Plastics

  • Wide and huge production area in million sq.ft
  • Energy consumption in million units per month
  • Unknown production energy rationalization
  • Unknown energy breakup by production line and shift
  • Unknown quantum and source of electrical problems
  • Excessive scrapping and remelting of virgin plastic
  • identify distribution imbalances across shop floor
  • Measure various electrical parameters of production equipment
  • Identify and Resolve Earth leakage faults
  • Identify load imbalances, Prevented fire hazards
  • Curb Unnecessary Usage to reduce overall Target bill
  • Enforce Overdue spare replacement to Enhance SLA Adherence
  • Eliminate need for unfruitful and expensive energy audits
  • cost cutting of Drive AMC & Energy

Iron and Steel Smelters

  • vast and wide production area in million sq.ft
  • Electrical consumption in million units/month
  • Electrical load imbalance across production area
  • Unknown individual consumption and load disturbances
  • Heavy consumption of energy in non working days due to unstructured facility expansion
  • Quantify Duty Cycle, Peak and Off-Peak consumption
  • Isolate and alert O&M on Wastage and Loading Pattern
  • Provide real time alert of energy and power quality metrics
  • Analyze Consumption, usage and wastage pattern
  • Enforce Overdue spare replacement to Enhance SLA adherence
  • Structure unwanted usage to bring down overall target bill
  • Continuous engagement in cost cutting of AMC ,energy and manpower
  • Quantify specific energy for each ancillary
  • Prevent fire hazards
  • Highlight pre-existing maintenance blind spots through workshop

Steel Structure and Pipe Fabricators

  • The most commonly used materials in commercial and industrial building construction.
  • 550˚C to 620˚C are commonly used in steel structuring
  • The large structures make up power plants
  • Largest cooling towers and the boiler frame structures
  • Unstructured production energy rationalization
  • Unknown energy consumption
  • Consistent load disturbances
  • Lack of optimization and synergy across facility
  • Vast amount of periodical data collection by sensors
  • Array of electronic measurement and monitoring systems
  • Record, network, and use numerous machine and product parameters to control the machines to ensure quality
  • Allow to trace back to exactly which operation and at which position a defect in a product occurs
  • SEnergy smart meters helps to cut their CO2 emissions and reduce wasted energy.
  • Periodic and frequent data helps in making gains in productivity,
  • Measure exactly the grades of steels that are the most energy intensive

Copper Smelters

  • Modern smelting involves more advanced types of furnaces, numerous smelting parameters to separate ore and metal most efficiently.
  • Temperature is a crucial factor controlling the efficiency of metal separation from ore
  • Dry or granulated form of copper, along with SiO2 flux and O2 (or air) is fed into a heated smelting furnace at 1200–1300 °C.
  • Harsh environment often prevents obtaining mineral information and measurement data.
  • Highly uncertain data and delayed measurements
  • Number of flash smelting furnaces, converter furnaces, anode furnaces, anode casting wheels, and refineries are isolated hence no data given to organization
  • Lack of real-time operational data collection
  • Provide automatic schedule advisory information to operators.
  • More efficiency in smelting copper
  • Give access of data to understand what went wrong when a fault needs troubleshooting
  • Real time data to predict the faults before they happen and reduce down time
  • Provide visualized intelligence

Aluminum

  • Aluminium smelting helps to pull aluminium from its oxide using electrolysis.
  • Process includes extreme temperature 800°C
  • Minor errors could lead to significant problems.
  • Aluminium decline cell often come upon inadequate performance
  • Increase in energy consumption,
  • Increase the emissions of fluorocarbon gases
  • Un identifiable noise patterns like metal pad roll, and short circuiting sound
  • Bridge the gap between industrial equipment, infrastructure and new technologies such as cloud
  • Inform business owners if their equipment functioning at most favourable health.
  • Provide handy and organized solutions for even the most composite device hierarchy
  • Initiates data collection on operation conditions for well being of machines
  • Analyze data in to meaningful information to automate process in machinery
  • Provide frequent and periodic data for predictive maintenance
  • SEnergy smart meters facilitates anomaly detection by continuous and consistent monitoring

Oil and Gas

  • Oil and natural gas are foremost industries in the energy market that participate an influential role in the global economy
  • Exploration and production sector
  • Explore from onshore/offshore acreage that might contain oil or gas.
  • Part of petroleum industry that includes activities like drilling wells, trucking supplies, and mining oil sands.
  • Upstream, midstream, and downstream are three major sectors of oil and gas industry
  • Finding and producing crude oil and natural gas a related to upstream sector
  • Midstream entail the transportation, storage, and processing of oil and gas.
  • Downstream sector involves oil refineries, petrochemical plants etc…
  • Fuel oil and gasoline (petrol) are fuel oil and gasoline (petrol)
  • Oil and Gas Industry spends trillions of dollars every year on exploration, development, and maintenance of assets.
  • The upstream industry loses billions of dollars every year due to non-productive time (NPT).
  • Accidents are major threats in upstream industry as even a small accident will have huge impact on position of the company
  • Lack of knowledge on leakages and lack of interaction on emergency shut down while transporting volumes of products to market and end user
  • Poor optimization of process
  • Unplanned shutdowns and lack of safer working environment
  • Provide digital oil field infrastructure
  • Superior safety and security of asset
  • Real-time machine and sensor integration
  • Real time data collection helps in Predictive maintenance that leads to reduced cost of maintenance
  • Trigger maintenance workflow by linking Enterprise Resource planning Data
  • Data collection in a periodic and continuous manner yield a historical record for the purpose of performance analysis
  • Real time alerts and interaction on emergency conditions
  • Monitor equipments and pipeline for updating health of equipments
  • Improve energy efficiency

Cables and Pipes

  • Cables and pipes are manufactured by Extrusion process to create a particular shape.
  • The raw material is fed into the extruder through hopper and a volumetric control system
  • Inside the extruder barrel the temperature is maintained around 200°C by electricity and the friction in the screw system.
  • Huge energy consumption process
  • Various types of pipes like seamless pipes ,welded steel pipes etc…are manufactured under different manufacturing process at various temperature levels
  • High temperature variations make the process difficult
  • Rigidity and inflammatory engineering system
  • Poor predictive maintenance on energy consumption
  • Lack of optimisation of process energy demand
  • Smart Manufacturing by means of software and data
  • Integrate end-to-end processes product measurement and quality data
  • Enterprise-wide integration of manufacturing and business processes
  • Frequent and Periodic Data collection for production process
  • Advanced data analytics for product quality measurement
  • Real-time alerts for better control of equipments to avoid un wanted cost of repairs
  • Faster and flexible large-scale operation of shop floor systems
  • visualize and enable decision making anytime and anywhere
  • Reduce operational complexity in few clicks
  • Offer framework for integration of internal and external processes to ensure alertness and responsiveness
  • Accelerate waste reduction and rework

Extrusions

  • A metal forming process to create objects of a fixed cross-sectional profile
  • Extruders are supplied with electrical energy for their operation and this energy is converted into mechanical or thermal energy
  • The most common material extruded are plastic and aluminium.
  • Extrusion is used in production of tubes and hollow pipes.
  • Aluminum extrusion is used in structure work in many industries.
  • Extrusion is widely used to produce plastic objects.
  • Temperature for extrusion hot extrusion process ranges from 350 C– 2000 C
  • Energy intensive production method
  • Generally extruders consume energy through the drive motor, barrel heaters, cooling fans etc..
  • Extrusion companies have considerable impact on their energy efficiency as the electrical motors are the dominant power consumers in extrusion plants
  • Accelerate waste reduction and rework
  • Improper System Engineering
  • Difficult to run the extrusion process at higher processing speed during thermal fluctuations
  • Poor process energy efficiency
  • Lack of ability to optimise energy efficiency and thermal efficiency concurrently when achieving desired output rate and melt quality.
  • Difficult to predict process energy consumption which plays a key role in optimising the
  • Provide vigorous data acquisition processes
  • Develop standardized protocols for machine-to-machine communication
  • Increase adaptability and extruder integration with other manufacturing line components
  • Real time monitoring of information of data on energy consumption, heating zones efficiency and temperature stability allow managers to examine operational cost in real time
  • Give alerts and notification in case of anomaly in critical equipments to avoid unexpected
  • Allow remote maintenance capabilities by means of secure connection protocols
  • Analyse data of connected devices for defects to indicate preventive maintenance
  • Review historical data and scheme production parameters trends that enable further effective operations outline and equipment management.
  • Enhance quality, productivity and efficiency all the way through better management of information and resources