GLOABTEL ENERGY MANAGER SYSEM FOR M/S POLYCAB WIRES FOR POWER & PRODUCTION DATA RECORDING, MONITORI

EMS SCADA will collect data from installed different make of digital meters over MODBUS RS 485 network.
EMS will collect data from start from Mian incomer transformer to DT feeder and machine level, currently meters are installed at Incomer and DT feeder
energy meters at each machine end to monitor machine wise energy consumption and to get complete energy accounting MIS report.
Company has to arrnage for 2 core shilded 0.75 seq mm shilded communciation cable for net working of meters and CAT 6 or CAT 5 cable usef for netw
system will installed at new office at admin building with required new PC, LAN and internet connectivity
EMS SCADA is devided in two parts, One part used to collect electrical power data over MODBUS RS 485 port and second module is connected with di
Ethernet. For comucniation there will be two seprate BUS.

Networking diagram of MODBUS and Ethernet with EMS SCADA

+ -
Digital meter RS 485 communication bus

Different Plant user

LAN Network RS 485 to RS
232 data con

Local plant LAN user

Master location EMS SCADA system

Different make of PLC Local Ethernet LAN network

EMS System shows online electrical parametrs from installed digital meters, which are
Phase to Phase Voltage
Avg current
THD V
THD I
Frq
KW
KVA
KVAr
KWH
KVArh
KVAh

User can view online data in numerical and Single line diagram format on realtime basis, please refer below image
User can view store data in online and history graphs format
Power MIS report format
User can generate various History grpahs which are:
1) Power Quality VS to date and time
2) Machine to Machine compare Vs data and time
3) THD V and I
* If required other please sepecifiy

Master User and Client LAN user has to login as per set different USER ID and Password to get different access with opration

User can generate different MIS reports

1) Power Consumption Report VS date and time wise
2) Feeder wise Or Machine wise Power reprot VS date and Time
3) Production and Quality Report
4) Process Analysis for all electrical parameters VS date and time
5) Multi wire cable machine VS date and time
6) Extruder Runnig data VS date and time
 DAILY POWER CONSUMTION REPORT
POWER CONS. OF SUPREME NONWOVEN UNIT-I TOTAL POWER CONS. OF

0009 380 MAIN

PANEL (Carding, 0012
0008 MAIN 0015 ROOF 0010 0011 0013 0014 0024 OFFICE MAIN PCC
Date Dilo 1&2, Bale UTILITY
PCC UNIT-1 LINER SAMHWA -1 SAMHWA -2 COATING I/C COATING AREA UNIT-1
Opner, Aero Mixcer, LOAD
FG

Total
MF Reading Reading Reading Reading Reading Reading Reading Reading Reading
Consumtion
1-Mar-08 14,082.00 4,612.00 1,000.30 90.00 14,567.00 156.40
2-Mar-08 17,435.00 5,812.00 1,132.30 113.00 14,765.00 252.90 3,353.00
3-Mar-08 20,748.00 15,236.00 1,405.00 118.00 0.60 1,001.00 3,313.00
4-Mar-08 24,594.00 8,020.00 1,582.80 221.00 15,569.00 3,846.00
5-Mar-08 26,011.00 8,818.00 1,589.30 229.00 100.00 15,638.00 1,025.50 1,417.00
6-Mar-08 29,737.00 0.60 1,813.00 230.00 149.30 15,851.00 1,191.40 3,726.00
7-Mar-08 33,590.00 11,137.00 2,045.10 244.00 251.10 16,287.00 1,663.70 3,853.00
8-Mar-08 37,260.00 12,201.00 2,262.80 346.00 356.30 16,660.00 2,059.90 3,670.00
9-Mar-08 40,633.00 13,299.00 2,490.90 451.20 467.90 16,744.00 2,140.00 3,373.00
10-Mar-08 44,196.00 14,444.00 2,718.70 559.10 585.50 16,969.00 2,396.90 3,563.00
11-Mar-08 47,419.00 15,377.00 2,938.00 645.50 678.20 17,122.00 2,572.90 3,223.00
12-Mar-08 48,360.00 16,154.00 2,948.20 698.80 733.60 17,127.00 2,572.90 941.00
13-Mar-08 51,321.00 16,865.00 3,169.80 779.30 819.70 17,306.00 2,743.00 2,961.00
14-Mar-08 54,861.00 17,909.00 3,357.90 905.60 928.70 17,552.00 2,973.60 3,540.00
15-Mar-08 58,406.00 19,047.00 3,572.00 1,020.20 1,028.50 17,826.00 3,223.20 3,545.00
16-Mar-08 61,994.00 20,196.00 3,759.20 1,112.90 1,123.00 18,250.00 3,648.80 3,588.00
17-Mar-08 65,649.00 21,525.00 3,980.60 1,218.30 1,239.60 18,418.00 3,786.90 3,655.00
18-Mar-08 68,847.00 22,717.00 4,106.00 1,328.10 1,339.00 18,535.00 3,915.70 3,198.00
19-Mar-08 69,670.00 23,145.00 4,114.10 1,329.60 1,340.50 18,589.00 3,915.70 823.00
20-Mar-08 73,312.00 24,276.00 4,341.10 1,428.50 1,432.20 18,856.00 4,172.30 3,642.00
21-Mar-08 77,609.00 25,572.00 4,559.40 1,552.40 1,546.00 1,307.00 19,527.00 4,891.00 4,297.00
22-Mar-08 81,244.00 26,689.00 4,696.40 1,643.60 1,630.60 1,520.00 20,016.00 5,388.20 3,635.00
23-Mar-08 86,161.00 27,928.00 4,831.00 1,761.30 1,736.90 1,939.00 20,555.00 5,961.90 4,917.00
24-Mar-08 89,225.00 29,291.00 4,942.20 1,897.20 1,853.70 2,367.00 21,312.00 6,791.60 3,064.00
25-Mar-08 92,506.00 30,302.00 5,078.70 1,989.80 1,946.90 2,788.00 21,672.00 3,281.00
26-Mar-08 94,177.00 31,056.00 5,084.40 2,050.40 2,011.00 3,303.00 21,741.00 7,214.60 1,671.00
27-Mar-08 97,481.00 32,222.00 5,300.80 2,129.50 2,093.90 3,927.00 21,876.00 7,315.80 3,304.00
28-Mar-08 100,870.00 33,143.00 5,504.00 2,199.60 2,166.10 4,566.00 22,404.00 7,791.40 3,389.00
29-Mar-08
30-Mar-08
31-Mar-08
Daily Time 7:00 AM Devloped By: Gloabtel Convergence Ltd
TOTAL POWER CONS. OF SUPREME NONWOVEN UNIT-I

380 MAIN
PANEL OFFICE AREA
(Carding, Dilo ROOF LINER SAMHWA - 1 SAMHWA -2 UTILITY LOAD COATING I/C COATING (A.C
1&2, Bale Opner, LOAD)
Aero Mixcer, FG

Total Total Total Total Total Total Total Total

Consumtion Consumtion Consumtion Consumtion Consumtion Consumtion Consumtion Consumtion

1,200.00 132.00 23.00 198.00 96.50

9,424.00 272.70 5.00 748.10
177.80 103.00 15,568.40
798.00 6.50 8.00 69.00
223.70 1.00 49.30 213.00 165.90
11,136.40 232.10 14.00 101.80 436.00 472.30
1,064.00 217.70 102.00 105.20 373.00 396.20
1,098.00 228.10 105.20 111.60 84.00 80.10
1,145.00 227.80 107.90 117.60 225.00 256.90
933.00 219.30 86.40 92.70 153.00 176.00
777.00 10.20 53.30 55.40 5.00 0.00
711.00 221.60 80.50 86.10 179.00 170.10
1,044.00 188.10 126.30 109.00 246.00 230.60
1,138.00 214.10 114.60 99.80 274.00 249.60
1,149.00 187.20 92.70 94.50 424.00 425.60
1,329.00 221.40 105.40 116.60 168.00 138.10
1,192.00 125.40 109.80 99.40 117.00 128.80
428.00 8.10 1.50 1.50 54.00 0.00
1,131.00 227.00 98.90 91.70 267.00 256.60
1,296.00 218.30 123.90 113.80 671.00 718.70
1,117.00 137.00 91.20 84.60 213.00 489.00 497.20
1,239.00 134.60 117.70 106.30 419.00 539.00 573.70
1,363.00 111.20 135.90 116.80 428.00 757.00 829.70
1,011.00 136.50 92.60 93.20 421.00 360.00
754.00 5.70 60.60 64.10 515.00 69.00
1,166.00 216.40 79.10 82.90 624.00 135.00 101.20
921.00 203.20 70.10 72.20 639.00 528.00 475.60
 Power Consumption Report

Sr.No. Date Energy Meter No. Energy Meter Location KWH KW For 24 hrs

kwh Consumed
Read in 24 hrs
Cumilative 6 AM to 6 AM Min.
port

KW For 24 hrs Power Factor for 24 hrs THDI(Current) For 24 hrs THDV(Voltage)

Avj. Max. Min. Avj. Max. Min. Avj. Max. Min. Avj.
THDV(Voltage)

Max.
Company Logo

Machine No Machine Name

Type of Bare
Line
Sr. No Date Job Size Batch No Batch Time Compou conducto Cable Length
speed
nd r Dia

From To Scrap

Zone wise Extruder Temp

Ext-01
Zone-1 Zone-2 Zone-3 Zone-4
Average Average Average
Stand Stand Stand
Set Temp Actual Set Temp Actual Set Temp Actual Set Temp
By Temp By Temp By Temp
Temp Temp Temp

Ext-02
Zone-1 Zone-2 Zone-3 Zone-4
Average Average Average
Stand Stand Stand
Set Temp Actual Set Temp Actual Set Temp Actual Set Temp
By Temp By Temp By Temp
Temp Temp Temp
 Production and Quality Report

Machine Name

No. of
Avrg Dia Master
spark Spqrk at
Cable Length Set lengh for the Screw Rpm, Ext. Amp. Pot
fault for lengths
Batch Setting
the Batch

OK
length Ext-01 Ext-02 Ext-01 Ext-02

Machine No: Batch time

Zone-4 Zone-5 Zone-6

Average Average Average
Stand Stand Stand
Actual Set Temp Actual Set Temp Actual
By Temp By Temp By Temp
Temp Temp Temp

Zone-4 Zone-5 Zone-6

Average Average Average
Stand Stand Stand By
Actual Set Temp Actual Set Temp Actual
By Temp By Temp Temp
Temp Temp Temp
 Date: 03-11-2008

Location details:

Ext-01 Ext-02 Capstan Running

Avg Kw
Pot Pot pot Flow
for Batch
Setting Setting setting Kg/Hr

Batch time Lcoation

Zone-7 Zone-8
Average Average
Stand By Stand
Set Temp Actual Set Temp Actual
Temp By Temp
Temp Temp

Zone-7 Zone-8
Average Average
Stand Stand
Set Temp Actual Set Temp Actual
By Temp By Temp
Temp Temp
 Running data observation
Extruder section

Ext-01 Ext-02 Ext-03 Ext-04 Ext-05 Ext-06 Ext-07

Ext-01

No. of
Type of Bare Avrg Dia
Batch Line spark
Date Job Size Compou conducto Set lengh for the Screw Rpm,
No. speed fault for
nd r Dia Batch
the Batch

Ext-01

Value Value Value Value Value Value Value Value Value

Ext-01
Zone-1 Zone-2 Zone-3
set set
Actual Actual Actual set Stand
Set Temp Stand By Set Temp Stand By Set Temp
Temp Temp Temp By Temp
Temp Temp
Value Value Value Value Value Value Value Value Value

Ext-02
Zone-1 Zone-2 Zone-3
set
Actual set Stand Actual set Stand Actual
Set Temp Set Temp Set Temp Stand By
Temp By Temp Temp By Temp Temp
Temp
 Ext-08 Ext-09 Ext-10

Master Ext-01 Ext-02 Capstan

Running
Screw Rpm, Pot Pot Pot pot
Ext. Amp.
Setting Setting Setting setting Running
Frequency.
Ext-02 Ext-01 Ext-02 Capstan Ext-1 Ext-2

Value Value Value Value Value Value Value Value Value Value

Zone-4 Zone-5 Zone-6

set set set
Actual Actual Actual
Set Temp Stand By Set Temp Stand By Set Temp Stand By
Temp Temp Temp
Temp Temp Temp
Value Value Value Value Value Value Value Value Value

Zone-4 Zone-5 Zone-6

Actual set Stand Actual set Stand Actual set Stand
Set Temp Set Temp Set Temp
Temp By Temp Temp By Temp Temp By Temp
 Running
Frequency.
Capstan

Value

Lcoation

Zone-7 Zone-8
Actual set Stand Actual set Stand
Set Temp Set Temp
Temp By Temp Temp By Temp
Value Value Value Value Value Value

Zone-6 Zone-7 Zone-8

set set
Actual Actual
Set Temp Stand By Set Temp Stand By
Temp Temp
Temp Temp
 Report for technical analysis
Company Logo

Machine No

Type of
Sr. No Date Job Size Line speed Batch No Batch Time
Compound
From To

Power Consumption for each drive

Ext-01

Set Max
Running frequency Running Amp.
Set Max Current
Frequency
Min Max Avrg Min

Ext-02

Set Max
Running frequency Running Amp.
Current
Set Max
Frequency
Min Max Avrg Min Max

capstan

Set Max
Running frequency Running Amp
Current
Set Max
Frequency
Min Max Avrg Min
 Zone wise Extruder Temp

Name of the Batch

Ext-01
Zone-1 Zone-2 Zone-3
Average
Stand By Average Stand Average
Set Temp Actual Set Temp Set Temp
Temp Actual Temp By Temp Actual Temp
Temp

Ext-02
Zone-1 Zone-2 Zone-3
Average
Stand By Average Stand Average
Set Temp Actual Set Temp Set Temp
Temp Actual Temp By Temp Actual Temp
Temp

Power Consumption Detail

Energy
Machine Machine
total kwh average KW Kva for consumptio
Name No.
Batch No for the batch for the batch the batch n for batch
 Production and Quality Report

Machine Name

Bare No. of spark Avrg Dia

Spark at
conductor Cable Length Set lengh fault for the for the Screw Rpm,
lengths
Dia Batch Batch
Scrap OK length Ext-01

Avrage
Running Amp. Voltage
Avrage (Phase to
Kw(Drive) Phase)
Max Avrg

Avrage
Running Amp. Voltage
Avrage (Phase to
Kw(Drive) Phase)
Avrg

Avrage
Running Amp Voltage
Avrage (Phase to
Kw(Drive) Phase)
Max Avrg
 Machine No:

Zone-3 Zone-4 Zone-5

Average Average
Stand By Stand Stand By
Set Temp Actual Set Temp Actual
Temp By Temp Temp
Temp Temp

Zone-3 Zone-4 Zone-5

Average Average
Stand By Stand Stand By
Set Temp Actual Set Temp Actual
Temp By Temp Temp
Temp Temp

Average Average
Average
THD I in THD V in
P.F
% %
uality Report Date: 03-11-2008

Location details:

Master Ext-01 Ext-02 Capstan Running

Avg Kw
Pot Pot Pot pot Flow
for Batch
Setting Setting Setting setting Kg/Hr
Ext-02
 Batch time Lcoation

Zone-6 Zone-7 Zone-8

Average Average Average
Stand Stand By Stand
Set Temp Actual Set Temp Actual Set Temp Actual
By Temp Temp By Temp
Temp Temp Temp

Zone-6 Zone-7 Zone-8

Average Average Average
Stand By Stand Stand
Set Temp Actual Set Temp Actual Set Temp Actual
Temp By Temp By Temp
Temp Temp Temp