Energy Management System — PlantAI EMS
One live view of energy across every plant. From the energy meter to head office: critical data every second, five years of history, and reports and analytics your teams can act on.
1 s
critical feeders — generator, grid and auxiliary — sampled every second
5 years
of history on your own servers for energy accounting and audits
Unlimited
users, meters and tags on a perpetual licence
0
writes to your DCS — read-only to the plant, by design
From Meter to Head Office in Five Steps
Your existing meters, connected through a layered architecture that keeps every plant running even when the link to head office drops.
STEP 1
Energy Meters
Your existing meters on RS485 daisy chains — any make, any model.
STEP 2
Gateways
One per loop, converting RS485 to Modbus TCP, with surge protection.
STEP 3
Plant Server
Polling, alarms and a local buffer; DCS data read over OPC, read-only.
STEP 4
Head Office
Five-year historian, reports and analytics for the whole fleet, over VPN.
STEP 5
Your Teams
Web and mobile access, e-mailed reports, alarms by e-mail and SMS.
Built on open standards: Modbus RTU/TCP, OPC UA, MQTT over VPN, and PostgreSQL with TimescaleDB. No proprietary lock-in — your data stays exportable.
What PlantAI EMS Delivers
For biomass, captive, waste-to-energy and multi-site industrial plants with a central energy team.
Engineered for 1-Second Data
Each plant gets fast loops for critical meters (kW, kVA, kVAr, PF, Hz, V, I every second) and standard loops for the rest — every loop planned to use no more than 70% of bus time.
Live Operations
Live single-line view of the HV bus and every LT panel, plant dashboards for generation, export, auxiliary, PF and steam rate, trends from seconds to years, and four-priority alarms.
Reports & MIS Every Morning
Energy balance, PLF and aux %, generator run sheets, specific fuel and steam, cost allocation, power factor and demand, fleet benchmark — as PDF, Excel or CSV, or e-mailed on schedule.
Analytics: From Data to Decisions
Baselines that flag unusual load, day-ahead forecasts for 96 blocks a day, PPA deviation block by block, time-of-day cost of every kWh and capacitor sizing per panel — each forecast checked against actuals on screen.
Your Data Is Never Lost
Each plant buffers its readings if the link to head office drops and catches up when it returns. Compressed five-year history, with nightly and weekly backups to a separate NAS.
Safe for Your Plants by Design
Read-only to the DCS — the system advises, it never trips equipment. A zoned network with firewall and VPN at every plant in line with IEC 62443, plant-level roles and a full audit trail.
See PlantAI EMS in Action
The software is built and running. Demo screens shown with simulated plant data.
Fleet Overview
Generation, export and auxiliary for all plants, live, with today’s energy and PLF compared plant by plant.
Live Single-Line View
Live flow on the 11 kV bus and every LT panel; click any meter for its trends.
Reports & MIS
Daily energy balance, PLF and auxiliary consumption — exportable or e-mailed automatically.
Day-Ahead Forecast
Generation, export and auxiliary demand forecast in 15-minute blocks, back-tested against actuals.
Prove It at One Plant, Then Roll Out
One accountable supplier for gateways, converters, servers, software, commissioning and site support.
01
Survey & Design
Site survey, meter register maps and a loop-by-loop design sized from your own meter list.
02
Pilot Plant Live
One plant, end to end, accepted by your team before the rollout.
03
Fleet Rollout
Remaining plants and the head-office platform from the proven template.
04
Handover & Support
Acceptance tests, training and site support after go-live.
What We Supply
Hardware, sensors, converters and licensed software for a complete, working system — not just the application.
- RS485 to Modbus TCP gateways with surge protection and enclosures
- Protocol, signal and fibre media converters where needed
- Plant servers, managed switches, firewalls and VPN routers
- Head-office server, historian and backup NAS
- Integration of your existing energy meters, mapped register by register
- Commercial software licences (operating system, database, security) where specified
- PlantAI EMS software on a perpetual licence, unlimited users
- Engineering, commissioning, training and site support
Scope note: cabling, erection work and energy meters are not in our scope — they are provided by the client or their electrical / EPC contractor, and we integrate your existing meters.
See It Before You Sign
We’ll run a live demo on simulated data built from your own meter list.