Case Examples - Energy Optimization

1. CASE EXAMPLES: HOW ENERGY OPTIMIZATION PREEMPTS FAILURE

2. Early Signal: Motor Energy Spike Mechanical Wear Detection Gradual mechanical wear increases friction and load in rotating equipment. Motors draw higher current to maintain torque and output. Consumption rises even when production output remains constant. Detection occurs weeks before vibration or temperature limits are breached. KEY INSIGHT: Rising energy demand at stable output is a leading indicator of mechanical degradation.

3. Compounding Impact of Micro-Stops Escalating Operational Risk Micro-stops disrupt steady-state operation, causing hidden inefficiencies: • Repeated start-stop cycles increase inrush current. • Thermal and mechanical stress accelerate component fatigue. • Solution correlates energy fluctuations with stop-start behavior. OPERATIONAL RISK Increased cost per unit • Accelerated degradation • Reduced process stability

4. Failure Escalation Timeline Initial: Inefficiency Intermediate: Escalation Advanced: Critical Final: Breakdown Energy inefficiency caused by wear and process instability. Rising consumption combined with frequent micro-stops. Excess heat, vibration, and significant load imbalance. Unplanned failure and forced shutdown of operations. OBSERVATION: Energy inefficiency appears weeks before downtime, offering a critical intervention window.

5. Early Intervention & Outcomes The solution continuously monitors cross-domain data to prioritize interventions based on failure risk and energy loss. Targeted inspection and lubrication Load balancing and alignment correction Process stabilization for micro-stop reduction Prevent Shutdowns Reduced Costs Extended Life Eliminate unplanned downtime Lower maintenance & energy spend Improve asset longevity Proactive intervention prevents failure before it disrupts operations.

6. Image Sources Source: https://www.infinite-uptime.com/downtime-is-draining-your-ebitda-the-real-role-of-industrial-energy-efficiency/ z