Operational technology (OT) networks and energy management systems can be powerful tools for driving energy efficiency. With ESG a chief mandate for many facilities teams, leveraging the data and capabilities of your energy management systems and OT networks has become a critical way to identify key opportunities to cut energy use and reduce costs.
Let’s explore five proven ways OT networks and energy management systems can help reduce energy consumption, along with real-life examples of organizations achieving impressive results. We’ve also included a list of newer innovations in energy efficiency management that rely on OT networks to further your optimization goals.
1. Centralized Energy Management
Facilities with big footprints often have a common issue: energy is either generated or acquired from different sources—public grids, steam boilers, propane, and natural gas—without a unified monitoring system. This lack of integration leads to missed opportunities to measure and optimize energy usage.
Centralized energy management systems extend the monitoring and reporting capabilities of your OT network to include all energy sources, consolidating the data in one place. Often implemented via industrial IoT arrays, this approach enables organizations to oversee and optimize energy use across multiple locations from a single platform, allowing facility managers to make more informed decisions to reduce consumption.
In Action: Steel manufacturing, India
A steel manufacturing organization in India implemented a comprehensive centralized energy management system (CEMS) to help with this issue. By working with their vendor, SensLive, the organization was able to integrate plant equipment sensors with real-time data collection and reporting. Not only were they able to reduce their overall energy consumption by 15% in the first year,they also leveraged the additional data to reduce unnecessary downtime by 20%.
2. Optimized HVAC Systems
Most people reading this will already know that HVAC operations are some of the largest users of energy in a building—up to 60% in some cases. Optimizing HVAC systems focuses on fine-tuning heating, ventilation, and air conditioning operations to achieve maximum energy efficiency. This can include basics like adjusting temperature settings and airflow, as well as advanced strategies like using real-time occupancy data to avoid wasting energy.
OT networks play a vital role by providing granular control over HVAC systems but they also provide the data necessary to measure and optimize those programs. An OT network that’s well integrated with other systems can enable adaptive energy management: continuous monitoring and dynamic adjustments based on real-time factors such as weather conditions or time of day. The ability to respond instantly to changing needs ensures that energy is used efficiently without compromising comfort.
In Action: Cammeby’s International, New York City
Working with data harvested from the building’s BACnet/IP OT network, AI building management company (and Optigo Networks partner), BrainBox AI, was able to help their client’s New York HQ save more than 15% in energy consumption, and reduce GHG emissions by 16% by tuning existing HVAC systems without disrupting tenant comfort.
Brainbox AI was able to deploy its solutions to the edge of the OT network to gather and process data, then work with the building’s system integrator to customize and upgrade its building management system.
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3. Lighting Automation
The second largest energy draw in any facility is lighting. With up to 20% of total energy spent, it’s another obvious target for optimization. Lighting automation uses sensors and control systems to adjust light levels based on occupancy and natural light availability. Often a simple retrofit, occupancy sensors ensure lights are only on when needed, saving energy and reducing costs.
Through OT networks, sensors and lighting controls are integrated, enabling seamless communication and real-time adjustments. These networks also allow for centralized oversight, making it easier to manage lighting across large facilities or multiple sites.
In Action: Department of Energy’s Federal Energy Management Program
The US federal government has developed a series of guidelines and toolkits to help achieve the mandate of greater energy efficiency and cost savings for taxpayer-funded buildings. This includes new codes and standards on lighting controls.
The study conducted for creating the Wireless Occupancy Sensors for Lighting Controls guide revealed some drastic potential savings: “One study conducted on a university campus (University of Illinois) found that installing… occupancy sensors to control lighting in more than 200 rooms in 10 buildings provided an annual cost savings of about $14,000 with a simple payback of 4.2 years.”
4. Real-Time Energy Usage Monitoring
Similar to centralized energy management systems, real-time monitoring tracks energy consumption patterns to uncover inefficiencies and identify areas for improvement. This data-driven approach helps organizations make informed decisions about reducing energy use.
OT networks enable comprehensive energy monitoring by collecting and aggregating data from various systems. This data provides actionable insights into usage trends, allowing organizations to pinpoint problem areas and develop targeted strategies for improvement.
In Action: Vietnam’s industrial sector
A strong economy in Vietnam has been putting increased pressure on energy demand. As a result, the government has instituted a number of policies and programs to encourage energy efficiency. In particular, industrial organizations have been encouraged to invest in energy conservation and efficiency, including the deployment of real-time energy monitoring systems managed through industrial OT networks.
In one case study, real-time power monitoring installed at a typical manufacturing facility contributed to an annual savings of 9.6% and a reduction of more than 139 tons of CO2.
5. Smart Equipment Scheduling
Like turning off unneeded lights, there’s a potential for energy savings in shutting down idle plant equipment. Implementing this involves using OT networks to facilitate precise scheduling by integrating real-time data from equipment and operational systems.
Automated controls dynamically adjust schedules, minimizing idle time and maximizing efficiency.
In Action: Eliminating 366 days of idle time from a Canadian industrial plant
Leveraging real-time usage data from the OT network, scheduling software experts Actenum were able to analyze and recommend an optimized schedule for tasks, materials, and equipment during a 4-day shutdown to their heavy industrial client in Canada.
By ensuring that “people were working and not waiting”, resources were able to be used to their fullest. The results were a 4% reduction of idle time, about 366 days, potentially saving the company 2 million dollars in wasted energy and other financial costs.
The Next Wave of Energy Efficiency Will Rely on OT Networks
OT networks and energy management systems are also positioned to be central to the next wave of energy efficiency strategies. One common theme we continue to see: these new projects rely heavily on reliable and real-time sensor data to perform – the kind of data that only a high-performing OT network can provide.
Here’s a sampling of new efficiency strategies we’ve found that leverage a facility’s OT network data.
Building Envelope Performance Monitoring
Monitoring a building envelope (the building components that keep the inside and outside environments separate) involves assessing walls, windows, and insulation for energy efficiency. By pulling relevant data from OT network sensors, facility managers can reveal issues that are not always obvious from a physical inspection, like increased moisture or uneven HVAC needs in certain areas, enabling proactive maintenance to fix issues before they can lead to major construction repairs.
Retrocommissioning
Retrocommissioning is, in simple terms, the process of optimizing a building’s BAS systems accounting for the change in use over time. As a building ages, its equipment may start to show signs of deterioration, struggling to keep environments in optimal condition or comply with ESG standards. Or perhaps the building’s use has changed completely, and new HVAC or lighting systems are needed.
Retrocommissioning encompasses all the examples we’ve looked at above, with an emphasis on replacing and upgrading aging systems that need to be updated to comply with today’s ESG standards. OT networks provide the data needed to set baseline measurements, identify patterns of performance vs. benchmarks, and address inefficiencies in system performance.
Carbon Emissions Tracking
Carbon emissions tracking isn’t just a good way to measure your improvements in energy efficiency, or good PR for customers and investors. In some places, carbon emission reporting is now the law.
While there are many carbon reporting solutions available in the market, most still rely on the data derived from OT and IoT devices. OT networks integrate emissions scope data with energy monitoring systems to provide a comprehensive view of environmental impact.
Distributed Energy Resources (DERs)
DERs comprise renewable energy sources like solar panels and wind turbines, in addition to traditional sources, connected to a building or campus grid. OT networks monitoring energy demands can optimize the use of DERs by integrating and prioritizing them over traditional energy systems, enabling better energy storage and distribution while keeping emissions low. For example, Sichuan University has been testing a series of microgrids fed by solar power.
Keep Your OT Network in Peak Condition with OptigoVN
OT networks and energy management systems are essential for driving energy efficiency in modern facilities. From HVAC optimization to real-time monitoring, these systems have grown to rely on advanced IP networks, IoT devices, and unquestionably reliable reporting data. Maintaining OT network health has become a more important factor than ever in supporting the tools needed to reduce costs, meet ESG goals, and improve operational performance. OT networks will remain at the heart of energy optimization strategies.
For that, you need network monitoring and management software built to keep you on top of issues long before they become potential emergencies. With OptigoVN, you can instantly assess your network health and pinpoint BACnet issues down to the device in seconds. No more manual decoding of packet captures, climbing ladders, or splitting networks. Take back your time from low-level tasks and move into a routine of preventive maintenance rather than a break/fix model.
Ready to see what OptigoVN can do for your OT network? Contact us to schedule a demo or sign up for a free account to explore on your own today.
Frequently Asked Questions About Energy Management Systems & OT Networks
Q: What is the relationship between OT networks and energy management systems?
A: OT (Operational Technology) networks provide the infrastructure and connectivity that enable energy management systems to function effectively. The OT network collects data from various sensors and equipment, while energy management systems use this data to optimize energy usage, control systems, and generate insights for better decision-making.
Q: How much can I expect to save by implementing these energy-saving solutions?
A: Based on the case studies mentioned in the article, organizations have achieved:
- 15% reduction in energy consumption (Steel manufacturing case)
- 16% reduction in GHG emissions (Cammeby’s International)
- 9.6% annual energy savings (Vietnam manufacturing facility)
- Up to 20% reduction in equipment downtime The exact savings will depend on your facility’s current efficiency and implementation scope.
Q: Do I need to upgrade my entire OT network to implement these solutions?
A: Not necessarily. Many organizations start with specific high-impact areas like HVAC or lighting systems and gradually expand their optimization efforts. However, having a reliable OT network infrastructure is crucial for successful implementation. A network assessment can help determine if any upgrades are needed.
Q: What’s the typical ROI timeframe for these energy optimization projects?
A: ROI varies by project type. For example, the lighting control case study showed a 4.2-year payback period. HVAC optimization projects often show returns within 1-2 years. More complex implementations like centralized energy management systems typically demonstrate ROI within 2-3 years through combined energy savings and operational improvements.
Q: How can organizations get started with energy optimization?
A: The recommended approach is to:
- Assess your current OT network capabilities
- Identify high-impact areas for energy savings
- Start with one or two key initiatives (often HVAC or lighting)
- Implement monitoring and measurement systems
- Gradually expand to other areas based on results
Q: What are the main challenges in implementing these energy-saving solutions?
A: Common challenges include:
- Integration of legacy systems with new technology
- Initial investment costs
- Staff training requirements
- Maintaining system security while increasing connectivity
- Coordinating between IT and OT teams
Q: How do these solutions support ESG goals and compliance requirements?
A: These solutions support ESG initiatives by:
- Providing accurate energy consumption data for reporting
- Enabling carbon emissions tracking
- Demonstrating measurable sustainability improvements
- Supporting compliance with energy efficiency regulations
- Generating documentation for environmental certifications
These FAQ answers are developed in coordination with the aid of AI.
