energy management system - elmeasure · • equipment of similar rating can be compared against...
TRANSCRIPT
ENERGY MANAGEMENT SYSTEM (THE CEMENT INDUSTRY)
From anytime ,anywhere connectivity for anyone, we will now have connectivity for anything!
● Dynamic control of industry and daily life ● Improve the resource utilization ratio ● Better relationship between human and
nature Forming an intellectual entity by integrating human society and physical systems
Why Internet of Things?
WHAT IS THE INTERNET OF THINGS
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ENERGY EFFICIENCY CHALLENGES • Finding and eliminating operating inefficiencies
• Modifying equipment and processes
• Energy management Planning - provide measurable results and
remarkable cost savings
TO BE NOTED
• The cost of the
expenditure on energy
resources for profitable
operations is the cost for
doing business
• It is difficult to optimize
the energy usage without
performance indicators
HOW WE SUPPORT ● Expert strategy ● Broad offering of energy efficiency services ● Best return on investment (ROI) plans ● Efficient monitoring and controlling of your energy ● In-depth analysis of your cost saving
ENERGY CONSUMPTION ANALYSIS
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Multifunctional Meters Sensors Billing Meter
Gateway
CLOUD
Local Monitoring
Remote Monitoring
Wired Wireless
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EMS COMMUNICATION MODEL
Pressure Monitoring Centrifugal pumps and fans / Compressors / Energy Consumption Analysis / Operating patterns / Load Analysis at different operating Parameters
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Steam Consumption Steam pressure & flow at boilers / Alerts / Pop ups for deviation in set value
Temperature Monitoring Preset temperature level - Kiln / Pre heater / Alerts on deviation
Lighting Loads Energy consumption / Day – Night
consumption Monitoring
Process wise Consumption Energy consumption /Run
hours / Load hours
Transformer Monitoring load analysis /
Maintaining Sanction Demand / Managing of non-critical / Individual Harmonic Monitoring
Electrical Related
Process Related
65
ELMEASURE SOLUTION
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OUR SOLUTION FEATURES
INDUSTRIES
*** Customizable as per the Industry/Customer Requirement
ELMEASURE
MIXING BED QUARRY CRUSHER
CLINKE
R
SILO
RAW MILL
PRE HEATER
CLINKE
R
COOLIN
G
KILN
CEMENT
MILL
PACKIN
G
UNIT
COAL
CRUSHE
R
COAL
MILL
ELMEASURE
GYPSUM AMBIENT AIR
Benefit: Avoids heat wastage hence
improves equipment life span
ELMEASURE
ELMEASURE
ELMEASURE
Benefit: Avoids heat wastage hence
improves equipment life span
ELMEASURE
ELMEASURE
ELMEASURE
Benefit: Idle running can be
Monitored and Controlled Benefit: Optimization of
consumption, Equipment
Efficiency can be monitored
Benefit: Optimization of Energy
consumption & Monitoring
Equipment Efficiency.
Benefit: Idle running can be
Monitored and Controlled
Benefit: Idle running can be
Monitored and Controlled
Benefit: Optimization of Energy
consumption & Monitoring
Equipment Efficiency.
ENERGY CONSERVATION SOLUTION
CONT...
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Location : Kiln, Pre heater Measurement : Energy in kWh, Temp Monitor & Temp Control Benefit : Avoids heat wastage hence improves equipment life span
Locations : ID & FD fans, Kiln drives, Mill drives, Material handling systems, Centrifugal pumps and fans, Compressor controls, VFD’s Measurement : Energy in kWh Monitor and Control Benefit : Optimization of Energy consumption
Location : Crushing -LimeStone & Coal Measurement : Energy in kWh Monitor & Control Benefit : Idle running can be Monitored and Controlled
Location : Mills - Raw, Cement, Coal Measurement : Energy in kWh, Temp Monitor & Temp Control Benefit : Optimization of consumption, Equipment Efficiency can be monitored
Location : Material Transfer Measurement : Energy in kWh Monitor & Controlling of conveyors Benefit : Idle running can be Monitored and Controlled
NETWORK ARCHITECTURE
LT Line
Packing Unit
Lighting Load
Energy Consumption at Process Side
EMS Server PC
LAN
Ethernet Switch
Ethernet Gateway
RS 485
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NETWORK ARCHITECTURE USING FIBER OPTIC COMMUNICATION
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8
… 1
Packing Plant SS
Switch with 2 SFP
LIU
Gateway
9
… 16
Gateway RS485 RS485
FO Cable from previous location FO Cable to next location
6 core FO cable
Location wise fiber optic communication
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Local
Remote
Monitoring Methods
Graph Display Benchmarking
Reporting Limit Value Monitoring
Trending Chart Display
Tools
OUR APPROACH
FEATURES OF ELMEASURE ENERGY MANAGEMENT SYSTEM
Economic Power Purchase
PF Management
Demand Management
Equipment Efficiency Study
Energy Balancing
Load Shedding
Alerts
Customized Features
• Analyzes Peak and Non Peak hour of the day
• Enables to run equipment/process when the Energy Tariff is
minimum
• Gives an idea to Plant Manager in planning the production
schedule & implementing load shifting
• Start / stop of equipment should be planned such that the
contract power demand fixed Energy Supply Company is not
overshot.
Time Of Day
Economic Power Purchase Economic Power Purchase
Power Factor Management
Low PF causes detrimental effects on equipments &
reduce the equipment efficiency
• Online Power factor monitoring
• Avg PF report enables user to take necessary
correct action if required
• Good Power quality results - enhanced
performance of equipment
PF Management
Demand Management
Benefits
• Energy reports assists to eliminate Demand Spikes
• Programmable Forecast Demand setting
• Ensures that demand not to exceed the sanction demand
• Avoids under utilization of the sanctioned demand Monitoring & Controlling
• Demand peaks with Time stamp can be identified. Events
can be studied and related with the production events
• Enables user to program threshold values of max demand
and initiate alarm / cut-off when demand surpasses
threshold values.
Demand Management
Equipment Efficiency
• Preventive maintenance based on Design Vs Actual
specifications
• Audio/Visual alarm - generated when the equipment
exceeds it threshold values
• Reduces equipment/plant down time
• Monitoring equipment performance to avoid wasteful usage
of Energy
• Equipment of similar rating can be compared against each
other with one equipment running under ideal condition is
taken as reference.
Equipment Efficiency Study
Energy Balancing
Energy Balancing
Energy Balancing essential to determining the Energy loss between Incomer and distribution loads.
Provides accurate energy loss details for design and operations. Necessary action can taken to cut down losses.
INCOMER
FEEDERS
Losses
Load Shedding
• Helps in optimizing energy consumption by shutting
down non critical loads.
• Auto and Manual options are available for user to select
predefined loads.
• Trip status of the incomer will be monitored real time
basis for tripping non critical loads
Load Shedding
Low PF Indication
Alerts - Email / SMS
• Reports like Hourly, Shift energy can be sent via Email
• SMS facility to the mobile for Hourly & Daily Energy, MD alerts
• Email and SMS can sent during abnormal conditions
• Customized Email/SMS alert options.
ELNet Server
Alerts
Customized Features 1
Specific Energy Consumption
Energy Consumed per unit of product, to analyze production cost
• Reports Energy Cost per yield
• SEC determines total cost of the production
• Process wise energy consumption Reports
• Indicates efficiency of the human Vs Machinery
Customized Features
Customized Features 2
Plant Load Factor
A measure of Plant capacity utilization
• Provides Plant efficiency
• Power generation capability of various units
• Power imported from and exported to Grid
Single Line Diagram
Schematic network visualization to monitor, manage the electrical distribution network
• Equipment Status Monitoring
• ncorporates critical equipment parameter details (UPS, battery, generator, power distribution etc)
• Provision for user configurable preset alerts
Customized Features
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Energy Saving - Corrective Maintenance & Predictive Maintenance
Corrective Action can be taken by analyzing Data
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Energy Consumption for Process related
Energy Consumption for Non Process related
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SPECIFIC ENERGY CONSUMPTION (PROCESS WISE)
● Energy Cost per yield will be report ● Coefficient of performance (COP) can be
programmed to produce reports ● Total cost for specific process
SPECIFIC ENERGY CONSUMPTION (SEC)
This is the energy consumed per unit of product to analyze production cost
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(Ref: ACC Cements)
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PRODUCTION & COST ENTRY for SEC
• Identifying unit consumption of each
machine
• Plotting Energy Vs production Curve
• Identifying Idle running or Over speed
of Equipment
• Pop up / Alerts for the events
Benchmark Entry
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OUR SOLUTION TO REDUCE WASTAGE
(Ref: ACC Cements)
Benchmarking the Energy Consumption
PROCESS WISE POWER REPORT
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(Ref: ACC Cements)
Spot Wastage
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ENERGY SAVING USING
BENCHMARKING
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DAILY AUXILIARY
REPORT (Ref: Penna Cements)
Configuration Screen
Controlling manually by clicking on required
feeder
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MANUAL CONTROL OF FEEDERS
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PROJECT REFERENCES
Excluding the other major ongoing projects...
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MANUFACTURING - PROJECT REFERENCES
POWER
STEEL
AUTOMOBILES
A global presence in over
36 countries with
10000+ clients, sales
offices in 6 countries and
2 Million products live on field.
*we’re a preferred OEM manufacturer for some of the leading international brands .
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