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Electrical Monitoring System for Energy Efficiency Audit

Many industrial plants do not have comprehensive electrical & energy consumption information due to various reasons and constraints. Amongst these are:

  • Manpower

  • Lack of Metering Facilities

For the better organized plants, the chargeman takes selected electrical parameters records manually based on the production shift. The data collected are often not complete and cannot be processed into meaningful data for management purposes.

Monitoring System Configuration


However, with the increasing market competition which resulted in lower profit margin, there is much pressure to lower production cost and increase productivity. One such area is energy consumption / demand charges.

For industrial E2 tariff the maximum demand charges is RM21.70 for each kW. For example a plantís average power demand is 2000kW for each half hour period over the month, the demand charges shall be 2,000 x 21.70 = RM 43,400. However if there is one specific 30 minute time period where the client has inadvertently started several equipment of high power consumption at the same period and causing the maximum demand to rise to 2,200kW, the demand charges for the month would amount to RM 47,740. (Increase of RM4,340)

The energy charges is a separate component and is based on the actual peak and off peak energy consumed for the month multiplied by the peak and off peak energy unit cost respectively. Hence if the client institute an energy saving program, there must be a measurable benchmark such as kWh / production unit. As production rate varies over the different shifts and days of the month, the management can use this information to chart out the effectiveness of their energy efficiency program.

Another common problem that the plant may encounter is the Power Factor Penalty. This occurs when the Capacitor Banks in the Main Switchboards deteriorate or fail, and unable to generate the reactive power (VARs) to maintain the power factor above 0.85. Below this threshold, the power factor penalty is levied on the client and the quantum is proportional to the power factor shortfall and the energy bill for the particular month.

As such, it is important for industrial consumers to start monitoring their energy efficiency and their production output. With this data, the client is able to formulate strategies to reduce energy / maximum demand costs through proper scheduling and equipment upgrade, and consequently improving productivity.


Voltage (RED), Current (ORANGE), Power (BLUE) & Power Factor (GREEN) Trends
Voltage (RED), Current (ORANGE), Power (BLUE) & Power Factor (GREEN) Histograms
Generated Energy Consumption Report

Copyright Vy Engineering 2004