ENERGY MANAGEMENT SYSTEM (THE CEMENT INDUSTRY)

www.powercorporation.in

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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