding media choices and signaling options is essential, and the overview of transmission methods for industrial networks explains tradeoffs between copper, fiber, and wireless.

A star configuration contains a central controller, to which all nodes are directly connected. This allows easy connection for small networks, but additional controllers must be added once a maximum number of nodes are reached. The failure of a node in a star configuration does not affect other nodes. The star topology has a central hub and one or more network segment connections that radiate from the central hub. With the star topology, we can easily add further nodes without interrupting the network. Another benefit is that failure of one device does not impair communications between any other devices in the network; however, failure of the central hub causes the entire network to fail. These design choices tie directly to the benefits of industrial networks that improve scalability and resilience.

In the bus topology, each node is directly attached to a common communication channel. Messages transmitted on the bus are received by every node. If a node fails, the rest of the network continues in operation as long as the failed node does not affect the media. This shared medium approach is often integrated under a facility's building automation system where distributed controllers share status and control signals.

In the ring topology, the cable forms a loop and the nodes are attached at intervals around the loop. Messages are transmitted around the ring passing the nodes attached to it. If a single node fails, the entire network could stop unless a recovery mechanism is not implemented.

In transportation settings like automated level crossings environments, deterministic performance and failover are crucial for safety.

For most networks used for industrial applications, we can use hybrid combinations of both the bus and star topologies to create larger networks consisting of hundreds, even thousands of devices. We can configure many popular industrial networks such as Ethernet, FOUNDATION Fieldbus, DeviceNet, Profibus, and CAN using hybrid bus and star topologies depending on application requirements. Hybrid networks offer advantages and disadvantages of both the bus and star topologies. We can configure them so failure of one device does not put the other devices out of service. We can also add to the network without impacting other nodes in the network. Hybrid architectures also support advanced energy management strategies that balance load and reduce downtime during maintenance.

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Energy Management Systems (EMS) enhance energy efficiency, reduce costs, and promote sustainability by monitoring, controlling, and analyzing energy use in buildings, enabling smarter resource allocation and a reduction in carbon footprint.

What are Energy Management Systems?

Energy Management Systems (EMS) are integrated platforms that monitor, control, and optimize energy consumption in facilities to enhance efficiency, promote sustainability, and achieve cost savings.

✅ Monitor and control energy use in real time

✅ Enhance efficiency, sustainability, and cost reduction

✅ Support compliance, reporting, and renewable integration

Energy management systems transform how we manage and consume electricity in industrial, commercial, and institutional power systems. By incorporating energy efficiency, building automation, smart grid technology, demand response, power monitoring, conservation, HVAC control, power optimization, renewable energy integration, and analytics, EMS offer a comprehensive EM for a more sustainable future.

By adopting Energy Management Systems, organizations can effectively manage consumption across their facilities, tracking energy usage in real-time to uncover opportunities for energy savings. This not only lowers operational costs but also reduces carbon emissions, supporting both financial performance and environmental responsibility.

Key Components of EMS

At the core of EMS systems are key components that work together to improve efficiency. These components include sensors, controllers, actuators, and communication networks that gather real-time data from various energy-consuming devices. This data is then analyzed to optimize the system's performance, ensuring cost-effective electricity use and minimal waste.

Energy Management Systems Overview

Building Automation and Efficiency

One of the primary ways energy management systems improve efficiency is through building automation. Building managers can monitor and control various aspects of their facility's electricity usage by integrating different systems such as lighting, heating, ventilation, and air conditioning (HVAC) control. This level of control enables them to make informed decisions, reducing power consumption while maintaining a comfortable and productive environment.

Smart Grids and Renewable Integration

Energy management systems also play a significant role in developing and implementing smart grids. These grids use advanced communication technologies and IoT devices to connect renewable energy sources, such as solar panels and wind turbines, with the electric utility. As a result, power supply and demand can be better balanced, leading to more efficient and reliable electricity distribution.

Demand Response and Conservation

Demand response is another crucial aspect of Energy Management Systems, allowing consumers to adjust their consumption based on real-time information from the electric grid. By participating in demand response programs, consumers can reduce their energy consumption during peak hours and benefit from lower costs.

Power conservation is a primary goal of energy management systems, which achieve this through various strategies, including efficient HVAC control, lighting optimization, and equipment scheduling. In addition, businesses and homeowners can significantly reduce their overall power usage by ensuring that power-consuming devices are used only when necessary.

Power optimization is a crucial aspect of EMS, achieved through the ongoing analysis of consumption patterns and equipment performance. Advanced power analytics tools can identify inefficiencies and recommend actions to maximize savings. These insights can help building managers create power-saving strategies, such as adjusting temperature set points, optimizing lighting controls, and scheduling equipment use.

One of the most exciting aspects of energy management systems is their seamless integration of renewable energy sources. By incorporating solar panels, wind turbines, and other clean power technologies, EMS can help businesses and homeowners reduce their reliance on fossil fuels and lower their carbon footprint.

The Role of IoT and AI

The role of IoT and AI in energy management systems is crucial, as they enable remote monitoring, real-time data analysis, and predictive maintenance. By utilizing IoT devices to collect data and AI algorithms to analyze it, EMS can identify inefficiencies and predict equipment failures, thereby ensuring optimal system performance.

By adopting EMS, businesses and homeowners can save money on their power bills and reduce their environmental impact. In addition, by optimizing power use, reducing waste, and integrating renewable energy sources, EMS leads to cost savings and contributes to the global effort to combat climate change.

Future Trends in EMS

The field of energy management systems is constantly evolving, with new trends and innovations emerging regularly. These innovations include integrating energy storage solutions, microgrids, and machine learning algorithms for even more precise power optimization.

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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.

Understanding the Role of Energy Management Controls in Power Systems

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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Advanced energy management integrates smart grid analytics, demand response, and SCADA/IoT sensors to optimize loads, enable peak shaving, enhance power quality, and coordinate renewables, storage, and microgrids for efficient, resilient electrical systems.

How Advanced Energy Management Works

Advanced energy management systems involve control systems and processes. Control systems can be as simple as a residential thermostat, to very complex computer controlled systems for multiple buildings, to industrial process control. Their diligence and repeatability can also serve to maintain the savings of project improvements for years, further justifying their existence by providing economic return to the customer. Advanced energy management systems include control technology and control mode categories, basic input and output instrumentation, and the practical need to temper “things possible” with the skill level of the operators who will inherit it. The importance of advanced energy management system controllability and user-friendliness as primary design parameters will be stressed. Industry overviews of energy management systems highlight common architectures and integration paths useful during early design.

The following is a very important first statement before any discussion about control hardware: “The type of advanced energy management systems hardware used in optimization is less important than the understanding of the process and of the control concepts that are to be implemented.” The main goal should be to become clear about the process fundamentals and what should happen—then the parts and pieces are just details. This discussion of different available hardware types is a familiar but sometimes laborious and dull part of any controls text. Remember that automatic controls are really nothing more than machines that do for us what we would do ourselves if we had nothing better to do; they do work for us like any other tool, and they are only as clever as the people who craft them. As a complement, primers on energy management controls summarize control modes and device families that support these concepts.

The field of automatic control in advanced energy management systems is similar in that we continually adjust some device to cause a particular measured variable to remain at a desired state. In facilities practice, deploying a building automation system provides the supervisory layer that implements such setpoint maintenance and scheduling.

Examples:

• The need to throttle heating and cooling equipment sized for maximum load that is effectively over-sized at part load conditions. Within building energy management systems these strategies are automated through reset logic and variable speed control for stable part-load operation.

• Varying occupancy, and systems attendant to the occupants (lighting, ventilation). Guides on energy management emphasize occupancy-based control sequences that tie lighting and ventilation to real-time demand.

• Varying product throughput rate through manufacturing facilities. Establishing an enterprise energy management program helps align throughput-driven process controls with measurable performance targets.

• Varying demands, and the need to maintain level or full state for water or fuel reservoirs, feed or coal bins, etc.

• Coordination: Organizing or sequencing multiple processes in a logical and efficient manner is an important aspect of automatic control applications.

• Automation: Human beings can make very good manual controllers because we can think on our feet and consider many variables together, but most control tasks are repetitive and suitable for mechanization. Introductory references explaining what building automation is clarify how routine tasks are delegated to algorithms while operators focus on exceptions.

Automatic operation allows people to provide oversight of advanced energy management system operations and more effectively utilize their time.

• Consistency: Manual control by people can be effective, although we are not all that repeatable and are sometimes forgetful. Using machinery for automatic control adds the improvement of consistent, repeatable operations. The repeatability and consistency feature of automatic control is very important in manufacturing.

• Conservation: Supplemental enhancement control routines can be incorporated to reduce energy use while still maintaining good control. It is important to note that control systems do not necessarily reduce energy consumption unless specifically applied and designed for that purpose.

Advanced energy management automatic 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 energy management systems are reliable and cost effective.

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

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What is building automation? An integrated BAS/BMS using sensors, PLCs, and SCADA to control HVAC, lighting, power distribution, VFDs, and safety systems, improving energy management, demand response, monitoring, reliability, and analytics.

What Is Building Automation?

A BAS/BMS that controls electrical systems for efficiency, safety, and performance.

✅ Controls HVAC, lighting, and power via PLCs, sensors, and actuators

✅ Enables energy management, demand response, and load shedding

✅ Integrates SCADA, metering, and VFDs for reliability and safety

What is Building Automation?

Building automation is crucial in creating sustainable, efficient, and comfortable living and working environments. By incorporating advanced technologies like IoT and data analytics, building automation systems can optimize energy consumption, enhance occupant comfort, and promote cost-effective building management. As technology continues to evolve, building automation's potential benefits and applications are set to expand further, making it an essential aspect of modern building design and operation. For foundational context on how organizations plan, monitor, and optimize consumption, consult this energy management primer that aligns with modern building objectives.

Building automation refers to the centralized building control system for various systems, such as heating, ventilation, air conditioning (HVAC), lighting, security systems, and other related subsystems. The main objective of a building automation system (BAS) is to optimize energy consumption, enhance the comfort of occupants, and ensure that the building operates efficiently and cost-effectively. A concise primer on system architectures and typical functions is provided in the building automation system overview, which clarifies scope and capabilities.

A BAS comprises interconnected components and subsystems, including sensors, controllers, and user interfaces. Sensors measure temperature, humidity, and occupancy, while controllers use this information to regulate various building systems, such as air conditioning and lighting. User interfaces enable facility managers and authorized personnel to monitor and adjust system settings as needed. To understand how setpoints, scheduling, and feedback loops are orchestrated, explore energy management controls guidance that illustrates controller strategies.

One of the primary benefits of building automation is its ability to reduce energy consumption and enhance energy efficiency for building owners. A BAS can optimize energy usage and minimize waste by continuously monitoring and adjusting building systems based on real-time data. For example, automated control of lighting and HVAC systems can help maintain optimal temperature and lighting levels while conserving energy when spaces are unoccupied. This leads to lower utility bills and a reduced carbon footprint. These practices are often formalized within building energy management systems frameworks that standardize analytics and reporting.

Building automation also promotes cost-effective building management system by reducing maintenance and operational costs. A well-designed BAS can detect and address potential issues before they escalate into expensive problems, allowing facility managers to maintain building systems and extend their life expectancy proactively. Additionally, building automation control can help maximize the productivity and comfort of building occupants by maintaining a consistent and pleasant indoor environment. When aligned with enterprise objectives, broader energy management systems can integrate with BAS workflows to coordinate maintenance and savings.

The Internet of Things (IoT) plays a significant role in the development and advancement of building automation. IoT output devices and sensors provide a wealth of real-time data that can be analyzed and leveraged to enhance building performance further. This integration allows for more precise control and monitoring of building systems and the developing of new, innovative energy management and conservation solutions. This data-driven approach enables advanced energy management techniques that support predictive control and optimization.

What is Building Automation?

Building automation is also closely linked to facility management, as both disciplines aim to optimize the operation and maintenance of building systems. By integrating building automation with facility management software, facility managers can monitor and control various building systems more effectively, streamline maintenance tasks, and make data-driven decisions to optimize building performance. Interoperability relies on reliable industrial automation communication methods that allow platforms to share telemetry securely.

The future of building automation technology holds exciting possibilities, including the development of increasingly intelligent and interconnected systems. In addition, advances in artificial intelligence, machine learning, and data analytics will enable BAS to become even more efficient and responsive to changing conditions, resulting in greater energy savings and reduced environmental impact.

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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.

Energy Management Program Fundamentals

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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