Energy Management for Industries
In this age of rapidly dwindling natural resources, the prudent use of available resources cannot be overemphasized both from the economic and environmental standpoints.
One such critical and increasingly expensive resource is energy. Energy in Industrial use constitutes a high percentage of all energy produced. Energy Management is therefore key to maximizing productivity at the least possible energy cost.
Energy Management involves the following basic cyclic steps,
Get - Get the right data on actual energy consumption
Set - Set Targets for optimum use of energy, Monitor deviations, Plan corrective action
Save - Execute Energy saving plans
Review - Monitor progress towards the goal and Refine action plans
As can be seen from the above, a good Energy Management System or Solution (EMS) must provide continuous, reliable and actionable information to effectively implement our energy saving plans.
A modern EMS has the following components,
Data collection - Information is everything
Fully automated, accurate meters for measuring real time data from all critical consumption points, 24x7. These may be to measure the key parameters to understand the quality and quantity of any critical resource such as Electricity, Water, Gas, Steam or Air
Data transmission - Data lost is opportunity lost!
Moving this measured data without any corruption or loss to a Data Processor for analysis using specialized software. This usually involves a system of Converters / Gateways connected to the meters on a MODBUS network one the side and Computers on the other on an Ethernet or Cloud Network. Intelligent Gateways available are available today with in-built memory to ensure zero data loss even in case of communication network failure. In addition these Smart Gateways can also capture and transmit Alarms via SMS and have multi-system (SCADA / DCS / ERP etc) communication capability so these can be integrated with EMS
Data Analysis - Reports & Alerts for Action
Converting the collected raw data into actionable reports to generate Energy saving plans and achieve cost savings. The software to do this needs to be user-friendly and precise in its analysis and in the presentation of reports.
The EMS generates reports in the following broad categories,
Electrical Energy Accounting & Power System Management:
l Plant Energy & Power flow monitoring
l Demand & PF Monitoring to avoid penalties
l Open Access and Time of Use planning
l EB meter cross check - Bill matching
l Power Quality Analysis including Harmonics
l Department wise / feeder wise energy - Flexi grouping
l Cost center reports (Shift wise, daily, weekly, monthly etc)
l Specific Energy Consumption (SEC / EPI) - Plant / Department wise
l Pareto Analysis to identify areas for action
Utilities Management
l Diesel Generators - Cost per Unit, Units per Litre
l Air Compressors - kW/cfm
l Steam Generation (Boilers) - kW/kg
l Heating, Ventilation or Air Handling / Air-conditioning Equipment - kW/ton, EER
l Water - Raw / Treated (ETP/STP) etc - Litres/person, Recycle %, kW/litre etc
Load Management
l Monitoring of critical Machinery loads
l Machine wise SEC analysis and Bench-marking across similar machinery
l Loss accounting in Machinery loads - Understand Electrical, Mechanical & Operator losses
l Utilization analysis
l Targets vs actual - highlight or alert on deviations
l Energy Saving & RoI Calculator
n Steps taken for conservation can be recorded and progress can be monitored pre and post implementation
n Investment, savings and RoI calculations can be performed based on actual savings recorded by the EMS
l Maintenance Module
n Maintenance alerts/reports based on run hours or calendar schedule
n Predictive maintenance alerts based on SEC or any other critical parameter
An EMS implemented with the right meters, right network, right software and most importantly the right partner will surely pave the way for a Energy efficient enterprise.
For more details visit : Energy Management Software
Contact Us on: +91 44 4278 0600
Email Id : energy@atandra.in
Very informative
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