Background:

The client, a prominent tyre manufacturer in Pakistan, aims to reduce its carbon footprint and enhance energy conservation initiatives. As part of this mission, the company decided to implement an advanced Energy Management System to effectively monitor and manage energy consumption across its facilities.

System Description:

FAIZAL undertook the project by installing advanced multifunction meters (MFMs) with communication capabilities in the MSB. The MSB distributes power to key sections of the factory, including the Mixing, Cutting, Tyre Building, Curing, and Air Compressor sections. The MFMs were installed at 9 feeders within the MSB to monitor parameters such as Current, Voltage, Frequency, Apparent Energy, Apparent Power, Active and Reactive Energy, and Active and Reactive Power.

These MFMs communicate the collected data via the RS-485 Modbus RTU protocol to a central Energy Management Software system. A two-wire communication cable, connected in a daisy chain configuration, links each meter, enabling the central EMS to gather comprehensive data from all feeders in a single loop.

The central Energy Management Software employed is eXware – IoT Gateway for Industrial Digitalization, deployed on local servers. This client-server based software allows the customer to analyze and monitor energy consumption and wastage across various sections. Multiple dashboards and reports are configured for detailed area-wise consumption and wastage analysis, as well as shift-wise, weekly, and monthly production versus consumption analysis.

Customers can access these dashboards and reports from any computer or laptop within the same network, facilitating easy monitoring and management.

Key Features of the Energy Management Software:

• Data Collection and Presentation: Collects, aggregates, and presents data in various formats using charts and graphs.
• KPI Analysis: Analyzes and compares Key Performance Indicators (KPIs) such as consumption, wastage, trends, power quality, performance analysis, peak demand, tariff analysis, fault analysis, efficiency, and idle time through dashboards and reports.
• User Access Control: Provides multiple user access with differentiated access rights.
• Notifications and Alerts: Generates notifications and alerts for critical events.

Implementation Approach

The implementation of the EMS enabled the customer to identify significant energy wastage in the Instrument Air Compressor section. It was discovered that the compressors were running continuously during weekends and non-production days due to leaks in the instrument air line. This discovery facilitated corrective actions, leading to substantial energy savings and improved operational efficiency.

Detailed System Components and Process:

1. Multifunction Meters (MFMs): Installed in the MSB to monitor critical electrical parameters. These meters provide real-time data on current, voltage, frequency, apparent energy, apparent power, active and reactive energy, and active and reactive power. The MFMs are capable of communicating this data using the RS-485 Modbus RTU protocol.
2. RS-485 Communication Network: A robust and reliable two-wire communication cable connects all MFMs in a daisy chain configuration. This setup ensures efficient data transfer to the central EMS.
3. Serial-Ethernet Converter: Facilitates the integration of the RS-485 network with the central EMS by converting serial data to Ethernet format.
4. eXware – IoT Gateway for Industrial Digitalization: This advanced client-server based EMS software provides comprehensive tools for data visualization, analysis, and reporting. It supports multiple dashboards and customizable reports, enabling detailed monitoring of energy consumption and wastage.
5. Central Monitoring and Analysis: The central EMS collects data from all feeders, allowing for a holistic view of energy usage across the facility. The system supports various analyses, including consumption trends, performance analysis, peak demand analysis, and efficiency monitoring.
6. Energy KPIs and Variables: Specific energy Key Performance Indicators (KPIs) and variables are monitored in each section of the plant. These KPIs help identify areas for improvement and optimize energy performance.
7. Notifications and Alerts: The EMS generates real-time notifications and alerts for critical events, ensuring prompt response to any anomalies or inefficiencies.

Impact and Benefits:

The implementation of the EMS has significantly enhanced the client’s ability to monitor and manage energy consumption. The system’s advanced analytical capabilities have led to the identification of key energy wastage areas, such as the continuous operation of air compressors during non-production periods. Addressing these inefficiencies has resulted in substantial energy savings and improved operational control.

The flexible and scalable nature of the EMS allows for future expansions and adaptations, ensuring that the system can evolve with the client’s changing needs. Overall, the project has provided the client with a reliable and sophisticated energy management solution, aligning with their goals of reducing carbon footprint and promoting energy conservation.

By partnering with FAIZAL, the client has successfully transitioned to a more sustainable and efficient energy management framework, reinforcing their commitment to environmental responsibility and operational excellence.