Cash & Energy Savings Using Wireless Sensor Networks

By: Jody Singleton

Industries everywhere are finding ways to save not only on energy and its costs but through the use of wireless networks and in numerous other ways too.

According to Oak Ridge National Laboratories, through the use of wireless sensor networks, savings on energy for motors used in industrial processes could improve efficiency by 20%, resulting in significant cost savings. Wayne Manges said: “With electric motor-driven systems accounting for nearly one-fourth of all electricity consumption in the United States, the potential for savings is huge.”

The Department of Energy’s Industrial Technologies Program works with US industry to improve environmental performance and energy efficiency. The ITP is distributing 15 million to support R&D specifically to improve energy efficiency in industrial processes. Already a number of new wireless sensor products are being developed together with the Department of Energy.

Cost savings with wireless systems are recognized in multiple areas including materials and labor where the cost of running wire in plants ranges between $155 and $3,700 per foot. The typical payback for wired systems is 24 months and less than a quarter of that for a wireless equivalent, only six months. Add in the on-going energy savings and the return on investment decision is very clear.

In a large number of industries, companies are recasting their product lines to implement wireless technologies. “We can’t think of any segment of the industry that isn’t going to be impacted by this,” states Honeywell’s CTO Dan Shiflin.

Wireless sensor networks of all varieties are exploding into our world. There is a massive amount of research & development, from academia to start-ups, pushing to create proverbial “better-faster-cheaper” products. A growing number of products are based on an emerging specification “ZigBee”. A majority of utility companies that have settled on a standard have identified ZigBee as their preference due in main to its inherent security capabilities. Real-time data from wireless sensors networks will enable companies to achieve greater productivity and efficiency by continually improving their processes.

Named BP International’s first Director of Technology & Sensory Networks, for the oil company’s Technology Office, Ken Douglas said “You don’t ask people ‘How would you use ZigBee?’ Because they don’t know, but if you ask them: ‘How would you use information that you can now access for the first time?’ They have to think about it for a bit, but then the ideas just starting pouring out.”

In addition to the benefits of ZigBee’s security layers, the mesh network is highly reliable, flexible and can connect a variety of sensors simultaneously including protocols such asOPC, Modbus and HART.

Companies whose product objectives include reducing costs or waste, more reliable equipment management; improved physical asset control or greater situational awareness should investigate the variety of capabilities wireless sensor systems can provide. In addition to the potential savings in energy, there are likely many additional cash benefits to be found.

Ref: eeweb.com/blog/jody_singleton/cash-energy-savings-using-wireless-sensor-networks