Energy Monitoring

Oncontrol Technologies developed in last years energy monitoring solutions for industrial environment. It offer solutions from the acquisition the different field energy counters, treatment of the collected data and data visualization.

The development of monitoring system have three main steps:

  1. Infrastructure analysis;
  2. Data acquisition and filtering;
  3. Data visualization.

Infrastructure analysis

For a turn-key solution, before providing a budget, it is necessary to analize:

  • Structure of the plant by sections and sub-section;
  • Existent counters in each section;
  • Energy types to measure;
  • Additional counter needs.

All the counters can have interface with the PLC, which can be a

  • Digital signal – Detected a known consumption of energy (eg. 1KW);
  • Analog signal – Normally providing flows or instantaneous consumption (eg. compress air flow);
  • Fieldbus communication – Providing consumption informations and others (eg. quality parameters).

The price of the overall solution must take all these informations from the client.

Data acquisition and filtering

The monitoring of different energies present in the process, it must be measured by sensors in the field installation. These sensors can be, for example:

  • Electric energy counters;
  • Water counters;
  • Oil Counters;
  • Gas Counters;
  • Compressed air counters.

The data of this several sensors/counters will be collected with a Programmable logic controller (PLC), using its digital or analog ports, or an communication protocol based on a fieldbus (eg. Profibus-DP, MODBUS-RTU) or ethernet-based protocol (eg.Ethernet/IP, MODBUS-TCP). OPC protocol can also be used to acquire data from field devices.

It is also possible to filter data and make small mathematical operations to the collected data. Take the example that a section consumption must be calculated by the formula

$$counter_{sec.A} = counter_{global}-counter_{sec.B}$$

If is possible to remove noise data by applying filters to the data. This characteristic is important when we have per example high-variance flows.

The filtering step is optional, but the objective is to have dataset with high quality and informative. After this step the datasets are recorded in databases in order to have an historic database for further analysis.

Data visualization

The main objective of the energy module is the visualization of data for user analysis. The platform possibilities the visualization of data by:

  • Type of energy;
  • Consumption of daily and monthly energy ;
  • Energy consumed by section and sub-section;
  • Comparison of energy consumption by day;
  • Raw energy consumption by counter;
  • Cost of energy.

It is also possible to design custom reports, which are generated periodically. Normal periods are weekly or montly reports, but other periods can be specified.