Short Definition
Energy monitoring refers to the systematic collection, transmission, storage, analysis, and visualisation of energy flows. It reveals when, where, and in what quantities energy is imported, generated, distributed, or consumed. This article focuses on the monitoring of electrical energy. Depending on the metering concept, however, other energy sources and utilities such as gas, heat, cooling, or compressed air can also be included.
A standalone energy monitoring system does not actively intervene in plant operation. Instead, it provides a reliable data foundation for analyses and subsequent optimisation measures.
Energy Monitoring at a Glance
- Energy meters collect electrical measurements for sites, areas, or individual loads.
- A monitoring platform processes the data into load profiles, energy balances, key performance indicators, and alarms.
- In industrial environments, production equipment, building services, cooling systems, compressed-air systems, and charging infrastructure can be analysed separately.
- A suitable metering concept and reliable data quality are essential for meaningful results.
How Does Energy Monitoring Work?
Data collection begins at defined metering points. Main meters record, for example, the total grid import and export of an entire site. Submeters represent individual production halls, production lines, machines, building areas, or utility systems.
Depending on the measuring device, different electrical quantities may be available. These can include active power, active energy, reactive energy, voltage, current, power factor, and, where applicable, grid frequency. The values that are actually collected depend on the meter used, its installation location, and the relevant metering concept.
Depending on the device, measurements are transmitted to a local gateway or monitoring platform via Modbus TCP, Modbus RTU, M-Bus, or application programming interfaces (APIs). Pulse interfaces, by contrast, generally provide only meter pulses from which energy quantities can be derived. They cannot usually transmit complete datasets containing quantities such as voltage, current, reactive power, or power factor.
The monitoring system records the data with timestamps and stores it for historical analysis. Depending on the application, raw data can be stored at different intervals or aggregated into minute, hourly, daily, and monthly values. Dashboards can display current power values, historical load profiles, energy distributions, key performance indicators, and site-specific comparisons. Thresholds or reference profiles can be used to identify unusual deviations and trigger notifications.
Meter hierarchies allocate the total energy consumption to the respective subordinate loads. This makes it possible to determine, for example, which proportion of the site’s energy consumption is attributable to production, cooling, building services, or compressed-air generation.
Differences between a main meter and the sum of the recorded submeters do not necessarily indicate an error. They may also result from loads that are not separately metered, measurement deviations, transmission or distribution losses, or differences in measurement and storage intervals.
Meaningful results require correctly positioned metering points, consistent measurement directions, synchronised timestamps, and unambiguous meter assignments. Measurement intervals, data resolution, and measurement accuracy must also be suitable for the intended analysis.
Typical Applications
- Consumption transparency in production: Machines, equipment, or production lines are metered separately to compare the energy demand of individual loads and time periods. When combined with operating or production data, energy consumption can also be allocated to shifts, products, or production orders.
- Monitoring of technical infrastructure: Building services, cooling, ventilation, and compressed-air systems can be examined for high baseloads, unusual operating times, and avoidable consumption outside regular operating hours.
- Analysis of load profiles: Historical load profiles reveal peak loads, recurring consumption patterns, and deviations from reference values.
- Monitoring of charging infrastructure: The energy consumption of individual charging points or charging areas can be measured and assigned to specific periods. Where identification or billing data is available, it can also be allocated to vehicles or user groups.
- Cross-site analysis: Standardised key performance indicators allow several buildings, branches, or production sites to be compared, provided that their metering concepts, data resolutions, and system boundaries are comparable.
- Foundation for energy optimisation: The collected data can be used to prepare technical or organisational measures and subsequently verify their effectiveness.
Distinction from Plant Monitoring, Control Solutions, and EMS
Energy monitoring focuses on collecting and analysing energy flows. It shows when, where, and in what quantities energy is imported, generated, or consumed.
General plant monitoring frequently records and visualises additional information alongside energy data, including operating states, temperatures, fault messages, running hours, or production figures. Active control is generally not part of standalone plant monitoring.
A monitoring and control solution combines data collection and analysis with the ability to intervene actively. It can, for example, transmit setpoints, switch loads on or off, or limit their power consumption.
An EMS goes beyond the basic control of individual assets. It coordinates multiple energy generators, storage systems, and loads based on defined objectives, rules, measurements, and operating limits. This can include peak shaving, self-consumption optimisation, or the price-based control of a BESS.
Energy monitoring can provide the data foundation required for such optimisation strategies. The actual control function, however, requires additional capabilities, suitable device interfaces, and defined control logic.
Benefits, Limitations, and Technical Requirements
Energy monitoring can reveal potential savings, provide benchmarks, and identify unusual consumption patterns. It can, for example, uncover high baseloads, unnecessary equipment operating times, or unusual increases in consumption. Historical data can also be used to assess implemented measures and compare different operating periods.
Measurement data alone, however, does not reduce energy consumption. Savings are only achieved through suitable organisational, technical, or automated measures based on the findings.
The quality of the results largely depends on the metering concept. Missing submeters, reversed measurement directions, data gaps, or inconsistent time intervals can distort energy balances and comparisons. Suitable energy meters, compatible communication interfaces, stable data transmission, a consistent meter hierarchy, and sufficiently accurate time synchronisation are therefore required.
Operating hours, production quantities, plant conditions, and system boundaries must also be considered for reliable comparisons. Higher energy consumption does not automatically indicate lower efficiency if production output increased during the same period. For production-related performance indicators, energy data must therefore be combined with suitable operating or production data.
Implementation with EcoPhi
EcoPhi can connect energy meters and other measuring devices from different manufacturers and consolidate measurements from individual machines, areas, or sites within a shared platform. The data can be provided through dashboards, historical analyses, load profiles, and alarm notifications.
The available measurements, transmission intervals, and interfaces depend on the devices used and the project-specific metering concept. Metering points, meter hierarchies, and system boundaries must be clearly defined during project planning to provide meaningful visualisations and analyses.
In addition to standalone monitoring functions, EcoPhi can provide control functions for loads, PV systems, or BESS. These functions require suitable device interfaces and project-specific control logic.
Brief Summary
Energy monitoring creates transparency regarding energy flows within companies and provides a foundation for consumption analyses, comparisons, and the identification of unusual consumption patterns. A suitable metering concept, reliable data transmission, and consistent assignment of measurements are essential. Shift-, order-, or user-specific analyses require additional operating, production, or identification data. Active optimisation requires advanced control functions or an EMS.
Frequently Asked Questions About Energy Monitoring
What Is the Difference Between Energy Monitoring and an EMS?
Energy monitoring collects, stores, and visualises energy flows. An EMS can additionally coordinate energy assets actively based on defined objectives, measurements, operating limits, and rules.
Which Industrial Loads Can Be Monitored?
Typical examples include production machinery, building services, cooling systems, compressed-air systems, charging infrastructure, and individual building areas. Each requires a suitable metering point or a reliable device interface.
Is a Site’s Main Meter Sufficient for Energy Monitoring?
A main meter shows total energy consumption but generally does not allow this consumption to be allocated unambiguously to individual loads. More detailed analyses therefore require submeters and a suitable meter hierarchy.
Can Energy Consumption Be Allocated to Individual Production Orders?
Yes, provided that suitable operating or production data is available alongside the energy data. This can include production order times, machine utilisation, production quantities, or operating-state data.
Does Energy Monitoring Automatically Produce Energy Savings?
No. Energy monitoring reveals potential savings and unusual consumption patterns. Actual savings are only achieved through subsequent operational, technical, or automated measures.