ABB: Cutting-Edge Energy Savings for Sustainability

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ABB's Florence site
An ABB Electrification Services facility is slashing costs, cutting carbon and pioneering a sustainable future through smart technology and innovation

Energy efficiency not only saves money, but can also reduce Scope 2 emissions from energy procurement.

The ABB Electrification Services facility located in Florence, South Carolina, USA is transforming its operations through energy-saving measures.

This sprawling 150,000sq ft site not only serves as a pivotal aftermarket support and service centre, but also excels in energy-saving practices that have redefined its operational protocols.

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Around 100 experts at the facility maintain vital power infrastructure by repairing, retrofitting and upgrading electrical distribution equipment, including switchgear and breakers, essential for continuous utility in various industrial and commercial sectors throughout the US.

The energy-saving measures adopted by ABB at this location underscore a significant reduction in its carbon footprint while also curtailing annual energy expenditure by more than US$150,000.

Optimising operations through technology

At its Florence site, ABB Electrification Services champions a dual focus on operational efficacy and environmental sustainability.

This approach is evidenced by its sustainable initiatives that have taken precedence in its operations.

Florence’s energy efficiency journey:
  • The site saw a HVAC overhaul, with the aging air conditioning system retrofitted with new roof units and modern control automation, eliminating the need for natural gas heating
  • Narrower restricted flow pipes and low-flow faucets were installed to reduce water consumption
  • Florence’s 90,000 sq ft shopfloor saw its 240v metal halide lighting replaced with modern LED units, an investment that paid for itself in less than three years
  • State-of-the-art software from Ndustrial was implemented to provide real-time insights into energy usage patterns

One transformative innovation is the deployment of Ndustrial’s real-time monitoring software.

By integrating more than 20 monitors throughout the site, Ndustrial's technology feeds vital consumption data to an online dashboard.

This setup provides the ABB team with actionable insights, enabling real-time operational adjustments and energy management strategies.

Shawn Shockey, Manager of Manufacturing for ABB Electrification Service says: “One of the first things we noticed were peaks in power demand for the AC system throughout the day and that immediately makes you ask what’s going on. 

Shawn Shockey, Manager of Manufacturing for ABB Electrification Services

“You want to know what’s happening at that time of day and what’s causing the extra demand.

“One thought we had was that because the warehouse is not air conditioned, perhaps the system was working extra hard at times to normalise the overall temperature. We thought we should do the math on this and find out if it would be more efficient to install another AC unit in the warehouse than pay the additional energy costs.

“Now we are bringing in an outside auditing firm to do the analysis and confirm our suspicion.”  

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The partnership with Ndustrial swiftly transitioned into tangible benefits including:

  • Detection and cessation of unnecessary air compressor usage during weekends
  • Thorough analysis and ongoing refinement of warehouse temperature regulation.

“Ndustrial is a powerful tool for helping businesses understand their energy intensity — the amount of energy, emissions and cost required for one unit of production,” Shawn adds. 

“We are only just scraping the surface of what the software is capable of.”  

Stepping towards renewable energy

The Florence site's roadmap for sustainability has an exciting future endeavour: a substantial solar project.

The installation of 1500 solar panels across three acres will generate 840kWac, potentially rendering the site's monthly US$15,000 electricity bill obsolete.

ABB Electrification Services' site in Florence has been overhauled thanks to Ndustrial software

Shawn explains: “You need to play the long game when it comes to investing in renewables. There is a plethora of fast-moving new technology in this space, so it pays off to do your research, get good advice and make sure you select the correct long-term solution the first time.  

“Alongside the solar farm, we will be introducing the latest Battery Energy Storage System (BESS) solutions to ensure a consistent, uninterrupted supply of electricity even when the sun isn’t shining. 

“You've got to be patient and vigilant with this type of project but ultimately the effort pays off.” 


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