1. Continuous monitoring of Data on PC
On mounting the energy analyzers at various load centers the analyzers can convey the data to a central Computer over an RS 485 protocol. Continuous monitoring of energy data by Cummins Energy Management System is thus possible, which can be viewed on the PC on a real time basis. Thirty one parameters can be viewed.
2. Graphical trends of electrical parameters
Real time and historic data can be trended to be viewed in tabular or graphical format. This feature is used to perform load flow analysis of a particular load or complete installation. This helps in evaluating that how close the plant or installation is to its maximum load capacity with currently installed equipment. This is very useful information for anyone considering upgradation in facilities or expansion. It can help take important decision, if new or additional equipment is required or additional investments can be avoided by increasing the production with existing resources. This will also help in Genset sizing.
3. Loading Management
Improper loading can cause the source (Genset) to trip or exceed MD in case of SEB. Cummins Energy Management System is capable of monitoring critical load parameters to determine the level of energy usage in electrical network. Proper load planning can be carried out based on the reports generated in order to take advantage of different tariffs offered during the day by utilities. The system is capable of giving each phase parameters. This helps in finding Phase imbalance conditions and necessary actions can be undertaken to balance the same.
4. Department-wise / Location-wise Energy cost
Apart from manufacturing, other departments are also consuming energy which often goes un-noticed. Cummins Energy Management System helps to segment the various cost centers like manufacturing units, administration building, Blocks and other departments. This determines how each of business units or process consumes electrical power to help promote accountability, increase efficiency and productivity.
5. Historisation
Presently the energy consumption is increasing each month or reducing is not known. All energy data is stored on a central PC by the system. This data can be used as a history for comparison at a later date by Cummins Energy Management System. Data auto purging feature is also available.
6. Effective utilization of manpower
Present manpower engaged in reading energy data at various load centers can now be utilized elsewhere for productive work. Thus the time and energy resources are productively utilized for upkeep while Cummins Energy Management System will carry out accumulation and evaluation.
7. Verification of Energy Conservation
Often there is no systematic record and tracking of an energy conservation activity. Has resuted in net effect of increase or decrase of energy consumption? The system records monthly consumption and calculates the variance in terms of percentage increase or decrease of consumption. Hence if the organization is carrying out energy conservation activities the percentage increase or decrease in energy consumption on a monthly basis or yearly basis is calculated and displayed by Cummins Energy Management System.
8. Voltage Imbalance and Current Imbalance
Improper single phase load distribution leads to phase imbalance leading to Lower PF and also causes performance problems on Genset besides loss of Energy. Cummins Energy Management System helps to identify the percentage of voltage imbalance and current imbalance at any location. This helps to identify imbalance condition in loading conditions. Each phase parameter is taken into consideration for the same. On real time basis identifying phase imbalance is very difficult without on line measurement of Electrical Parameters.
9. Management Reports Generation
The system is capable of generating quick MIS reports in terms of pie charts, trends and tabular data releted to electrical data. This helps in saving time and generating timely and accurate reports.
10. Calculation of Transmissions and Distribution losses within the plant
Distribution losses from Source end to load end is the result of low load PF or old cables / switching systems. This loss aften goes un-noticed. Our system can calculate and present these Distribution losses in Energy Terms ie kWhr. This helps in identifying areas of losses and eventually suitable action can be taken to curb them. This is shown as below -
| Transformer units |
: |
600 |
| DG units |
: |
400 |
| Total Units (source) |
: |
1000 |
| Energy consumed (feder level 1) |
| Feeder 1 |
: |
200 |
| Feeder 2 |
: |
150 |
| Feeder 3 |
: |
150 |
| Feeder 4 |
: |
200 |
| Total Units (level 1) |
: |
700 |
| T&D Loss |
: |
1000 - 700 = 300 units |
11. Location wise energy consumption difference
Two production lines producing the same product may not be consuming the same amount of energy. Cummins Energy Management System helps to define zones (locations) and see energy level difference between two locations. For e.g it is possible to calculate the energy consumption of production line1 and production line2 and see the difference. This will further help to know which line is (less )not efficient.
12. Production and Energy
In today's cost competitive scenario it is important for any organization to have and establish bench mark for energy input per product. Cummins Energy Management System gives out Production Vs Energy consumption reports. This report informs about the amount of production for per unit of energy. Production information has to be keyed in.It also informs on the amount of energy consumed for per unit of production. This helps in sizing the energy requirements for a particular demand of production level.
13. Diesel generator set - Utility ( State electricity board) Utilization ratio
Cummins Energy Management System records the energy consumption from Utility (Electricity board single transformer) and Diesel generator set (single backup). This helps in establishing a utilization ratio. For e.g. the report shall say a particular load center consumes 30 % from transformer and 70 % from diesel generator set. This is usually done manually scanning series of reports incurring huge manpower cost.
14. Plant load factor
Cummins Energy Management System also displays instantaneous values of Plant load factor indicating what percentage of the plant is loaded. This helps in identifying un-utilized capacities. This is a ratio of operating load to total connected load.
15. Maximum Demand identification
As per SEB guidelines in most of the states, demand crossing MD will lead to penalty. Cummins Energy Management System helps in identifying MD of any location. This helps in understanding the MD required for the plant. This will help in identifying conditions causing high MD leading to penalty. Subsequent corrective actions can be taken to avoid the same. In addition there is an instantaneous plant MD display available.
16. Percentage Loading
Improper loading on transformer or generator will lead to Energy losses. Cummins Energy Management System gives a graph of percentage loading on the Transformer (State Electricity board) or the generator. This will give user an indication of the load factor on that particular source. This will also help in sizing the source (transformer or generator). Percentage loading can be seen on KVA basis or KW basis as loading on Generator has to be assessed from kW and kVA both simulataneously.
17. PF corrections and improvements
As per SEB guidelines in most of the states low PF at transformer end leads to penalty. Low PF at the load end leads to distribution losses.Cummins Energy Management System helps in identifying area of low PF. This will thus help in understanding which phase has contributed to low PF. Capacitors can be installed at these locations to correct the same. kVAr readings
18. PF - Lead / Lag
Lagging PF leads to losses and leading PF leads to addition KWHr billing and can also cause damage to equipments.The present systems existing in various industrial plants may not be able to identify the leading PF situation. This situation arises due to improper sizing of fixed capacitor or APFC (auto power factor correction) capacitor at any location due to high load fluctuations. Cummins Energy Management System helps to chart the PF and the leading or lagging PF values are displayed to the user. The suitability of the capacitor bank gets verified too.
19. Plant View - Single Line Diagram (SLD)
Cummins Energy Management System helps the user to draw the single line diagram of the plant. The system is capable of displaying the parameters details on the PC screen at the particular location. In addition symbols library is available to the user for quick SLD designing. The package is inbuilt, easy to use and hence any special software or training is not required.
20. On-Line Alarms
Cummins Energy Management System can be configured to display on line alarms. The alarms can be assigned priorities in three levels : -
ü High
ü Medium
ü Low
In addition each parameter can be configured for an alarm for the following four conditions -
ü Higher value wrt a set point
ü Lower value wrt a set point
ü Between a range of values
ü Outside a range of values
21. Computer Networking
Cummins Energy Management System is capable of working in Client - Server environment. Hence more than one user will have access to the system.
22. Security Levels
Cummins Energy Management System has three tier security level. The levels are defined as below
Level 1: Individual Login Id and Password
Level 2: Individual Analyzer View rights
Level 3: Individual Functional Access rights
Level 4: In addition to the above, it is possible to virtually lock the analyzers from the Cummins Energy Management System server station. Once this is done manual resetting of analyzer parameters will not be possible.
23. Time based Tariff
Cummins Energy Management System provides a feature wherein the user can enter tariff rates based on time. This is useful if the tariff rates vary in different time zones.
24. Parameters Single Screen view
It is possible to view all thirty one electrical parameters of one analyzer simultaneously on a single scrolling screen. This will help to instantly view various parameters of a location.
25. Analyzers View
Cummins helps to give the user a quick view of all the locations of energy analyzer along with their configured scan rates, locations and addresses.
