Facility and power monitoring systems are equipment for collecting measurements of daily energy usage for analysis. Based on the usage status, such systems reveal clearly where energy-saving devices could be introduced and identify control methods to boost equipment efficiency. Using such systems, Fuji Electric FA Components & Systems (FCS) aims to provide support to customers in cutting energy consumption at offices, factories and other facilities.

A step toward prevention of global warming

Amendments to Japan's Energy Conservation Law that came into force in 2006 require all Japanese companies to adopt tougher energy conservation measures. Many small-to-medium-sized firms, however, are hesitant about how best to proceed in this area. Technical Administration Division manager Hideo Masumoto sees the role of FCS as one of applying in-house systems development expertise gained as a maker of components to find effective ways of helping customers to reduce environmental burden. The idea is to build simple, low-priced systems to monitor the power usage of facilities using components selected from ranges of measuring and control devices. Ascertaining energy consumption status helps point companies in the right direction for saving energy.

  A typical system comprises measuring devices to monitor power consumption or other forms of energy usage along with software to collect and analyze the data. The measuring devices record the energy consumed by lighting or air-conditioning units. Displaying this data in graphical form aids in the analysis of effective energy-saving methods based on actual performance. Assessment of current energy consumption status and comparative analysis with historical data provides a method for managing the variation in energy usage across similar processes. It can also help to identify more effective energy conservation methods by showing where to install devices such as inverters and automated control equipment.

Measurement and evaluation of power usage as the first step in energy conservation

Power monitoring systems only measure energy consumption and do not have any explicit energy conservation function. However, according to FCS manager Yasunori Nagata, assessing usage is the critical first step in saving energy. In many cases, simply introducing the system makes people more energy-conscious, and cuts of 510% in energy usage can be achieved by eliminating wasteful consumption. The monitoring of energy consumption enables quantitative assessments to be made, thus helping to highlight areas that previously might have gone unnoticed, such as failures to turn off unused lighting or cooling equipment (for instance, when only one person is left working late but the entire building remains lit). Many companies now seek to increase the energysaving gains made with power monitoring systems by installing control functions that can automatically turn air-conditioning equipment on and off according to a pre-programmed schedule.

Energy Conservation Management Problem-solving Cycle

Aiming to be a comprehensive facility management services provider

One important feature of these systems is that they are scalable. As Mr. Masumoto explains, "Our smallest system, which has a series of devices to measure and manage a number of data feeds from a central location, is priced at around 200,000 yen. Customers can start by installing a small-scale system and then gradually expand its scope from the main voltage supply and central power circuits to cover a number of measurement nodes at different power distribution points. Some customers choose to expand the installation base by a building or block per year." Since the equipment is compatible with different types of communications infrastructure, users can also graft the system onto an existing IT network and expand one device at a time.

  Customers also apply the systems in various ways. At some firms, such systems help to encourage spontaneous energy-saving initiatives by disclosing energy consumption across different divisions for instance, by showing how much power was used to meet sales targets. Within the Fuji Electric Group, FCS plans to treat its Fukiage site as a model plant by installing systems to cover all the secondary substations and by disclosing the energy usage data obtained.

  "Introduction of such systems has led many of our customers to ask us about possible energy-saving measures and about facility management in general," says Mr. Nagata. Consulting opportunities have flourished to help clients achieve greater reductions in CO₂ emissions, both by introducing wind power generation or other energysaving equipment supplied by the Fuji Electric Group and by promoting communication with companies that have already installed such systems.

  Among the latter group, some companies are using existing network infrastructure to adapt systems to cope with the general management of other environment-related data besides electric power, such as noise, vibration and water quality information. Based on this trend, regular discussions are taking place within the Fuji Electric Group with a view to developing comprehensive facility management systems. Mr. Masumoto confirms, "In the future, we aim to develop this business toward total facility management." General systems that cover energy usage along with other aspects such as pollutant, disaster and security controls could contribute to the total management of various environmental issues. In turn this would help the Fuji Electric Group better fulfill its responsibilities as a corporate citizen.

Increased energy-saving awareness in the field level the main benefit
(User feedback)

Case study of power monitoring systems: Honda Motor

Facility Management Block,
Operations Management Division
(Saitama Works)
Honda Motor Co., Ltd.
Makoto Shimoo sawa (Center)
Block Leader
Hiroyuki Takahashi (Left)
Technical Manager, Electrical & Motive
Power Group
Noriaki Sugayama (Right)
Technical Manager, Electrical & Motive
Power Group

Honda Motor's manufacturing operations at Saitama began full-scale use of power monitoring systems in 2000, mainly in response to the cuts in power consumption required at that time by the newly revised Energy Conservation Law. Honda decided that the first step required was to assess energy usage at each separate production line and facility. System installation enabled Honda to identify where energy was being wasted and, using the data as a yardstick, to target the replacement of any equipment that was energy-inefficient. Honda also instituted energy-saving measures, including shutting off power supplies whenever possible. The primary effect of these measures was a significant increase in energy-saving awareness in the production field. The monitoring data painted a clear and convincing picture to site managers. Using the data breakdown on power usage throughout the site, production lines began competing against each other to achieve energy savings. Today, Saitama is the most energy-efficient site within the Honda manufacturing universe.