Project Summary
ICES Solutions has developed a powerful, flexible, and scalable Energy Monitoring System (EMS) to address the growing need for real-time energy management in industrial plants.
EMS helps factories monitor, analyze, and optimize electrical consumption across multiple power panels and meters.
The system provides both edge-based local control and cloud-ready SCADA integration for enterprise-wide visibility.
This solution supports everything from live data visualization and detailed analytics to historical reporting and alarm/event tracking—all accessed through a centralized dashboard.
Challenges
Industrial setups often suffer from fragmented monitoring systems, with outdated manual logging, poor real-time insight, and a lack of centralized visibility.
Energy usage remains unchecked, making cost control, preventive maintenance, and operational efficiency difficult to achieve.
Solutions
The EMS developed by ICES bridges this gap with an advanced yet user-friendly platform built for robust field environments.
Key components include:
Edge Device & HMI Panel
- Edge Device & HMI Panel
- Real-time data collection from multiple energy meters via RS-485
- Communication to SCADA using MQTT over Ethernet
- Touch-enabled 7” HMI Panel for local monitoring
- Phase-wise readings for VLL, VLN, AMP, kW, kVA, kVAR, PF, THD, Frequency
- Instant communication status indicators per meter
- Real-time updates every 1 second
IA-ACU – Advanced SCADA Dashboard
- Real-time and historical trends with comparative analysis
- Mimic, Matrix, and Dashboard views for consumption monitoring
- Automatic and manual report generation (daily, shift-wise, monthly)
- Alarms & event logs for operational traceability
- Multi-user access, with admin-controlled settings and secure login
Results
- Real-time monitoring of energy parameters across all panels
- Improved traceability and faster fault diagnostics
- Data-driven energy optimization through shift, daily, and monthly analysis
- Flexible scalability to add meters and panels in future expansions
- Remote-friendly architecture with MQTT and MySQL backbone
- Centralized reporting supporting audits and compliance