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Energy Management

Energy management enhances power systems via smart grid controls, demand response, load forecasting, SCADA, and IoT sensors to improve energy efficiency, peak shaving, power quality, and renewable integration across industrial and utility operations.

 

What Is Energy Management?

Energy management is the control of electrical loads and assets to optimize efficiency, reliability and cost.

✅ Predictive load forecasting and peak shaving strategies

✅ SCADA/EMS integration with IoT sensors and analytics

✅ Demand response, power quality, and DER coordination

 

Energy management (EM) is a crucial practice today, as it helps businesses and individuals reduce their carbon footprint, save money, and contribute to a more sustainable future. By incorporating key elements such as efficiency, demand response, building automation, audits, smart grid technology, HVAC optimization, conservation, renewable energy, monitoring, and analytics, a comprehensive EM program can lead to significant savings and environmental benefits. As the world continues to face the challenges of climate change and dwindling resources, EM will remain an indispensable tool for creating a more sustainable and efficient future. For organizations starting out, an energy management program can provide a structured roadmap for setting goals and tracking performance.

Energy management is crucial for several reasons. First, it helps reduce carbon emissions and the overall environmental impact of energy use. Second, it saves money by lowering costs and making facilities more energy efficient. Third, EM practices contribute to businesses and organizations' long-term sustainability and competitiveness. Modern energy management systems offer centralized dashboards and automated alerts that help sustain these gains over time.

Building automation is one of the primary ways energy management systems improve efficiency in buildings. These systems utilize sophisticated technology to control and optimize energy use in various systems, such as heating, ventilation, air conditioning (HVAC), lighting, and security. By automating these systems, buildings can operate more efficiently and effectively, reducing waste and saving on costs. For broader context, guides on building automation fundamentals can help teams understand integration points with HVAC and lighting controls.

Energy management in industrial facilities requires a combination of best practices, including implementing EM systems, regular audits, and data analytics. By monitoring and analyzing data, asset managers can identify areas of inefficiency, implement targeted improvements, and track the success of their energy management strategies. As operations mature, adopting advanced energy management practices can unify analytics, forecasting, and optimization across multiple facilities.

Renewable energy sources, such as solar, wind, and geothermal, can be integrated into energy management systems to improve sustainability further and reduce reliance on fossil fuels. For example, a facility may use solar panels to generate electricity during peak sunlight hours, reducing the need for grid-supplied energy and reduce energy costs. Additionally, renewable energy can be used with energy storage systems to provide backup power during high demand or grid outages. Well-designed building energy management systems coordinate on-site renewables with storage and loads to maximize self-consumption and resilience.

An effective EM strategy comprises several key components, including a thorough understanding of use, a commitment to continuous improvement, and a focus on energy-efficient technologies and practices. For example, businesses can implement energy-saving measures, such as retrofitting lighting systems with energy-efficient LEDs, upgrading HVAC systems to more efficient models, and improving building insulation to minimize heat loss. Upgraded energy management controls enable granular scheduling, sensor-driven setpoints, and measurement and verification to prove savings.

Smart grids and demand response play a critical role in EM by enabling a more flexible and responsive approach. Smart grids use advanced technology and real-time data to optimize electricity generation, distribution, and energy consumption. On the other hand, demand response programs incentivize consumers to reduce or shift their energy use during periods of high demand, helping to balance the grid and lower overall costs. When paired with a capable building automation system, demand response signals can trigger coordinated load shifts with minimal occupant disruption.

Audits are an essential part of energy management, as they provide a comprehensive assessment of a building's performance and identify opportunities for improvement. During an audit, an EM professional evaluates the consumption of a facility, typically an office building or industrial plant, and recommends cost-effective measures to reduce use and costs. These recommendations may include upgrading equipment, implementing energy-efficient practices, and addressing inefficiencies in the building's design or operations.

 

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Benefits of Industry-Standard Networks Explained

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 Controls - HVAC Systems

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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Automated Level Crossings - A futuristic solution enabling Smart City Infrastructure

Smart city automated level crossings integrate IoT sensors, AI, and V2X to optimize traffic management, enhance rail safety, enable predictive maintenance, and deliver real-time monitoring via 5G, edge computing, and SCADA platforms.

 

What Are Smart City Automated Level Crossings?

Systems using IoT, AI, and sensors to automate rail-road gates, boost safety, reduce delays, and optimize city traffic.

✅ Adaptive control via AI, V2X, and edge analytics

✅ Integrated SCADA with remote monitoring and diagnostics

✅ Fail-safe design with SIL-rated controllers and redundant sensors

 

Around the world, railway tracks pass through villages, towns, cities and metropolises which creates the problem of ubiquitous Level Crossings as they transect roads, highways, etc. The real-time train data, collected through Global Positioning System (GPS) satellites can be used to calculate critical distance to a level crossing. A sensor (receiver) keeps polling the approaching train data and actuates a motor that closes the gate of an unmanned LC.

 

Case Study – Indian Railways and problems with its LCs

Since the past few years, Indian Railways (IR) has been making strides in the realm of digital technology. Being the largest employer in the world, means managing a mammoth workforce and movement of passengers every day, equal to the population of Australia. Unfortunately, this includes running trains and transporting goods on a stagnated infrastructure of railroads. Both manned and unmanned Level Crossings, cause several accidents. The manned LCs, that have an operator, to pull the gate, are unreliable and often lead to delays for public, that wants to get from one side of the railway track to another.

 

Solution - Data from satellites

Taking advantages of advancements made in the field of satellite communications technology, Indian Railways has started using Global Positioning System data for running its trains. It collects the actual data as received from the satellites and links it to mobile phone applications and its web portal where travelers can find the running status of a train, they are interested in. This gives any user, information, such as speed, last station passed, time to reach the selected destination (approx.) and whether if the train is running late or at the right time.

 

Building Blocks of the proposed system – PLC and its FBD

A Programmable Logic Controller, or PLC, Fig. 1, is like a mini computer used for industrial automation everywhere around us. These controllers can automate a specific process, machine function, or even an entire production line. They can be made to calculate positions and take actions based on the status. The PLC receives information from connected sensors or input devices (thru the Input Modules), processes the data (in its Processor), and triggers outputs (connected to the Output Module) based on pre-programmed parameters. Depending on the inputs and outputs, a PLC can monitor and record run-time data, automatically start and stop processes, generate alarms if a machine malfunctions, and more. Programmable Logic Controllers are a flexible and robust control solution, adaptable to almost any application. For field deployments, reliable controller-network interoperability relies on industrial automation communication standards that govern data exchange between sensors, PLCs, and supervisory systems.

 


Fig. 1 - A Programmable Logic Controller consisting of a Power Supply, CPU and input and output modules.

Modern PLCs are programmed using Functional Block Diagram (FBD). They were introduced by IEC 61131-3 to overcome the weaknesses associated with textual programming and ladder diagrams. An FBD network, Fig. 2, primarily comprises interconnected functions and function blocks to express system behavior. Function blocks were introduced to address the need to reuse common tasks such as AND gate, OR gate, counters, and timers at different parts of an application or in different projects. A function block is a packaged element of software that describes the behavior of data, a data structure and an external interface defined as a set of input and output parameters. A function block is depicted as a rectangular block with inputs entering from the left and outputs exiting on the right. Key features of function blocks are data preservation between executions, encapsulation, and information hiding. Engineering teams can accelerate safe commissioning by leveraging PLC training courses that focus on FBD practices, diagnostics, and lifecycle maintenance.

An FBD is a program constructed by connecting multiple functions and function blocks resulting in one block that becomes the input for the next. Unlike textual programming, no variables are necessary to pass data from one subroutine to another because the wires connecting different blocks automatically encapsulate and transfer data.

A function block is not evaluated unless all inputs that come from other elements are available. When a function block executes, it evaluates all its variables, including input and internal variables as well as output variables. During its execution, the algorithm creates new values for the output and internal variables. Outputs of function blocks are updated because of function block evaluations. Changes of signal states and values therefore naturally propagate from left to right across the FBD network.

 


Fig. 2 - Functional Block Diagram (FBD) used to program a PLC. Complex mathematic operations are performed by simple functions in steps, deriving outputs from one or multiple inputs.

 

Automated LCs

The GPS data collected from satellites can be used for supplementary applications using simple systems integration technologies to improve a city’s infrastructure. In municipal deployments, integrating these feeds with a building automation system enables coordinated signaling, energy use, and roadway messaging across adjacent facilities.

The LC has a sensor (receiver) which keeps polling the approaching train data continuously from the satellites. The receiver sends this information to a Programmable Logic Controller, which calculates the "critical distance to the crossing" (difference, based on coordinates) The FBD can be designed using a comparator that compares real time position input to a pre-set value (say 300 ft.). It shall then proceed to calculate the difference of these 2 values. If this value is zero, then the output should become 1, which means that the train is now in the crossing envelope and the gates need to be shut. This output feeds the motor starting circuit. An important thing to note here are the factors influencing this calculation such as, the speed of the train and its distance away from the crossing envelope. Another parameter affecting this calculation is the width of the road, across the railway track. For wider roads, crossing envelope is more, on both sides of the road, which leads to the crossing envelope’s pre-set value to be more (than 300 ft.). While for narrow roads the crossing envelope pre-set value can be set to a lesser margin (less than 300 ft).

Making use of the several digital outputs available at the output module of the PLC, extra functionalities that can be added to the PLC circuit may include a horn sound, to alert the public near the crossing and a stop (RED) or go (GREEN) light. The power supply for this system is derived from Uninterruptible Power Supply (UPS) system with a battery unit, See Fig. 3. Integrating the UPS and load profiles into an advanced energy management strategy can optimize battery sizing, charging windows, and lifecycle costs.

 


Fig. 3 – GPS based Automated Level Crossing for Railroads

 

As the train, approaches the crossing, the gate will be closed, stopping the traffic on the road, until the train has moved away from the crossing envelope on the other side of the road.

 

When the train has gone out of the critical distance, using real time polling from GPS, the PLC will run its FBD again. The FBD will now not have a zero output but a positive value as the difference of the pre-set value (300 ft. in our example) and the current coordinates of the train is a positive number. After running this sequence for 2 minutes, and finding a positive number in the output of the FBD, it can open the gate by reversing the motor. This restores movement of road traffic.

 

Have more data? Use it for automation

The PLC can be programmed to detect and transmit alarms for faults in cases such as when the Motor does not start or the Battery units are low on the charge and need replacement. During such situations, PLC can send this information thru a wireless signal to the nearest control center, Fig.3. A Rail Infrastructure Operations & Maintenance (O&M) app or website could collect all this data and send out maintenance personnel to look after the equipment periodically thereby enhancing the life of the LC unit. A Central Control Operator (CCO) screen, Fig. 4, can display erroneous behavior of any equipment. The development of interface between the PLC and CCO requires detailed engineering and sound knowledge of communications. Choice of media and protocols should consider the available transmission methods in industrial networks to balance latency, range, and resiliency.

 


Fig. 4 – A sample Central Control operator screen shows the health of all the equipment. It is very important to keep monitoring the real-time status of critical infrastructure so necessary action can be taken subsequently.

At the control-center side, architects should map data paths to the hierarchical levels of industrial networks so alarms, control, and historian traffic are segregated appropriately.

 

Advantages aplenty

Railway Operators have a responsibility towards everyone, from the travelers on the trains and stations to people using its infrastructure elsewhere. Automated LCs will prevent accidents. This system is faster, as often guards at LC tend to shut the gates 10 to 15 minutes before the approach of the train, causing loss of valuable time of the public. Being a satellite based system, it is bound to be very precise and accurate. It will also save money as the need for guards to be present at such crossings will be eliminated. Beyond safety, standardized connectivity delivers measurable ROI through the benefits of industry networks such as improved uptime, easier scaling, and vendor interoperability.

 

Way forward

As various Railway Operators around the globe, look for ways to keep themselves functional and profitable, all railway crossings should be converted to automatic type, removing the need for a guard to be present 24x7. This solution can be a lynchpin to a digital revolution. Within a city’s limits, such automated LCs will enable transition towards a smart city and smart transport initiatives. Railway Operators must realize the importance of the data that they generate and put it to several innovative uses that makes people’s life easy.

 

Kshitij Saxena received his BTech in electrical and electronics engineering from Vellore Institute of Technology (2008) and MS in electrical engineering from University of Southern California (2010).

                He is currently working as a Senior Traction Power Engineer at WSP Oakland, USA. Previously he has worked with Bombardier Transportation and Pennsylvania Transformer Tech Inc.

                Mr. Saxena is an Engineer in Training from Pennsylvania and is a PMP. He’s passionate about Mass Transit & Renewable Energy.

 

 

 

 

 

 

 

 

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Industrial Network Components Explained

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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Advanced Energy Management

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.

 

What Is Advanced Energy Management?

A control-and-analytics approach to optimize electrical loads, integrate renewables and storage, and improve reliability.

✅ Load forecasting and demand response reduce peaks and costs.

✅ SCADA, IoT, and EMS enable real-time monitoring and control.

✅ Optimizes power quality, peak shaving, and asset utilization.

 

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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PLC Training Courses

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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