Overview
A leading steel product manufacturer sought a comprehensive energy management solution to monitor and optimise electricity usage across its multi-functional complex. Our customer, aiming to reduce operational costs and carbon footprint, required a system capable of remotely tracking energy consumption, identifying inefficiencies, and supporting preventative maintenance. With Metromatics’ energy management system, we enabled effective monitoring across the complex’s key areas—Office, Manufacturing, Warehouse, and Dispatch—and provided real-time solar production insights from their solar banks.
Client Needs
The client’s goals included:
- Efficient Equipment Monitoring: Ensuring that all machinery and systems operated optimally across the facility.
- Area-Specific Energy Tracking: Measuring energy use in each section to uncover potential cost-saving opportunities.
- Remote Access for Sustainability Management: Enabling the sustainability manager to remotely assess and act upon inefficiencies.
- Preventative Maintenance Capability: Identifying early signs of potential failures to sustain high operational efficiency.
- Real-Time Solar Production Measurement: Tracking energy output from solar banks to optimise energy sourcing and reduce grid reliance.
Solution Implementation – Energy Management System for Steel Plant
We deployed our Energy Management System with multiple Power Quality Analysers (PQA) strategically installed across distribution boards to capture detailed energy data from each section of the complex.
Office (18-channel PQA)
To manage the office area, an 18-channel PQA was installed, which monitored:
- Main Supply (3-phase)
- AC Units (3 units, each on 3-phase)
- Lighting (single-phase)
- Server Room (single-phase)
Manufacturing Plant (3 Distribution Boards, each with an 18-channel PQA)
- Distribution Board :
- Main Supply (3-phase)
- Industrial Presses (2 units, each 3-phase)
- Industrial Rollers (2 units, each 3-phase)
- Lighting Section 1 (3-phase)
2. Distribution Board:
- Main Supply (3-phase)
- Welding Bay (3-phase)
- Box Machines (2 units, each 3-phase)
- Lighting Section 2 (3-phase)
3. Distribution Board:
- Main Supply (3-phase)
- Welding Bay 2 (3-phase)
- Assembly Bay (3-phase)
- Charging Station (3-phase)
- Compressor (3-phase)
- Lighting Section 3 (3-phase)
Main Switchboard (9-channel PQA)
The main switchboard included a 9-channel PQA to monitor:
- Main Supply (3-phase)
- Solar Production (2 units, each 3-phase) providing real-time solar energy production insights.
Outcomes and Benefits
The Power Quality Analysis system met the client’s requirements by enabling efficient, remote, and granular energy monitoring, which delivered the following benefits:
- Enhanced Efficiency and Cost Savings: By identifying high-energy-consuming areas and equipment, the client adjusted operations to reduce waste and cut costs.
- Sustainability and Carbon Footprint Reduction: Real-time data facilitated decisions that contributed to a reduced carbon footprint, supporting the client’s commitment to net-zero emissions.
- Remote Monitoring and Control: The sustainability manager could remotely access energy data across the facility, making informed decisions without being onsite.
- Preventative Maintenance: The PQA system’s insights into energy usage patterns allowed proactive maintenance, reducing downtime and extending equipment life.
- Real-Time Solar Production Tracking: Monitoring the solar bank’s output provided a clear view of alternative energy contributions, helping reduce dependency on grid power.
Conclusion
The Energy management system enabled the steel manufacturing client to optimise operations, reduce costs, and progress toward sustainability goals. Through precise monitoring, remote management, and preventative maintenance, the facility now operates with enhanced efficiency and a lower environmental impact, positioning it as a forward-thinking player in the industrial sector. Looking for Energy Management System for your Steel Plant or Manufacturing Facility? Contact our friendly team now.