Electrical Power & Protection


Optimising electrical consumption on a process plant

January 2024 Electrical Power & Protection

More than ever, business owners and operators of factories and industrial plant need to know that their facility is optimised in terms of electrical energy consumption, not only to mitigate the rocketing cost of electricity, but also to ensure efficient machinery operations against a backdrop of continuous but irregular loadshedding outages.

Iritron, an automation and control systems integration specialist, advises business owners to conduct an energy study to reveal the health and efficiency of a plant’s electrical system. Based on this study, recommendations can be made for improvement to the reticulation and the energy-hungry machinery, which can result in substantial cost savings while identifying potential safety issues and lack of compliance.

Plant layout, usage, equipment and personnel changes can over the years result in an industrial plant’s electrical diagrams no longer accurately reflecting the ‘as built’ installation. Distribution boards and electrical equipment may not be correctly labelled, and protection gradings may be incorrect due to changes over the years. Apart from the potential danger and the non-compliance that outdated drawings create, it also makes energy studies almost impossible. Therefore, prior to embarking on an energy study, it is recommended that this situation be rectified. With accurate documentation, it will be much quicker and easier for Iritron’s technicians to start investigating and analysing the energy consumption in different plant areas, and provide recommendations for improvement.

Iritron’s energy study requires the installation of measurement equipment such as Schneider Electric’s power meters, for example the PowerLogic&bsp;PM5320R with Ethernet interface and modbus TCP/IP protocol. This power meter provides a host of critical measurements, including:

• Instantaneous values of current, voltage, frequency and real, reactive and apparent power and power factor.

• Accumulated active, reactive and apparent energy.

• Power quality measurements including total harmonic distortion and total demand distortion.

• Data logging of min/max of instantaneous values, plus phase identification.

Once the granularity of the measurements has been determined, the energy meters can easily be installed in a number of distribution boards on the plant site to allow the measurements of specific areas and equipment. The energy meter measurements can be historised, and the data provides the ability to analyse and pinpoint exactly what is happening in the plant at any given time.

The energy study takes into consideration and analyses the energy mix that is present in the facility, be it solar, generator or utility power. Once all the data is compiled, Iritron engineers conduct detailed and complex analyses to identify areas of potential savings. This includes the analysis of the electrical account from the service provider, as it is important to understand the tariff structures and rates. Hidden in the account information are several areas where costs can be saved through the implementation of monitoring, automation and control.

The final step is to implement the cost saving strategy, which can include any number of control measures. These include automated controls to reduce energy cost, power factor correction, maximum demand control, peak shaving, and working around the peak tariff periods. All these are potential areas of saving and need to be considered together with all the data from the energy measurements in order to develop and implement a successful energy optimisation plan.


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Power portfolio with enhanced static transfer switch for critical applications
Electrical Power & Protection
Vertiv has launched the Vertiv PowerSwitch 7000, a next-generation static transfer switch that strengthens the company’s position as a complete power solutions provider.

Read more...
Why utilities must prioritise maintenance of SA’s remote data
Schneider Electric South Africa Electrical Power & Protection
The story of power generation is more than meets the eye. Beyond energy distribution and the infrastructure are invisible, point of presence data centres located the remotest parts of our country that play a fundamental role in keeping systems running

Read more...
The house that revolutionises substations
WEG Africa Electrical Power & Protection
Traditional substations have major drawbacks in terms of their construction and resilience. One solution is the E-house, a prefabricated, customised and transportable steel structure designed to house a range of electrical and automation equipment.

Read more...
Localised inverter-integrated transformer
Electrical Power & Protection
ACTOM, South Africa’s largest manufacturer, repairer and distributor of electromechanical equipment, is launching a breakthrough in renewable energy integration with its localised inverter-integrated transform

Read more...
Steinmüller Africa integrates advanced technologies at Mondi’s boiler project
Electrical Power & Protection
Steinmüller Africa is leading a boiler project at Mondi’s Richards Bay mill. The 18-month undertaking showcases the company’s blend of engineering excellence and cutting-edge technology.

Read more...
ABB innovation for energy efficiency and sustainability
Electrical Power & Protection
The application of sensor technology to reduce the operational and standby power losses of traditional current and voltage transformers can lead to energy savings of 181 MWh over a 30-year period, the lifetime of a typical switchboard in the African environment.

Read more...
UPS systems are key to keeping SA’s automotive industry up and running
Schneider Electric South Africa Electrical Power & Protection
During loadshedding, PLCs and OT systems often fail, not because they are directly tied to the factory’s core manufacturing process, but because they are now an integral part of IT infrastructure. When an IT system shuts down, the impact is far more complex than simply restarting machinery.

Read more...
ACTOM advances energy infrastructure
Electrical Power & Protection
At this critical juncture where South Africa is poised to modernise its power infrastructure, ACTOM’s Engineering Projects and Contracts (EPC) Division showcased its capabilities for the first time at Enlit Africa 2025.

Read more...
Advanced contactor solution to revolutionise motor management
Schneider Electric South Africa Electrical Power & Protection
Schneider Electric South Africa has launched the TeSys Deca Advanced, an advanced contactor solution designed to revolutionise motor management with unparalleled efficiency, reliability, simplicity and sustainability.

Read more...
Steaming ahead with boiler skills development
Electrical Power & Protection
As an expert in steam and boiler operations and maintenance, AES is very focused on safety, quality, technology advancement and the development of human capital. The company invests heavily in training and the promotion of talented people on an equal opportunity basis into the industrial operations environment.

Read more...









While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.




© Technews Publishing (Pty) Ltd | All Rights Reserved