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