End User:

Leading Tyre Manufacturer in India (Confidential)

 Scope:

Supply, Installation and Commissioning of Energy Management System including Data Acquisition System with Central Monitoring Software for 9 energy meters in MSB and its networking via RS 485 cable to the Serial-Ethernet converter. Scope of work also includes CT mounting, paneling, cabling and configuring of meters, converter and software.

 Background:

The customer is one of the leading tyre manufacturers in India and is on a mission to reduce carbon footprint and to initiate its activities towards Energy Conservation. Towards this mission the customer thought of implementing an Energy Management System.

System Description:

CONSYST approached this assignment by installing smart multifunction meters (MFMs) with communication capabilities in the Main Switch Board (MSB) from where the Power is transferred to major equipment in the factories like Mixing section, Cutting section, Tyre Building Section, Curing section, Air Compressor etc.. The MFMs were installed at 9 feeders in the MSB, the parameters like Current, Voltage, Frequency, Apparent energy, Apparent power, Active and reactive energy, Active and reactive power etc were fetched from each of the feeders. The MFM has the option to communicate the collected parameters in RS 485 Modbus RTU protocol to a central Energy Management Software. A two wire communication cable connected in daisy chain fashion from each of the Meters will help the central EM software to fetch the complete parameters in a single loop.

The central Energy Management Software is IIoTNext platform deployed on local servers. This client server based software allows the customer to analyse and monitor the energy consumption & wastage in each section. Multiple dashboards & reports are configured for area wise consumption and wastage analysis, shiftwise, weekly and monthly production v/s consumption analysis. The customer could access the dashboards and reports from any computer or laptop connected in the same network.

Apart from regular monitoring & reviewing of energy  consumption, We have implemented Energy variables & Energy KPIs at each section which can impact  the consumption & performance. These variables are  checked & monitored to achieve consistent energy  performance.

Key features of Energy management Software:

• Collects, Aggregates and Presents the data in required formats using different charts & graphs
• Analysis & Comparison of KPIs like Consumptions, wastage, trends, Power quality, Performance analysis, Peak demand analysis, Tarif analysis, fault analysis, Efficiency, Idle time etc using Dashboards and Reports
• Multiple user access with different access rights
• Notifications & Alerts on Critical events

Result:

By Implementing the Energy management system the customer identified a key energy wastage in the Instrument air compressor section. The compressors were running continuously during the weekend and no production days due to the leakage in the instrument air line.