“The system has exceeded our expectations in terms of both energy savings and other resource conservation.” —James Breeze, energy services business manager, Eastman Kodak
Energy Information System saves millions on water, power consumption
Kodak’s Eastman Business Park industrial complex in Rochester, NY, is more like a city than a manufacturing plant. With 1,300 acres and 150 buildings, the park is Kodak’s largest manufacturing site and has 30 miles of roads, its own fire department and railroad, and power plant.
Not surprisingly, it takes a lot of power and water to keep this industrial city going.
Five years ago, Kodak set out to monitor and reduce the amount of power and water consumed at the site. The company launched what it calls an Energy Information System that allows production teams and plant and building managers to access in near–real-time information about water and energy use. As part of the company’s overall sustainability initiative, Kodak also set energy and water usage goals and made those same managers responsible for meeting these goals.
The results have been impressive. Between 2002 and 2008, Kodak was able to reduce energy consumption by 40%. Energy savings now run at about $30 million per year compared to 2005 levels. And, in 2008, Kodak reduced water consumption at the site by 16.5%, or 1 billion gallons of water per year.
Since then, Kodak has reduced its water consumption by an additional 300 million gallons in both 2009 and 2010.
“The system has exceeded our expectations in terms of both energy savings and other resource conservation,” says James Breeze, energy services business manager at Kodak. Such results earned Kodak a 2011 PM100 Award in the Leadership Mastery category.
At the heart of the Energy Information System is OSIsoft’s Pi data historian system. Kodak uses Pi to collect real-time information from some 30 systems including distributed control, programmable logic controllers, and building automation systems. Presented through an SAP portal, the information allows engineers to understand energy consumption as it happens. Using the real-time energy consumption data, plant teams are able to quickly understand the impact that their energy conservation efforts are having.
Kodak is now beginning to use the Energy Information System for diagnostic applications as well. The system collects comprehensive data about infrastructure such as water-main flow rates that can be used to detect if a problem has occurred or is about to occur.