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Operational Analytics Helps Lower Maintenance and Energy Costs to Danfoss Customers

Operational Analytics Helps Lower Maintenance and Energy Costs to Danfoss Customers
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Operational Analytics Helps Lower Maintenance and Energy Costs to Danfoss Customers - 1

CASE STUDY Project Summary Organization: Danfoss Solution: Buildings and Facilities Location: Global Project Objective: • Lower operational costs through food safety monitoring Operational Analytics Helps Lower Maintenance and Energy Costs to Danfoss Customers Alarm Management Helps Minimize Food Loss and Energy Consumption Monitoring 5,000 Sites around the World • Reduce overall energy costs (lighting, refrigeration, ovens, and so on). Danfoss, which specialises in producing refrigeration monitoring equipment, compressors, and controllers for grocery stores, required a solution that would help its customers view their operations at a presentation level, create reports on alarms and performance, and reduce energy costs for around 5,000 sites worldwide. • Filter alarms to reduce false alarms • Reduce maintenance and replacement costs Products used: Amulet Fast Facts • Used in nearly 5,000 supermarkets worldwide • 200,000 refrigeration-related data points across all stores, including compressor pressures, liquid levels, temperatures, energy use, and currents • 40 million real-time changes daily from readings every five minutes, 24 hours a day ROI • Reduced maintenance call outs; false alarms and energy consumption • Strengthened the bottom line by lowering operation costs • Identity performance levels across all sites via benchmarking • Achieve compliance in temperature HACCP Refrigeration consumes a major portion of a large grocery store’s electricity (up to 30% in some UK stores), with the remainder consumed by HVAC equipment, lighting, and other utilities such as in-house bakeries and restaurants. Add to this the risk of asset failure, which can result in food loss, unplanned asset down time and maintenance call outs – unexpected costs that can quickly escalate. Retailers now operate in a market where the demand for frozen foods is increasing, causing them to invest in large-scale refrigeration equipment. This has led to tight margins in an increasingly competitive market where assets are expected to perform constantly. Historically, supermarkets have accepted that the cost for high customer volume, regulatory compliance, and increasing energy costs were part of the business model. Danfoss addressed these business challenges with an operational analytic solution provided by Bentley‘s Amulet that saves money, categorizes and filters alarms, improves energy efficiency, and gives customers peace of mind. as it allowed them to present a real-time visualization of performance and current conditions, particularly focusing on generated alarms. Using the operational analytics solution, customers are able to view alarm counts and status, view, and email reports on performance on a daily, weekly, monthly, or annual basis, as well as the facility to create ad-hoc reports as required. Alarm Management System An underlying alarm management system means any alarms based on a potential failure or a threat to an asset when a threshold has been reached is raised automatically. The difficulty here is identifying which alarms needed attention and which could be dismissed as a result of defrost cycles, or when refrigerator doors are being accidentally left open. Danfoss uses Bentley’s Amulet software to count repeated similar alarms and identify which were real and which were false, and notify the right people, leading to a more proactive approach to maintenance as opposed to reacting after an incident. Eliminating false alarms from the system significantly cuts costs by reducing needless callouts of maintenance engineers. Alarm histories could also be used against the asset, the fault, or the site to highlight patterns, such as determining the reason why a particular alarm was occurring against the same asset consistently across multiple stores. Solutions There were many key solutions that enabled Danfoss customers to manage their supermarkets more efficiently and to aid decision making. Central to these is the alarm management system that is in place to monitor food quality and energy efficiency along with a visualization component to bring all of the information to together in one platform. Visualization and Reporting The collection, organization, and visualization of operational information were an important factor to Danfoss customers Managing, categorizing, and filtering alarms lead to the iden

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Operational Analytics Helps Lower Maintenance and Energy Costs to Danfoss Customers - 2

Danfoss have been using the Amulet solution for many years, helping our customers optimize their stores and reducing significant energy costs.” – Ole Skovbæk Senior Director, Product Management and Services, Danfoss HACCP Reporting Danfoss addresses regulatory food compliance with Hazard Analysis and Critical Control Points (HACCP) reports, a monitoring and reporting system that assures food production and storage facilities are safe. Using Amulet for data collection and visualization, HACCP reports show the average temperature during an hour (from typically four 15-minute intervals) of any...

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