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1
The Future of Energy Intelligence for Smarter Industries
Harit Soni
2
The Problem
Shrinking Margins
Globalization and competition
means consumers feel the pinch
but have limited transparency and
visibility into their energy
consumption.
Inefficiencies
There are significant
inefficiencies in purchase and
use of electricity and equipment;
eroding margins. As per UNIDO,
this is around 20-30%
Low Asset Utilization
New asset purchase, maintenance and up-
gradation is gut-based and not data-driven
– causing downtime, wrong product
selection and sub-par asset utilization.
Reducing costs and optimizing asset purchase and use is critical to staying competitive.
Businesses worldwide are faced with a challenge to operate more efficiently in muted economic conditions
3
Our Business
An SaaS Energy Analytics platform where businesses can optimize their operations
by making
Smarter asset management decisions using Energy Intelligence
OPERATE MORE EFFICIENTLY
by controlling input costs and optimizing asset quality
and utilization
MAINTAIN OR REPLACE ASSETS
Smartly using our recommendation engine
SmartSense changes the way businesses take decisions on Power utilization, Asset maintenance,
replacements and purchase
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Smarter way of Energy and Asset Management
Traditional approach
• Auditors
• Manual +Excel
• Post facto analysis
• Scheduled Maintenance
SmartSense
• Real-time + highlight or alerts on deviations
• Data driven, cause and effect based maintenance or preventive maintenance
• Data driven efficiency
Challenges
• Monthly Bill reconciliation
• Network Audit
• Penalty Management
• Power Sourcing Strategy
• Equipment management (Transformers, Motors, Compressors, Boilers & Furnaces)
Cost of Monthly Energy bill
reconciliation : $80,
Yearly : $1000
Cost of Analysis of Energy
consumption : $166
Cost of Energy Audit : $8,500
Much Cheaper, faster and more
accurate than traditional
methods
5
Smartsense Architecture
SmartSense is an Industrial IOT platform with a communication gateway, designed for quick deployment of
Monitoring and analytics. It monitors all the energy parameters, including Electricity, Gas, air, etc.
6
Key Features of Smartsense Platform
Completely WirelessReal-Time & Scalable
Minimal or no cabling required. 30 mins
to install our h/w platform. Bi directional
communication.
RetrofitFits to existing Infrastructure
We do not have a prejudice for any
sensor make / model. Same hardware
supports 200 sensors.
AlertsProactive Actions
Preventive Maintenance
Sms and email alerts helps in fixing the
issue before it becomes a problem
Secure Cloud Hosted
InfrastructureCan be accessed from anywhere
Client does not need to host and manage
I.T infrastructure
ReportsAdvanced Analytics
Automated.. Before he gets on his desk
and the way he wants to look at it.
Centralised PlatformLocation Agnostic
Monitor and control various plants distributed
over multiple geographies from a single
platform
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SmartSense makes Analytics possible
Billing Insights
Power Sourcing
optimization
Network Insights
Transformer Insights
Motor Insights
Compressor Insights
Data Acquisition and Monitoring Very low cost making
it a no brainer
Insights and
Recommendations
based on the data
Plant / Building level analytics Asset level analytics
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Analytics Objectives
Sourcing Side Management
Enabling power purchase and asset
maintenance decision
1. Energy trading bid optimization
2. Equipment maintenance & Repair
Demand Side Management
Monitoring, intervention and analytics for
efficiency and maintenance of
1. Whole Network (Real-time energy audit)
2. Billing Optimization
3. Individual Equipments
o Transformers
o Motor/Pumps
o Furnace/Boiler
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The SmartSense Analytics Model
What Happened
Reporting
What is Happening now
Alerts
How and why did it happen
Modeling, Experimental design
What’s the next best action
Recommendation
What will Happen
Extrapolation
What’s the best / Worst that can
happen
Prediction, optimization, Simulation
Info
rma
tio
nIn
sig
hts
Past Present Future
10Analyzing the Network
11Asset Analytics
Motor/ Pump analytics Transformer analytics
We Provide condition Monitoring and predictive maintenance insights for Key assets
12SmartsSense Alerts and report Module
13Data brings results!
Annual Electricity
Bill
USD 3.4 Million
Sector
Food &
Beverages
Contract Demand
5000 kVA
Company ProfilePepsico is the leading F&B player in India with more than 25 plants across the
country
Pepsi Problem and Ecolibrium’s Solution
PepsiCo had huge problems in data monitoring of its energy consumption and
correlate it to the production numbers on a live platform. Due to this delay the actions
to improve any issue was delayed
Ecolibrium’s solution helped Pepsico in the following areas:
1. Real time monitoring of energy and production data
2. Power Usage Optimization using automated alerts and reports
3. Power Factor Management
Phases of Project
Phase 1
1. Preliminary survey to understand plant operations and power consumption for all
the locations. SmartSense was implemented in 3 key locations in India
Phase 2
1. Analytics on their consumption vis-à-vis their working hours and production data
2. Identification and correction of problem areas
Increased Visibility of
Problem Areas
Corrected Low Power
Factor, Demand
Management, Idle
Running Cost
~ USD 400,000
Savings annually
14Intas Pharmaceuticals
Annual
Electricity Bill
Rs. 28 Crore
Sector
Pharmaceutical
Contract
Demand
4500 kVA
Company Profile
Intas Pharmaceutical - a leading name in healthcare - offers
wide range of formulations from tablets to injectable to
capsules to newer drugs globally.
Intas installed SmartSense to monitor around 77 points
across India for Power and Temperature.
Ecolibrium’s Solution
Ecolibrium’s solution helped Intas in the following areas:
1. Maximum Demand Management
2. Lowering their Maintenance costs
3. Optimization in Electricity Bill
15Intas Pharmaceuticals – Ecolibrium Effect
Power Usage Optimization
Phase 1
o Monitoring of the 66KV and 11KV input points
o Contract demand regulation & Bidding strategy Optimization
Phase 2
o Monitoring of 30 additional locations including transformers,
chillers and compressors.
o Identification of Compressor Leakages on a regular basis.&
Monitoring of Chiller efficiency
Phase 3
o Monitoring of temperature of 45 drug storage locations to
avoid spoilage of drugs
o Maintaining a specific temperature range
1.5% Reduction in yearly
Electricity bill
10% savings in
Compressor efficiency
Stock wastage
reduction by timely
temperature alerts
Contract Demand
Management
Use of the SmartSense system is a big
boon for us to do centralized monitoring of
key energy parameters. We would
recommend this system to all
Pharmaceutical production units
Milind Kadia
(Intas Pharma)
‘‘
’’
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Smart Transformers for Utilities
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The Customer Engagement Model
Utility Dashboard
and Analytics Consumer app and Billing Analytics
Consumer Billing and Tariff
Change Information
Outage and other Alerts Energy Efficiency and Green
Energy Campaigns
Bill and other grievance Management Bill Payment
Ecolibrium provides a platform for engaging customer in a meaningful and targeted manner
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A deeper look how utility can engage..
Utility Dashboard
and Analytics Consumer app and Billing Analytics
Data : Consumer Billing
Information
Information and Notifications Energy Efficiency and Green
Energy Campaigns on App
Ecolibrium provides a platform for engaging customer in a meaningful and targeted manner
• Live Electricity Consumption
data
• Access to past and present
Billing data
• Reminder for bill payment
• Bill pattern Anomaly Alert – “
You are consuming 50% higher
than normal..”
SMS / Email / Mobile App
• Tariff Update: “ Your Tariff has changed to..”
• Account Change: “ Your Contact Demand has changed
to xx”
• Regulatory Notifications for taxes, Charges, Or from
CERC / SERC, etc.
• Alert on health - Power factor penalty/ Billing demand
penalty, Harmonics, etc. – “ Your Phase imbalance is in
unhealthy range – please improve for savings.”
• Potential rebate alert on payment of bill in a timely
manner – “ If you pay your bill tomorrow – you will
save Rs. 5000”
• “What if” Tools and alerts for Solar and other
DSM applications
• Alerts for new schemes from BEE for
improving power quality
• DSM Success Story sharing in emails
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We use analytics to track Engagement Metrics.
• Live engagement level of each consumer
• Consumer Engagement Metrics and identification of
high engagement consumers for DSM/ Demand
Response
• Constant nudging for low engagement consumers by
SMS / Personal Calls
20SmartSense: Industry proven Energy Management
600+ Customers
across India
5000+ Equipments
on the platform
150+ Million
Data Pointscaptured daily
Global Recognitions
Global Entrepreneurship Award,
BarcelonaIndia Power Award Climate Solver 2013UNFCCC- Light House
Momentum for Change 2014
Customer Base
Strategic Partners
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Equipment's on our platform v/s industry utilization
200+Motors
100+Furnaces
700+Transformers
150+Compressors
Industries TransformerInduction
MotorCompressor Pump Blower
Automobiles
(Auto-ancillary)Yes Yes Yes Yes May be
Pharmaceuticals Yes Yes Yes May be May be
Metals (Re-Rolling mills,
Foundries)
Yes Yes May be Yes Yes
Engineering Yes Yes May be May be May be
Textile Yes Yes Yes Yes Yes
Cement
(Process)Yes Yes Yes May be Yes
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We have just scratched the surface
Smart Sense aims to capture a large slice of the efficiency and cost conscious industrial and
commercial segment.
Global Addressable Market (~ 20x)
48,000,000+ MSMEs
including 200,000+ factories
6,000,000+
Medium and large energy customers
MSME and Factories will
need to become efficient
to stay competitive
600+ SmartSense customers
23Creating a world where every watt counts!
www.ecolibriumenergy.com
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Case Studies
25Intas Pharmaceuticals
Annual
Electricity Bill
Rs. 28 Crore
Sector
Pharmaceutical
Contract
Demand
4500 kVA
Company Profile
Intas Pharmaceutical - a leading name in healthcare - offers
wide range of formulations from tablets to injectable to
capsules to newer drugs globally.
Intas installed SmartSense to monitor around 77 points
across India for Power and Temperature.
Ecolibrium’s Solution
Ecolibrium’s solution helped Intas in the following areas:
1. Maximum Demand Management
2. Lowering their Maintenance costs
3. Optimization in Electricity Bill
26Intas Pharmaceuticals – Ecolibrium Effect
Power Usage Optimization
Phase 1
o Monitoring of the 66KV and 11KV input points
o Contract demand regulation & Bidding strategy Optimization
Phase 2
o Monitoring of 30 additional locations including transformers,
chillers and compressors.
o Identification of Compressor Leakages on a regular basis.&
Monitoring of Chiller efficiency
Phase 3
o Monitoring of temperature of 45 drug storage locations to
avoid spoilage of drugs
o Maintaining a specific temperature range
1.5% Reduction in yearly
Electricity bill
10% savings in
Compressor efficiency
Stock wastage
reduction by timely
temperature alerts
Contract Demand
Management
Use of the SmartSense system is a big
boon for us to do centralized monitoring of
key energy parameters. We would
recommend this system to all
Pharmaceutical production units
Milind Kadia
(Intas Pharma)
‘‘
’’
27Akshat Ispat Ltd
Annual
Electricity Bill
Rs. 4 Crore
Sector
Iron & Steel
Contract
Demand
2000 kVA
Company Profile
Akshat Ispat Ltd. is leading manufacturer of fabricated metal
products, TMT Bars and other metal products. It has made a
famous name for its specialized TMT Bars.
Akshat installed SmartSense to monitor 8 points at their plant
for Power.
Ecolibrium’s Solution
Ecolibrium’s solution helped Intas in the following areas:
1. Maximum Demand Management
2. Power Usage Optimization
28Akshat Ispat Ltd – Ecolibrium Effect
Power Usage Optimization
Phase 1
o Preliminary survey was done to understand the
plant operations, power consumption for all the
locations
Phase 2
o Installed SmartSense Meter+ at 8 different
locations across their plant - Started tracking real
time data and formed their load profile based on
data of 3 months
Phase 3
o Corrected their MD breach issue which was
responsible for lot of hefty penalties every month
INR 7.6 Lacs
savings in Annual Electricity bill
INR 63,000
Monthly Benefit
ROI of Less than
1 MonthMaximum Demand
Management
29Ashok Leyland
Annual
Electricity Bill
Rs. 12 Crore
Sector
Automobile
Contract
Demand
5000 kVA
Company Profile
Ashok Leyland is the 2nd largest manufacturer of commercial
vehicles in India, the 4th largest manufacturer of buses in the
world and the 16th largest manufacturer of trucks globally.
Ashok installed SmartSense to monitor 8 points across 8
locations in India for Power.
Ecolibrium’s Solution
Ecolibrium’s solution helped Intas in the following areas:
1. Maximum Demand Management
2. Power Usage Optimization
3. Power Factor Management
30Ashok Leyland – Ecolibrium Effect
Power Usage Optimization
Phase 1
o Preliminary survey to understand plant operations and
power consumption for all the locations
Phase 2
o Installed SmartSense EMS at 8 plants
o Tracking of real time data and load profile for 3
months
Phase 3
o Analytics on their consumption vis-à-vis their working
hours
o Identification and correction of problem areas
18% Savings in monthly
Electricity Bill
INR 28 Lacs
Annual savings
Corrected Low PF,
MD Breach and idle
Running lost
Improved Power
quality
Smartsense UI snapshot
showing consumption data
of different locations in India
on a single dashboard
31Jet Granito
Annual
Electricity Bill
Rs. 24 Crore
Sector
Marble
Processing
Contract
Demand
5000 kVA
Company Profile
Jet Granito Pvt. Ltd., established in 2006 is the one of the
reputed manufacturer of vitrified tiles and ceramic wall & floor
tiles in India and serving the domestic and international
clients on the sphere.
Jet Granito installed SmartSense to monitor their plant for
Open Access Trading optimization.
Ecolibrium’s Solution
Ecolibrium’s solution helped Intas in the following areas:
1. Power Sourcing Optimization
32Jet Granito – Ecolibrium Effect
Power Sourcing Optimization
Phase 1
o Preliminary survey to understand plant operations, power
consumption and their current bid strategy
Phase 2
o Installed SmartSense ET
o Tracking of real time data and load profile for 3 months
Phase 3
o Analytics on their consumption vis-à-vis their working hours
o Provided daily Benefit reports, Monthly reconciliation reports
and Bid strategy matrix
1.5 % Overall Yearly
Saving
INR 1.8 Lacs
Monthly savings
Optimized
Bid Strategy
Customized
Alerts
Ecolibrium is to be commended for the
excellent quality of work and the prompt and
efficient service you provide.
Smartsense ET is an ideal product for Open
Access consumers and we strongly
recommend Smartsense ET for all Open
Access consumers. It was pleasure working
with their team
Head - Electrical
(Jet Granito)
‘‘
’’
33AIA Engineering
Annual
Electricity Bill
Rs. 7.5 Crore
Sector
Engineering
Contract
Demand
5000 kVA
Company Profile
AIA Engineering is the 2nd largest Hi-chrome casting producer
in the world. It is a global solution provider of specializes in the
design, development, manufacture, installation and servicing of
high chromium wear, corrosion & abrasion resistant castings
used in cement, mining & thermal power generation industries.
AIA installed SmartSense to monitor 6 points at 1 plant for
power and Furnace optimization.
Ecolibrium’s Solution
Ecolibrium’s solution helped Intas in the following areas:
1. Furnace Optimization
2. Power Usage Optimization
34AIA Engineering – Ecolibrium Effect
Power Sourcing Optimization
Phase 1
o Initially 5 Smartsense devices were installed
Phase 2
o Ecolibrium & AIA worked together to identify Energy
Hotspots at AIA - Locations with the highest energy
consumption with possible scope of savings
o Installed SmartSense Furnace at their Furnace
Phase 3
o Data was analysed by the EI team for further insights
o Monitored and Controlled their blower speed based on
feedback from the O2 sensor
INR 17 Lacs Overall
Yearly Savings
8 – 10 % Improved
Combustion Efficiency
Payback period of less
than 7 Months
Compressor savings of
500 kWh/month
The Smartsense furnace solution is useful for
not only energy saving, but also product
quality improvement due to reduced oxidation
Electrical Engineer
(AIA Engineering)
‘‘
’’
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CESCOM – Case Study | 500 KVA Transformer
• Voltage Imbalance of around 30-40% and
current imbalance of 25-30% - Leading to
possible degradation
• Power Factor of 0.95 – Possible reduction in
line losses if improved
• Transformer severely underlaoded – of only
around 10-20% -- Thus increased losses due
to fixed losses.
• Huge Voltage drop in y phase : Check for
CT or Winding failure
Possible Actions could increase the life of the
transformer substantially and also decrease
losses by nearly 10-15%.
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CESCOM – Case Study | 500 KVA Transformer
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CESCOM – Case Study | 100 KVA Transformer
Possible Actions could increase the life of the
transformer substantially and also decrease line
losses
• Voltage Drop from from 426 to below 410 from
August to November 2015
• Power Factor of 0.93
