Case Study · Steel manufacturing · A major steel manufacturer · Abu Dhabi, UAE

Smart energy management for a major steel manufacturer in the GCC

13 buildings. 300,000 sq ft of admin and ancillary floor area spread across 1.75 sq km. 1.25 million units of monthly electricity consumption. Six years of unstructured facility expansion had buried the energy signal under noise. SEnergy IoT brought it back.

~5%
Annual energy savings
13
Buildings instrumented
1.25M
Units/month baseline consumption

The challenge

  • 300,000 sq ft spread across 13 buildings in a 1.75 sq km facility, with six years of unstructured expansion.
  • Excessive off-peak energy usage and unmanaged blind spots in power consumption.
  • Unknown power factor, harmonics, power quality, and no energy disaggregation.
  • Supply and load disturbances that could not be traced back to a source.
  • Inability to quantify and isolate recurring electrical problems.

Objectives

  • Reduce energy and maintenance cost.
  • Identify distribution imbalance in the targeted buildings.
  • Measure the electrical parameters of critical and representative equipment.
  • Alert users on threshold breaches in the electrical parameters.
  • Quantify ongoing usage and wastage.

What SEnergy IoT did

Site survey & instrumentation

A site survey identified the energy guzzlers across the admin and ancillary buildings. Smart energy meters and monitoring hardware were installed and networked to the SEnergy Cloud.

Per-building visibility

Energy metrics were produced for each individual building. A virtual meter was configured to show the total energy metrics of the facility as a whole.

Power quality analysis

The complete power quality profile was analysed with time stamps. Efficiency and conservation metrics were defined and quantified against baseline.

SEnergy Operating Centre

An SEnergy Operating Centre was created, configured, and the on-site O&M team was trained to use it, with an alerting system wired for time-bound action on anomalies.

Results

  • Close to 5% annual energy savings delivered across the admin and ancillary buildings.
  • Load imbalances identified and corrected, with real-time alerts preventing threshold breaches of electrical parameters.
  • Improved visibility surfaced pre-existing maintenance blind spots, which were addressed through workshops and training.
  • Unnecessary usage curbed and overdue spare replacements enforced.
  • Better SLA adherence across operations.
  • Continuous engagement for cost cutting in AMC, energy, and manpower.
  • Specific energy quantified for each ancillary.

Platform & integrations

Smart Energy Meters Virtual Metering Modbus TCP Power Quality Analytics SEnergy Cloud Threshold Alerting SEnergy Operating Centre O&M Training

Running a multi-building industrial site? See how we instrument it.

30-minute walkthrough. Energy monitoring, power quality, and real-time alerts across admin and ancillary operations.

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