Plant Historian 5 EM

Energy monitoring refers to the continuous collection and presentation of energy consumption data, while energy controlling uses this data to generate key performance indicators, evaluate deviations, and thus provide the basis for targeted energy-saving measures. Together, these two components form the basis for systematic energy management in accordance with DIN EN ISO 50001.

Energy monitoring provides transparency regarding consumption and key performance indicators, while an energy management system compliant with ISO 50001 also establishes processes, responsibilities, and continuous improvement measures within the company.

Process data archiving records continuous physical process variables such as temperature or pressure, while energy management focuses specifically on consumption data, cost centers, and emissions metrics. Both modules can use the same plant connection but analyze the data for different purposes.

DIN EN ISO 50001 is the international standard for energy management systems, which requires companies to systematically track, evaluate, and continuously improve their energy consumption. Software that provides energy monitoring and control as the foundation for this process thus fulfills a key technical requirement of the standard.

The Federal Office for Economic Affairs and Export Control (BAFA) has classified Plant Historian EM as eligible energy management software, which means that its purchase may generally be subsidized under certain funding programs. The specific requirements, subsidy rates, and application procedures are determined exclusively by the BAFA and should be verified directly with the BAFA or a funding consultant before making an investment decision.

Plant Historian 5 EM provides consumption reports with freely configurable KPIs, such as totals and averages, as well as flexible, savable analysis options for custom reports. In addition, calculation parameters for variable reports and manually recorded consumption values can be incorporated.

Emissions monitoring refers to the generation of a CO2 footprint based on recorded energy consumption data, enabling companies to document their CO2 emissions in a transparent manner. This is relevant for both internal sustainability goals and external reporting requirements.

Meters can be specifically assigned to individual cost centers, allowing energy consumption and costs to be analyzed not only on a company-wide basis but also broken down by department, plant component, or process step. This enables a more targeted identification of savings potential than a simple analysis of total consumption.

Metering data is validated online, and alerts are automatically triggered when readings exceed or fall below defined thresholds, ensuring that deviations in balancing groups are detected early. This prevents erroneous metering data from being included in consumption analyses without being noticed.

Connectivity is standardized via M-Bus to TCP/IP, Modbus connections (e.g., via RS485), and 4–20 mA or 0–20 V signals to TCP/IP, either via OPC or Modbus. This allows both traditional energy meters and analog measurement points to be integrated centrally.

Plant Historian 5 EM can be integrated with common process control systems via standardized OPC connectivity, including Siemens Simatic PCS7 and S7, Emerson DeltaV, Honeywell Experion and PHD, ABB Freelance and 800xA, and Foxboro I/A Series. This enables the centralized analysis of even heterogeneous control system landscapes for energy management purposes.

Yes, the integration of existing data sources is a core feature of the system, so existing meters and measurement points are not replaced but are incorporated into the central analysis. This reduces the investment costs compared to completely overhauling the measurement infrastructure.

Yes, as a centralized, company-wide solution, additional PLS/PLC server connections can be added later without having to rebuild the existing structure. This makes it suitable for a phased rollout across multiple locations.

By identifying instances of excessive consumption and promptly implementing corrective measures, energy costs can be reduced in the long term, as opportunities for optimization are specifically identified rather than merely assumed. Automated reporting also reduces the manual effort required for cost control.

By monitoring emissions and assessing efficiency based on key factors, CO2 emissions can be documented in a transparent manner and reduced in a targeted way, rather than simply estimated as a general figure. This supports both internal corporate sustainability goals and external reporting requirements.

An energy management system aligned with ISO 50001 enhances the company’s public image among customers, suppliers, and investors, who are increasingly demanding proof of energy efficiency and sustainability. This can be an increasingly important competitive factor in bids or supplier audits.

Energy monitoring and controlling are particularly relevant for energy-intensive industrial companies whose energy costs account for a significant portion of their total costs and that must comply with regulatory requirements such as ISO 50001.

The cost depends primarily on the number of meters and measurement points to be connected, the number of PLS/PLC server connections, and the effort required to integrate the software with existing data sources. A flat-rate price quote is therefore not very meaningful; for a reliable estimate, we recommend a no-obligation consultation with our sales team.