Industrial Zone Energy Management System
Turnkey safety upgrade to CE and EN ISO 13849-1 standards with SIL 3 safety PLC architecture and SafeMove zoned robot protection.
🎯 Challenge / Goal
Zone-wide annual electricity bill reached $5.1M. Peak-demand penalties were punitive. Transformer efficiency suffered from phase imbalance and harmonic distortion. Each building read meters independently with no unified reporting.
⚙️ Solution Applied
Deployed Schneider EcoStruxure EMS architecture. 148x PM5350 power analyzers polled on Modbus TCP and visualized in AVEVA System Platform SCADA. Active Harmonic Filters (AHF) installed at transformer substations. Microgrid controller orchestrates 5x 500 kW diesel gens and a 1 MWh Tesla PowerPack lithium bank. AI-based 15-minute demand forecast drives load-shedding decisions. Fully automated ISO 50001 reports.
📈 Results
- ✓Annual energy cost: $5.1M → $3.55M (30% saved)
- ✓THDi harmonic distortion: 28% → 4.5%
- ✓Transformer efficiency: 91% → 97.8%
- ✓Peak-demand penalties eliminated
- ✓ISO 50001 certification achieved
🔧 Technologies Used
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