Going Green With Zenon Supervisor: CarrefourSA Turkey Implements Zenon For Efficient Energy Management

Carrefour opened their first shop door in 1963 in France and today they boast with more than 16,000 stores in over 30 countries engaging around 470,000 employees. In 1993, CarrefourSA opened their first store in Istanbul, Turkey and with the help of its cooperation with Sabancı Holding,the business began to take off. Today, CarrefourSA has 243 stores in Turkey, employing 8,000 staff.

Reducing energy expenditures

For the retail sector, energy is one of the main expenditures and this, in turn, has a direct effect on the price of the end product. Lighting, cooling, heating and refrigrator systems consume energy in significant amounts, and these should be monitored for energy efficiency and consumption. At the beginning of 2012, CarrefourSA started an energy saving program with an investment plan to improve their lighting and automation systems. The program required a central control and management system with the ability to control and monitor all consumption areas.

The goal of the project was to reduce the overall annual energy consumption, particularly where equipment was out-of-date, and gain full control of the retail stores from one central location

The solution for fully automated retail markets consisted of implementing central and remote SCADA servers with the ability to handle large numbers of parameters, installing new energy meters, automation panels and PLC control panels. For CarrefourSA, zenon was the best solution – with its ability to handle numerous monitoring parameters and its advanced networking features.

The SCADA solution

zenon Supervisor is an independent SCADA system, with which you can operate more profitably in the long term. Make work easier, inspire your customers and motivate your employees. Automate quickly and safely with zenon Supervisor and have the perfect tool to bring ergonomics to your projects, from engineering to the runtime, or in maintenance. With the proven principle of “setting parameters instead of programming” you can shorten your engineering time by up to 80%. Extensive network functions, simple access via any web browser and connection of any desired hardware – zenon already offers all this “out of the box”.

Using zenon, you can develop projects in your own particular style, use available templates and intelligent wizards. You are able to reuse previously created objects and symbols in other projects and keep an overview with the multi-project administration, also when working in a team. What’s more, well documented administration allows you to quickly find your way around any project and also easily access projects and equipment remotely.

You will be informed of whatever is happening in as detailed a way as you wish. Starting with the history of changes in engineering, up to effective reports in the Runtime, right up to calculating complex KPIs such as OEE.

Full data security, maximum availability without downtimes as well as secured data is guaranteed. zenon network technology with seamless redundancy and circular redundancy makes it possible. zenon is continually adapted to meet modern safety standards. This provides stable and safe equipment running.

Energy saving strategy  

zenon Supervisor has over 300 communication protocols available, making integration of projects easier.These benefits have been utilized by SGE Engineering who have integrated DALI Automation in CarrefourSA hypermarkets, meters, various PLC systems and I/Os.

As part of the energy saving project at CarrefourSA, the SGE Engineering team executed a dimming project which resulted in 50% savings in hypermarket lighting and even more when there is adequate sun light. All lighting is controlled by zenon Supervisor in the hypermarkets where zenon SCADA is integrated and each dimming level can be monitored and controlled.

Dimming levels can be adjusted by use of a schedule, or by light levels directly in the hypermarkets. Retail stores are automated by using PLCs and contactors with user-configurable schedules.

Special Elnet MC Multifunction Energy meters were used for the project with the ability to monitor 12 feeders simultaneously using one meter. Not only energy values but also power quality values can be monitored – up to 12 three phase feeders, or 36 single phase loads.

Measured results

Using zenon, technical engineers can access the retail stores or hypermarkets remotely and have full control of the system from the SCADA server at their headquarters. Retail stores have automated control and hypermarkets have their own SCADA systems, where the main SCADA server is redundant to the hypermarket SCADA system.

Without monitoring you cannot be in control and have the ability to react efficiently. Therefore, having a central cost control system, CarrefourSA engineers can monitor their retail stores, compare the M2 consumption values and react at the retail stores where consumption of M2 kwh is higher than it should be.

Any energy saving investment can be monitored online and decisions can be taken when previous reference values are given. The project had been designed by SGE engineers who have integrated more than 30,000 monitoring tags in zenon Supervisor, giving 1 second updates on local servers.

CarrefourSA has invested in zenon Supervisor. The result of all their energy consumption optimization measures is extensive savings of more than 1.5MW per hour.

On COPA-DATA

COPA-DATA is the technological leader for ergonomic and highly dynamic process solutions. The company, founded in 1987, develops the software zenon for HMI/SCADA, Dynamic Production Reporting and integrated PLC systems at its headquarters in Austria. zenon is sold through its own offices in Europe, North America and Asia, as well as partners and distributors throughout the world. Customers benefit from local contact persons and local support thanks to a decentralized corporate structure. As an independent company, COPA-DATA can act quickly and flexibly, continues to set new standards in functionality and ease of use and leads the market trends. Over 100,000 installed systems in more than 50 countries provide companies in the Food & Beverage, Energy & Infrastructure, Automotive and Pharmaceutical sectors with new scope for efficient automation.

On zenon

zenon is COPA-DATA`s highly versatile product family for industry-specific ergonomic process solutions: from sensors through to ERP. It consists of zenon Analyzer, zenon Supervisor, zenon Operator and zenon Logic. zenon Analyzer provides templates to create tailor-made reports (e.g. on consumption, downtimes, KPIs) based on data from IT and automation. zenon Supervisor, an independent SCADA system, allows comprehensive process monitoring and control of redundant systems, even in complex networks and with secure remote access. zenon Operator guarantees, as an HMI system, safe control of machines and simple, intuitive operation – including Multi-Touch. zenon Logic, which is an integrated IEC 61131-3-based PLC system, allows optimum process control and logical data processing. As a platform-independent portfolio for process solutions, the zenon Product Family integrates smoothly into existing automation and IT environments and provides set-up wizards and templates to enable easy configuration and simple migration from other systems. The principle of “setting parameters instead of programming” is a characteristic feature of the zenon Product Family.