Reference · Industry and manufacturing

Energy monitoring integration

Client: Vegumrubber industry
Project goal: Electricity sub-metering

40
Metering points: 45
Electrical devices installed

How it is connected

Solution diagram

Simplified diagram based on the project description.

01 · Metering
Existing electricity meters with a pulse output
- Electricity
- 40 · metering points
- 45 · electrical devices installed
02 · Transfer
Pulses into pulse counters · Wi-Fi connectivity
03 · Network
Company network
04 · System
Monitoring
- Real-time consumption
- Data archiving

Project summary

Sub-metering in production
Metering of the factory’s total consumption
Integration during full operation

In this project, we delivered a complete integration of electricity sub-metering at a manufacturing plant that needed detailed tracking of consumption for individual machinery in order to optimise its energy management. The technical solution was based on semi-direct metering and took into account the client’s preference for connection over Wi-Fi. All the collected and aggregated data is stored on a local server on the factory premises.

Implementation

Wi-Fi connectivity
Real-time monitoring
Pulse metering

During the installation, we connected a total of 40 metering devices in the operating areas and 2 metering devices in the control room, which provide continuous tracking of the whole plant’s total electricity consumption. Our key step was connecting to the existing electricity meters that provide pulses indicating current consumption. These pulses are then processed by pulse counters connected to the company network, ensuring smooth transfer and archiving of all operating data. During the project we had to deal with problems with Wi-Fi connectivity and signal stability caused by strong electromagnetic interference on the plant site. After thoroughly measuring the signal strength, we concluded that external antennas would be the best solution. These were then installed on the switchboards, achieving more reliable coverage and more stable communication.

Results

Forty metering points
Installation during operation
Stable internet connection
A satisfied client

During the installation, we connected a total of 40 metering devices in the production areas and 2 metering devices in the control room, which provide continuous tracking of the whole plant’s total electricity consumption. After the successful integration, together with a partner company we extended the project with visualisation tools that give the client useful overviews and help them manage energy effectively.

It is worth noting that the plant was running non-stop on three shifts. Thanks to close cooperation with the management and the people responsible for the machinery, all installation work was carried out without interrupting production, while strictly complying with all occupational health and safety requirements.

On site