Case Study · Steel pipe manufacturing · A helical pipe manufacturer · GCC

Smart energy management for a helical pipe manufacturer in the GCC

3 million sq ft of built-up area. Four pipe production lines spread across a 100-acre yard. 5.3 million kWh of monthly consumption in the main production unit. Years of unplanned expansion had left power quality, consumption, and earth-fault risk largely invisible. SEnergy IoT changed that.

15–17%
Average annual savings over 3 years
5.3M
kWh/month monitored in main unit
100 acres
Production yard instrumented

The challenge

  • 3 million sq ft, 4 pipe production lines, 100-acre yard — and no central view of energy.
  • 5.3 million kWh per month consumption in the main production unit, with excessive energy usage in non-working hours.
  • Frequent unplanned plant expansion over the past years, leaving distribution and metering out of step.
  • Unknown power factor, harmonics, power quality, and no energy disaggregation.
  • Inability to quantify and isolate electrical problems; source of input/output power disturbances unidentified.

Objectives

  • Reduce energy and maintenance cost.
  • Quantify electrical parameters of major and critical production equipment.
  • Identify distribution imbalances across the entire plant.
  • Alert on threshold breaches in current, voltage, power, power factor, harmonics, and more.
  • Quantify usage and wastage of power by shift and by product.

What SEnergy IoT did

Targeted instrumentation

Site survey identified the energy guzzlers. Smart energy meters and monitoring hardware were installed on the targeted equipment and networked to the SEnergy Cloud.

Per-line, per-shift metrics

Energy metrics were produced for each product line and shift. Duty cycle, peak, and off-peak energy consumption were quantified against baseline.

Power quality & analytics

Consumption, usage, and wastage analysed. Visual analytics and reports delivered. Efficiency and conservation metrics defined and tracked.

Safety-grade alerting

Real-time alerts configured for threshold breaches of critical electrical parameters. Earth-fault conditions alerted and eliminated, preventing fire mishaps.

Results

  • Average annual energy cost savings of 15-17% over 3 years.
  • Specific energy consumption quantified for the main product line.
  • Earth-fault conditions alerted and eliminated; chances of fire mishaps averted.
  • Enforced overdue spare replacements and improved SLA adherence.
  • O&M team made aware of pre-existing maintenance blind spots.
  • Eliminated the need for unfruitful and costly external energy audits.

Platform & integrations

Smart Energy Meters Modbus TCP Earth-fault Monitoring Power Quality Analytics Duty-cycle Tracking Per-line Disaggregation SEnergy Cloud Threshold Alerting

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