Summary:

The energy management system is designed to reduce energy consumption, improve the utilization of the system, increase reliability, predict electrical system performance, and optimize energy usage to reduce cost.

Solution:

Energy Management system is the combination of the Hardware and Software which helps to:

Monitor: Monitoring the regular consumption of the Energy and checking any deviation from the target.
Analyze: Collecting Data and Analyzing to identify trends as to how energy was used at various production levels of a manufacturing process.
Target: Setting Targets to control the energy consumption according to the need and process.
Control: For meeting Target setting up management and technological measures.
Engagement: By displaying real-time consumption information, user can see the immediate impact of their actions. Letting user to know their real-time consumption alone can be responsible for a substantial reduction in energy consumption.
Architecture:

An EMS consists of smart energy meters, sensors and devices that monitor energy consumption and factors effecting consumption. These devices transmit data over wired network to a central server.

To Implement the EMS, we follow the below guidelines:

1. Identify the key areas where energy is being consumed, the plant is broken down into these areas/zones.
2. Installing individual meters to monitor these areas. The meters will have capability to communicate on an open protocol like MODBUS.
3. Installing Zone wise PLC for better communication with energy meters.
4. The Zone wise PLC is communicated with Master PLC.
5. Master PLC will act like a gateway to Cloud/Server. And the master PLC is having SQL connectivity to transfer the data to Local Server/Cloud.
6. We will assess what other measurements will be required to analyse the consumption appropriately. This data will be used to chart against the energy consumption, these are underlying factors which influence the consumption, often production.

Features of Software:

• Data Collection: Collect real-time and historical energy data from smart meters and sensors that will allow you to address issues within your facilities, manage energy use, and control expenses.
• Monitoring: Continuous measurement and evaluation of energy consumption.
• Data Analytics: In-depth information about all your energy consumers. Monitor measurements, metrics, and find savings and where any potential energy wastage is. Determine expected savings when negotiating new energy contracts. Check for patterns in power quality.
• Reporting: Fully automated energy reports that show an overview of relevant energy management data at a glance. Cost and energy consumption reports.
• Utility Bill Tracking: See current daily loads and compare costs and consumption with last year’s statistics. Check for irregularities in your current utility bill versus years past. Set alerts for bills that are outside of standard deviation so they can be evaluated further.

Parameters Measuring:

• Voltage (L1, L2, L3)
• Current (L1, L2, L3)
• Power Factor
• Active Power
• Apparent Power
• Forward Apparent Energy
• Forward Active Energy
• Average Voltage Harmonics
• Average Current Harmonics

We have implemented the energy management system in Automotive Industry and total of 243 energy meters are integrated and the Data is collected into the local server. Where whole data is analysed to get a better understanding of energy consumption in the Industry.

Energy Management Systems (EMS) can improve productivity and expand production, while at the same time reduce the energy consumption of production and increase economic efficiency. After implementing an EMS, a company is able to carry out energy planning, energy efficiency, consumption analysis, equipment and system management to help management make faster and better-informed decisions by providing up-to-the-minute information. This lets enterprises reduce overall operating costs, maximize profitability, accelerate growth and increase asset efficiency.