An IoT and AI Platform Company
Faclon Labs
Energy Management with I/O Sense Platform
Advanced monitoring, analytics of energy meter data
Benefits of Real Time Energy
Monitoring System
Accurate Energy Consumption Data: A real-time energy monitoring system enables
accurate measurement and tracking of energy consumption at various stages of the
manufacturing process. This data serves as a baseline for identifying energy-saving
opportunities.
Identification of Energy Inefficiencies: By monitoring energy consumption in real-
time, the system can identify areas of high energy usage or inefficiencies. This helps
in pinpointing specific processes or equipment that need optimization.
Performance Monitoring: Real-time energy monitoring provides insights into the
performance of manufacturing equipment. By analyzing energy consumption patterns,
operators can detect deviations, malfunctions, or maintenance issues that may affect
energy efficiency.
Behavioral Changes: When employees are aware of their energy usage and its impact,
they tend to adopt energy-saving behaviors. Real-time energy monitoring can serve as
a motivational tool to encourage employees to reduce energy consumption and
contribute to overall efficiency.
Grasim Vilayat Case Study
Guidelines for Energy Saving through Real-
Time Energy Monitoring
Process Optimization: Use real-time energy monitoring data to analyze process efficiency
and identify energy-intensive steps. Optimize manufacturing processes by implementing
energy-saving techniques such as process automation, heat recovery, or equipment
insulation.
Continuous Monitoring and Analysis: Regularly monitor energy consumption data and
analyze trends and patterns. Implement an alert system to notify operators of sudden spikes
or abnormalities in energy usage, allowing for immediate corrective action.
Benchmarking and Performance Evaluation: Compare energy consumption across different
manufacturing lines, shifts, or facilities to identify best practices and areas for improvement.
Recognize and reward teams or individuals who consistently achieve energy-saving targets.
Guidelines for Energy Saving through Real-
Time Energy Monitoring
Set Energy Consumption Targets: Establish energy consumption targets based on historical
data and industry benchmarks. Regularly monitor and analyze energy usage against these
targets to identify areas for improvement.
Real-Time Data Visualization: Display real-time energy consumption data on screens or
dashboards visible to employees. This creates awareness and encourages individuals to
make informed decisions about energy usage.
Equipment Optimization: Analyze real-time energy consumption patterns to identify
equipment that operates inefficiently or consumes excess energy. Implement maintenance
schedules, conduct energy audits, and upgrade equipment to improve efficiency.
Energy Management with I/O Sense
Platform
● Individual Energy Meter Management
● Drill Down Analysis
● I/O Lens
● Automated Diagnostics
● Overview Dashboard
● Events and Alerts
● Drag and Drop Dashboards
● Custom Reports and Scheduler (PDF and Excel)
● Smart Access Control
● Integration with ERP, Ticketing systems
● Cloud/On premise
● Mobile apps
Individual Energy Meter Analysis
This feature allows user to specifically monitor and analyse the all
the parameters of a particular energy meter
Active energy data and trends
Phase wise voltage live data and trends
Phase wise current live data and trends
I/O Sense - Drill Down Analysis
This feature enables smart mapping of all the energy distribution and specific power
right from all the plants to sections to process to final equipments
Plant 1 and 2
Inside Plant 1 > Section 1
Inside Plant 1
Inside Plant 1 > Section 1 > Process 1
Inside Plant 1 > Section 1 > Process 1 > Sub process 1
I/O Sense - Events & Alerts
This feature allows user to setup threshold based sms, email and
call alerts. Also it logs all the activities done by user for
configuration.
For example Alerts can be set for below parameters, Full load
current, High / Low Voltage, Phase Imbalance, Low Power Factor,
High T&D losses, MD Alert, Harmonics Alert
Logging of alert messages
Analytics of events and alerts Alert Configurator
Sankey Diagram
This feature allows user to create multiple sankey diagrams to
compute energy balance, energy distribution and losses
across the plant, sections, transformers etc.
Sankey Diagram
IO Lens (SCADA)
This feature allows user to create SLD diagrams or any
other diagram and show data/trends/alerts on top of it
SLD Diagrams
Daily Custom and Scheduled Reports (email)
Hourly Consumption Analysis
Report Log
Daily In-Depth Consumption Analysis
Advanced Analytics
Smart Actionable Insights
Smart AI powered, custom, complex logic based identification of losses and inefficiencies providing field teams realtime information
about the areas of optimization.
Compute Flow
Computation of complex formulas and combining with process parameters to monitor equipment efficiency or any
specific KPIs. Integrable any feature of I/O Sense.
Energy Forecast
Forecast of energy consumption based on the historical trends
Energy Prediction
Predicting energy consumption based on production or based on other process parameters and raising alerts with
there is deviation compared to actual
Smart System Maintenance
Smart AI powered and complex logic based identification of configuration issues, meter resets, meter failure, data
disconnections for effective maintenance.
Customers Cases
Grasim Industries
Connected 1000 energy meters in Grasim Pulp and Fibre plant in Vilayat. Fulfilling scaleup order for 2 more
plants having 600 more energy meters. Implemented on Grasim’s central azure server provided smart MIS &
alerts.
Escorts
Connected 700 energy meters, 40 flow meters, compressed air meters for 3 plants of Escorts. Customer
reported 8% savings in first 3 months from the effective monitoring. Provided smart centralized dashboard to
monitor the KPIs
IOCL NRPL
Centrally connected energy data of 22 pumping and delivery locations of IOCL Northern pipeline. Helped IOCL
with real time monitoring of pump efficiency, sec and energy consumption
Other Customers in EMS
Why Faclon?
● Expertise in all the areas - hardware, connectivity, cloud, software and AI
● Security enabled with multiple VAPTs
● Flexible deployment - cloud, on prem, hybrid
● APIs for third party systems like SAP, SCADA or other vendors
● Scalable for other utilities data like water, steam, fuel, compressed air,
chilled water etc.
● Scalable for another applications of Falcon as well such as steam trap
failure detection, HVAC automation, process data monitoring, bus bar
monitoring, machine monitoring, process data monitoring, any sensor
data monitoring etc.
● Smart architecture for high availability and performance
● Smart project life cycle management with strategic software and AI
development
● D-I-Y platform allowing user with larger control in terms of creating
dashboards, reports, alerts, users, onboarding new meters etc.
● Smart actionable analytics
Further Digitization Opportunities
● Bus Bars Temperature monitoring
● Transformers Monitoring Oil Level & Temperature,
Winding Temperature, OLTC, etc.
● Key Equipment’s Mechanical Parameters - Pressure,
Vibration, Temperature
● Relays monitoring
● VFD Condition Monitoring
● Panel room temperature and humidity Monitoring
An IoT and AI Platform Infrastructure Company
Thank You
Siddhant Somani l | siddhant.s@iosense.io | +91 8421727129
