Energy consumption monitoring – CMMS as part of an energy efficiency strategy

Energy prices have been steadily rising in recent years. At the same time, the pressure to reduce emissions is intensifying. This means that monitoring energy consumption is no longer just an addition to a company’s strategy – it’s a mandatory element of every plant’s operations. However, kWh metrics alone are no longer sufficient. Knowledge is needed to determine which machine, where, and how it generates costs. The same applies to identifying maintenance and organizational activities. These can constitute unnecessary expenses or lead to real savings. It’s worth implementing a CMMS system . Combined with IoT measurements, such software allows for precise tracking of energy consumption at the asset and process levels. How does CMMS support the development of an energy efficiency strategy?

Energy monitoring in a facility. Why is it worth paying attention to detail?

Most plants use only aggregated reports that show total energy consumption. However, such data often masks the problem. Even if a factory has stable consumption, for example, in a monthly summary, it may be simultaneously losing energy from many small, hidden sources of waste. What are we talking about? These include equipment in standby mode, leaks in compressed air systems, suboptimal settings, or failures, such as bearing failures that increase friction. Therefore, it’s worth focusing on identifying these points. How can this be achieved? Above all, accurate, detailed data is required. It’s worth separating, for example, energy consumption by a specific line, a specific machine, or sometimes by switchboard. The greater the granularity of the data, the easier it will be to obtain a complete picture of the plant’s energy demand. This, in turn, leads to faster identification of losses and, consequently, greater savings.

CMMS in the plant’s energy management system

How can a CMMS be used in this area? It’s a system that serves as a natural link between measurement data and operational activities. This type of software can also integrate with EMS (Energy Management System) or SCADA systems. How does it work? In this case, the EMS or SCADA system is used to report deviations and record historical measurements. The CMMS, in turn, allows these signals to be translated into tasks. The system can, for example, order an inspection, schedule a maintenance, reserve parts, or record the results of an intervention. This creates a closed loop from measurement, through diagnosis and corrective action, to verification of the effect. This allows for effective determination of the actual effectiveness of the implemented savings measures.

Integration of CMMS with IoT and measurement systems

To effectively implement a CMMS for energy management, it’s important to ensure proper integration. What does this look like in practice? CMMS interaction with IIoT at this layer primarily involves transmitting alarms and metrics from energy meters, measurement gateways, and PLC controllers. Data transfer protocols are used for this purpose, both industry-specific and more general-purpose protocols, such as OPC UA, MQTT, and REST API. These protocols can be used to transmit values ​​such as power, energy, power factor, and instantaneous trends.

The CMMS then accepts the data and stores it in its database. What’s next? Based on this, rules can be created to help manage energy efficiently. For example, if idle consumption exceeds a threshold, a diagnostic request is created. If peak power occurs outside the planned schedule, a process audit is triggered. This means that a CMMS alert is more than just a notification. It’s the first step towards resolving the problem.

Consumption calculation by individual assets and processes

Another significant benefit of CMMS in the context of energy management is the ability to map measurements to specific assets. Meters can be assigned, for example, to a specific line, machine, or zone. This allows the system to know which components are affected when anomalies are detected and which maintenance procedures should be implemented. It is particularly recommended to identify the most energy-intensive components. In most plants, these will be compressors, circulation pumps, and furnaces. It is worthwhile to maintain dedicated energy management plans with reference measurements for these types of equipment.

Energy KPIs and CMMS Efficiency Analysis

What else is worth considering in the context of energy management? It’s certainly worth remembering that no strategy will deliver real savings unless it is continuously monitored and verified. Therefore, a way to collect and present the most important energy-related KPIs is essential. These might include:

• kWh consumption per unit of production;
• energy intensity (kWh consumption per tonne or piece of product);
• energy costs on the line;
• number of hours of operation in rest mode;
• percentage of work in nominal mode;
• number of events that increase power consumption.

How can these metrics be monitored? CMMS comes to the rescue once again. Professional maintenance software can integrate with IoT sensors and continuously collect energy consumption data. Measuring these metrics over time allows us to determine the effectiveness of optimization efforts, providing a basis for sound business decisions.

Corrective and optimization actions supported by CMMS

Energy losses often result from failures. A CMMS system provides numerous tools that ensure better service in this area. What is it all about? For example, software can help detect compressed air leaks, calibrate drives, identify bearing failures, or optimize line startup. It’s crucial to prepare and customize CMMS functionality. This should be done so that the system meets the actual needs of the given company. A properly configured CMMS allows for planning corrective actions, minimizing the impact on production, and then tracking changes in energy consumption.

Predictive energy consumption and investment planning

CMMS can also support energy consumption forecasting. How does it work? Predictive models can indicate expected increases in consumption, for example, due to deteriorating technical condition of machinery. Based on this, preventive maintenance can be planned before significant cost increases occur. This is particularly useful for high-power devices, where even a small increase in mechanical resistance translates into a noticeable increase in energy demand.

CMMS can also collect the data necessary to calculate the return on investment for projects aimed at optimizing energy consumption. How should such an analysis be conducted? The primary consideration should be the reduction in energy costs after implementing the measures compared to previous consumption. Furthermore, the costs of maintenance and component purchases must also be considered. CMMS serves primarily as a reliable source of input data for further calculations.

How to implement CMMS as part of an energy efficiency strategy?

The first step should be identifying the machines, lines, or processes with the highest energy demand. Next, install meters and submeters where the most valuable information can be obtained. This is where the CMMS comes in. How do you connect them? Meters should be assigned to assets. It’s also a good idea to set alarm rules for threshold values. Before final implementation, it’s a good idea to conduct a preliminary audit and pilot on a single line.

It’s worth noting that implementation alone isn’t the end. To achieve the greatest added value, the effects of implemented actions must also be continuously measured. This allows data to effectively support decisions. In this way, a CMMS will provide real support in energy management.

Energy consumption monitoring is now an essential element of daily management. CMMS, integrated with measurement systems and IoT, allows you to transform raw data into concrete actions. This allows you to identify sources of losses, prioritize repairs, and measure the impact of changes. The result: lower energy consumption, reduced operating costs, and improved market positioning. If you need a practical implementation plan or want to learn more about the capabilities of our CMMS system, contact QRmaint specialists.