When the energy you consume is the metric of your performance & growth, Frequent Energy Auditing is the best way to achieve your energy targets.
The energy audit is the key source of energy efficiency initiative. With the changing time and technology, energy audit report needs more detailed analytics representation. At present, an energy audit standard report contains the details of the plant/facility, energy usage analysis and energy conservation measures. This standard reporting contains the information that is already available with the client.
The smart reporting here means more analysis of the data to get more insights. Regression analysis is such an analytical tool that needs to be a part of an energy audit report. Regression analysis gives a clear picture of how energy usage varies depending on multiple variables.
Calculation of boiler efficiency is essential if its parameters need to be controlled for either maintaining or enhancing its efficiency. But the determination of boiler efficiency using the conventional method is time-consuming and very expensive. Hence, it is not recommended to find boiler efficiency frequently. The loss due to dry flue gas, loss due to hydrogen in fuel and loss due to moisture in fuel are the major boiler losses which contribute for the overall boiler losses.
To evaluate the boiler performance multiple regression analysis need to be performed on boiler efficiency based on the boiler losses due to dry flue gas, the hydrogen & the moisture content in fuel. The coefficient of determination (R2) determines the goodness of fit.
The technique can determine the factors that are best controlled or changed to affect (increase) the efficiency or other primary performance indication of the plant, as well as to establish a baseline or best-possible operational constraints to be used to control the plant in future.
Why is it required?
The advanced technology let us have access to huge connected data that are readily available for the industrial plants. Thus there is no time constraint to an energy expert to get a huge amount of data. Analytics of these data will lead many energy saving options. To achieve this, we need more details of the inter-dependency of different plant parameters. Hence with the help of this technique, we can save more energy with the united effort by subject matter expert, operation & maintenance personnel.
We have evaluated the applicability of this technique in a power plant. But these details enable a better analysis in all the sectors as a part of the energy audit report. This type of analysis helps us perform the first level energy analysis in frequent time. This technique will have a number of applications like the prediction of future energy consumption, equipment efficiency, possible energy waste areas, etc. If this type of insights is provided in the energy audit report, the submitted report will have more impact as compared to the standard report will help choose the right energy management for you.
Here are the few tools that come handy for an energy analyst, consultant or auditor & the software that help measure, monitor, control & conserve energy.
The Maverick Energy Analyst in Johnson Controls – Pune with zeal towards energy data analytics with an interdisciplinary approach between engineering, maths & statistics. He is an Energy consultant & performed the efficiency test for most of the thermal & electrical equipment including, The Power Plant (200 MW), Chemical, Iron, Mining, Textile, Engineering, Tea and Building, etc.
Yeah, that's true because we are not cared till now.
Dear reader, Let's have a small analogy addressing you, to clearly understand what pharma industry is undergoing.
There can be multiple reasons why you undergo depression. When you are "The need of the hour" & you have not cared at all, What would you do in such situations?
You keep calm, try to give some space & time so that your importance will be noticed. Unfortunately, if you still see no response, Then you will burst out the pain you are bearing. Irrespective of the reasons for your instability, you will be surely cured by the doctors & advanced technology we have now.
If it is the same case with an industry, there are no doctors to cure this.
But, there is a hope for the owners which is, There are devices & solutions to curate the reasons & a way of stopping it from draining energy.
Let's dwell into deeper.
How is the Pharma Industry in India:
The reports provided by Pharma 2010 suggests a vision that India would be in the top 20 in the industry by 2025. This would help in enhancing the per capita GDP growth leading to further expansion of the economy.
What if Pharma Industry & the Energy Sector are not talking to each other anymore?
It will be chaos. Pharma & Energy are the basic needs now. Energy industry may survive even without pharma, but not vice-versa & ultimately the humans will be affected if either of it doesn’t exist.
Does this sound like a triangular Love story? Well, It is one but it will be adverse if humans don't patch the gap between pharma & energy because both Pharma & Energy are dependent on you & you need them the most.
Right now, Do you feel the adrenaline flowing in you?
I mean, is this curious enough?
What if Pharma Industry didn’t get a proper support from the Energy & Us?
The Machinery degradation & the manufacturing process gets hectic, Technically we will be behind the growth.
Medicine is going to be a luxury, those who have a big balance can only afford it.
Pharma Industry slowly drowns the way it operated & eventually slows down the Economy.
WHAT TO LOOK AT?
Measure, Monitor & Conserve the energy wherever possible.
Take control of the Machines by a proper process management.
You can save energy at Hospital equipment & provide uninterrupted medical treatments.
Take care of the different HVAC parameters & making both the hospitals & pharma industries more user-friendly.
HOW TO DO THAT?
As you know the utilities are the common requisites for a manufacturing Industry & one of the major areas to look at where a lot of bills can be saved in terms of electricity, water & gas. Also making them available seamless will make sure the timely usage, avoid productivity losses & reduce human interventions. Make the Pharma Industry more productive with uninterrupted power with our products like ATeS, ACCL & monitor the usage of electricity, water, and gas from a single device: Prepaid Meters. They can avoid the misfortunes in terms of equipment functioning, light, etc. by keeping the power supply intact.
Energy & Process Management:
Different opportunities exist to reduce the energy consumption in pharmaceutical laboratories, fabricating offices, and manufacturing sectors to diminish energy utilization while enhancing efficiency during production. You might need to look at Interoperability in process-centric industries.
Energy & Process Controller:
A single device to monitor & control both the electrical & Process parameters & suggest the preventive measures while analyzed using an Energy & Process Management System. Know about the product.
Real-time monitoring and reporting
A Composite system with EMS and PEMS
WHAT CAN BE MEASURED?
There are various departments that consume a lot of energy in any manufacturing unit. If it comes to commercial buildings like hospitals, there are places that need an eye to monitor. Here are a few major things where you need to concentrate to save a lot of energy & costs.
Power Quality Analyzer for Hospital equipment testing & Pharma Manufacturing:
iD-LOG 8000, an ultra-lightweight power quality analyzer with high accuracy help troubleshoot all your power quality problems by measuring harmonics, sag & swell without involving any external devices as per medical standards.
0.25% high accuracy.
Compliance to EN 50160
>24 hrs endurance
5 CT inputs 5mA- 10,000A AC
Anyways, Pharma industry is now breathing due to the commencement of a panacea for all the industrial ills & see how it helped few of the major players in this field.
Read a few success Stories:
Helping Dr. Reddy’s in their optimized productivity, energy consumption & saving.
Mastered in Technology in Electronics & Communications with 12 years of learning & expertise, A proud mother of one, Ms Chandrakala is a certified six sigma – green belt holder & featured in the inaugural edition of The Machine Maker – Felicitating the Women in Manufacturing Industry.
Indian Textile Industry hits the 5th Millennium: The archaeological surveys and studies have found that the people of Harrapan civilization knew to weave, and the spinning of cotton four thousand years ago. Apart from the Bronze age civilization, There was a proof for textile trade in India during the early centuries, A block printed and resist-dyed fabric, whose origin is from Gujarat was found in the tombs of Fostat, Egypt.
Needless to say that, we are very old in the business, but then it was very much less compared to now.The textile industry is now is not just manufacturing of yarn, fabrics, and textiles for clothing, carpets but, further classified based on distinct sections such as research, design, manufacture, and distribution.
What is the Indian Textile Industry weaving now?
Name anything in the Textile industry, Either India was already there or India was the only one there. The oldest sector & the greatest contributor to our economy has set benchmarks in various ways.
The growth of the Textile industry looks promising with the increase in market demand worldwide for textile products. Sneak into the facts & figures to understand what is weaving in the Indian Textile Industry now.
Although the industry is well poised to grow at an annual rate of 15% but going ahead will be tough unless the industry acquires technological know-how related to ” From Connecting Each Module to Automating the Whole Process”.
Besides the inferior technology, the industry has been persistently facing various external issues which need immediate attention. Major issues are:
Skill gaps and the shortage of skilled manpower as the process is yet to be automated
Very high-interest rates
Lack of sustained demand from the user sector
Import of second-hand machinery whose life cycle is less & the average energy consumption/cost is more.
The Process which has to be measured, monitored & controlled for avoiding unnecessary variable costs & eventually gaining more profits.
The knowledge for the owners to Invest in the technology.
Is the Fashion Industry still running Old-fashioned?
The process involved in the textile industry is found to be highly complex with the beginning of research, design, development to finished products. These processes are performed using a wide range of machines such as spinning, weaving, dyeing, printing, finishing and manufacturing fabrics.
It is completely process-based where each & every stage has the power that will lead to a large impact on productivity and profitability during any obstructions. We need keen monitoring at every stage in complex processes such as textile that demands an Integrated system to measure the precise details of each machine.
An interoperable platform for Textile Factories?
The textile industry is found to be the leading sector that needs immediate digitalization as it is dependent on precise details of equipment functioning, management of dyes, and monitoring of raw materials. Further, it is necessary to consider the deviations occurring in the industry from Standard Operating Conditions to minimize the revenue losses. This suggests the need to effectively utilize technology in the textile industry either it is IIoT based products or the IoT solutions.
Energy & Process Monitor:
A single device to monitors the electrical & Process parameters & suggest the preventive measures while analyzed using an Energy & Process Management System.
Speed Vs Kw curve, trends, bar graphs, comparisons
Alerts on higher UKG, lesser production, utilization & power fluctuations.
Maintenance alerts based on run hours production cost analysis – Cost Audits – Energy Audits
An Energy & Process Management System at 50001:2011 standards:
Interoperability is the concept evolved by the way Internet of Things (IoT) based solutions works, which is generally defined as a network of physical objects with internet connectivity for the communication between the devices and the system.
The optimum productivity is achieved only when the system is process oriented & the process is automated!
Industrial Internet of Things (IIoT) is found to be a gateway between the computing technologies, cloud, mobile machine learning, and industrial infrastructure to help industries elevate their productivity and efficiency. IIoT solutions is a world of the monotonous throng with networks, sensors, operating equipment and devices in comparison to smart home appliances. The information collected from the devices will be used to analyze, monitor, maintain high performance and efficiency in industrial applications such as production and maintenance.
Further, data collected can be directly uploaded to a cloud server using products like EPC through various communication protocols.
It is necessary to utilize process management systems in textile industries to monitor and receive real-time data for the effective decision-making process.
These solutions can help in preventive maintenance to reduce the overall energy consumption and to provide a sustainable environment.
Enhance Life & Economy through Textile industry:
In several textile industries, sensors were placed in washers, dryers, and other equipment to improvise their performance by attaining real-time data, in addition to detecting the failure of equipment thereby reducing the downtime.
Specific energy consumption of heavy loads: Calculation of section-wise energy consumption against product output
Performance check and periodic maintenance: Verification of equipment data with respect to rated specs
Monitoring of cyclic operation of spinning unit (Ring frame): Number of Stoppages with duration during doffing; Energy comparison of various ring frames bis-à-vis product outputs (Ring UKG); Different Yarns count and specific energy consumption (UKG) per Ring frame
Identifying the idle running of the machine.
There are multiple Case studies on Pacific Textiles, Getzner Textile, Everest Textile industry indicates the need for their rapid transformation towards the digital revolution to improvise their operations & productivity.
Frequent challenges observed in incorporating IoT in the textile industry:
Recent studies on IIoT indicates a rapid growth towards automating textile industry from the initial stages of development to production, storage, and marketing to improve the time to market (TTM). However, the practical implementation of IoT in the industry will undergo various challenges while redefining the textile industry as listed below:
IoT being a network of physical objects, it is necessary to ensure appropriate connectivity of weaving machines with huge bandwidth through Ethernet.
A large amount of structured/unstructured data will be available on the integration of IoT and it is necessary to manage these voluminous data.
Suitable IoT management platforms that are compatible with ERP, administrative and management systems are required.
Data integrity and confidentiality of the data transferred needs to be considered with the integration of IoT platforms.
“How about your process automation + RoI in < 6 Months” with a system customizable for any industry as per the needs?
A simple and easy-to-use IoT platform from ELMEASURE® can be used to perform periodic assessments which stores, monitors and measures to perform detailed analysis for any industrial challenges.
This is a single platform that can be customized based on the industry’s process whether Food Processing, Textile, Engineering, Automobiles, etc.
Founder & CEO of Elmeasure India Pvt. Ltd., Mr. Babu is an innovator & practitioner of energy saving products & solutions. He is obsessed with the idea of making the world a better place in the area where the impact is huge & faster i.e., Energy.
Energy is the biggest resource every country can count on for their seamless future. When the future is determined based on your ability to manage energy resources, how sure are you to get an adequate amount of electricity is the question to answer. When saving is not on the bucket list, it comes to the traditional way of any developing country’s life, rich get more access & poor get limited access.
“Energy is central to nearly every major challenge & opportunity the world faces today.”
Affordable & clean energy is one of the 17 goals to transform the world called ‘sustainable development goals’ by UNO. They believe that the world revolves around energy to evolve the new phases of development.
It is one of the requisites for the sustained growth of an individual, organization, factory, state or even nation.
So, the necessity of energy & its management is like a fingerprint that can’t be the same for everyone. Even 2 similar plants might need different areas of energy saving. So, we don’t have something called ready-made EMS available. Though some made it available online, it actually does show you a picture of whole bills but no predictions or suggestions to your RoI, Savings.
In short, If a system can’t save your manpower, money & resources that are as good as doing nothing.
So, how do you choose an EMS that actually works for you?
What is an EMS?
Energy Management System is a platform that helps Residential complexes, manufacturing plants, commercial buildings to define & suggest what all the possible areas to save energy.
“Measuring your energy usage and cost is the first step to properly managing energy”
Energy is not an expenditure; it is an asset where the monitored & controlled utilization can bring a lot of saving.
What exactly an EMS offers?
Improve strategic energy management capabilities.
Build the case to leadership on the value of energy management and gain additional support.
Improve control and transparency of energy costs and budgets.
Improve operational efficiency.
Facilitate demand response and energy purchasing.
What do you need to do?
There are various elements involved in taking the decision to finalize an EMS, from installation to reports until predictive analysis of the energy & process parameters, the requirement varies from organization to organization. In such cases, there should be few parameters to recognize the feasibility of the system with your organization like,
1. Multiple communication possibilities:
The Software you use should be capable to accept the ocean of changes & ready to mingle with any other third-party devices. Keeping aside the compatibility of a system, It should allow the change management that we consider mandatory even for the systems, would definitely save us a fortune. It should be able to get along with any type of communication protocols which is only possible with an interoperable platform with the capability of accepting any kind of devices.
2. Technology & Customization:
Technology is far most important any other aspects, it seems you are working very hard but, you are still not growing. Just like Nokia, we fail & still, we didn’t know the reason. It decides your epitome of growth.
The better the technology the better the results in the industry. It is very important to check with the technology & the platform it is built on. It is well-versed that the need for EMS varies for every business, of course, every sector. It is thus very important to customize the solution that solves your pain points, & leave the rest unless given for free of cost.
Technology that can’t be customized for you is not the right one for you.
3. Future Proof:
An organization is a living object. Every invention & investment in the organization should be made sure to be compatible with future changes either in terms of technology or the people. An organization can be successful when it is process oriented & the platforms you use to make it happen are future proof.
The software once designed for your organization should be made sure that the same software can be upgraded with multiple aspects of technological advancements like compatibility with other party vendors, possible vertical integration, easy technological upgrade, etc. It should be made future-proof to fit the organization at any time.
4. Data Safety, Security & Analysis:
Data is a very important asset for every organization now & the vulnerability of data leads to unprecedented consequences as it mainly depicts the privacy of an individual, an organization, etc. If your data is compromised your competitor is as good as you or may be better than you because Data has a better idea than you do.
The output of every invention is based on the ease of data accessing along with its safety & security. Technologies like Blockchain may be advanced, but many countries are still in dilemma whether to imbibe it due to its data decentralization. It is not applicable for every Industry, also not everyone in the industry that is applicable may not be happy with low secure technologies but, This kind of technologies will be the essential part of the industry in the coming years if the safety & security is taken care of.
5. Return on Investment (RoI):
People should consider spending on systems in saving Energy as an investment but not as the expenditure. For people who consider it as the investment here is what you need to consider, The RoI (Return on Investment). Less the payback period, better the solution you have invested on & early start saving the energy resources.
Apart from these major requisites, there are few secondary factors to look at before choosing, else the Other Requisites can be:
There are 100s of players in the market who has software that named as Energy Management System, just create an account, purchase the online software even at 10000 bucks, Which is where people got confused with the word “affordability” of a system. Affordability is actually the price-product-premises fit which self-defines as the price you pay is worth the product features, aesthetics, & technology that should help solve the pain of your enterprise.
Being in the Energy sector for one & half decade, we have read about different customer needs, consumed a lot of data & spoke with multiple domain experts & designed software that works towards your future.
Introducing the Energy Management System by Elmeasure India Pvt. Ltd., EL-Net.
There are various reasons people say to choose our products & solutions, see it for yourself.
Lifestyle has an issue with power thefts from its vendors & various energy reports for easy analysis & RoI monitoring. Elmeasure then helped with EL-Net & resolved the issues & saved at least 1 man hour per day.
Sam is a complete Technology savvy, sports lover, most patient & responsible citizen to explore the infinite possibilities in the energy space to make the world a better place to live. Hear out for the Chairman at Elmeasure.