Energy Consumption Management And Energy Saving Analysis System

1. Product Overview

The Energy Management and Energy-Saving Analysis System is designed for municipal water treatment plants, industrial water treatment plants, and water supply pumping stations. It monitors and analyzes energy data by collecting information from electricity meters, flow meters, PLC control systems, and SCADA systems. It centrally manages and analyzes electricity consumption, water consumption, chemical consumption, and the operating status of major equipment throughout the water treatment process.

By combining water production volumes, equipment operating hours, process parameters, and operating loads, the system analyzes energy consumption across process units, equipment, and time periods. It identifies abnormal energy use and potential energy-saving opportunities, providing data support for equipment optimization, energy management, and operating cost control.

For major energy-consuming processes such as raw-water intake pumps, treated-water delivery pumps, backwashing systems, chemical dosing systems, and sludge dewatering systems, the system analyzes operating efficiency based on site data and process conditions and provides optimization recommendations. Where suitable control interfaces are available and process validation and safety requirements are satisfied, the system can also be integrated with automatic control systems to enable energy-saving control in specific scenarios.

2. Key Functions

1. Energy Data Collection and Management

Collect and manage major energy consumption data from the water treatment plant in a unified manner, establishing an energy data framework organized by plant, process unit, and equipment.

Key functions include:

• Collection of electricity, water volume, and other configured energy data
• Integration of operating status, operating hours, and load data for major equipment
• Classification by plant area, process area, equipment, and time period
• Real-time display and historical queries of energy data
• Energy data aggregation, statistics, and trend analysis
• Alerts for missing data, abnormal fluctuations, and similar issues (configured per project)

Data may come from smart electricity meters, flow meters, PLCs, SCADA systems, or other systems with compatible data interfaces. The actual collection scope depends on the instrumentation installed on site and the availability of data interfaces.

2. Itemized Energy Consumption Statistics and Visualization

Break down energy consumption across the entire plant to help managers understand the energy consumption profile of different process stages and equipment.

Key statistical dimensions include:

• Total electricity and water consumption across the plant
• Energy consumption of process units such as raw-water pumping, backwashing, and sludge removal
• Energy consumption of major equipment such as pumps, blowers, mixers, and dewatering equipment
• Energy consumption by shift, day, week, month, and year
• Energy consumption share of each process unit and piece of equipment
• Energy consumption comparisons between sites (for multi-site projects)

The system presents data through trend charts, statistical charts, energy consumption breakdowns, and management dashboards, helping managers quickly understand energy consumption distribution.

3. Energy Consumption per Unit of Water Produced

Comparing total electricity consumption alone cannot accurately determine the operating efficiency of a water treatment plant. The system combines energy data with water production volume to calculate and compare energy consumption per unit of water produced.

Key analysis indicators include:

• Electricity consumption per unit of water produced
• Energy consumption per unit of water produced for different process units
• Changes in energy consumption across different time periods
• Energy consumption comparisons between sites or operating conditions
• Relationships between energy consumption, treated water volume, and equipment load

Statistical definitions can be standardized for each project. Analysis should also consider influent water quality, treatment processes, effluent requirements, and actual operating loads rather than judging energy-saving performance solely by total electricity consumption.

4. Analysis of Major Energy-Consuming Equipment

Analyze the relationships among operating hours, load, energy consumption, and process requirements for major energy-consuming equipment used in water treatment.

Pump Systems:

• Track operating hours and energy consumption for lift pumps, return pumps, and other pumps
• Analyze operating conditions at different flow rates and water levels
• Help identify extended operation, frequent starts and stops, or low operating efficiency
• Provide a basis for optimizing pump combinations and variable-frequency control

Blower and Backwashing Systems:

• Track blower operating hours, electricity consumption, and load changes
• Analyze available data such as head loss and treatment load
• Help identify excessive backwashing, inefficient operation, and inappropriate equipment operation
• Provide a reference for optimizing backwash volume and blower operating strategies

Sludge Handling Systems:

• Track operating hours and energy consumption of sludge dewatering equipment
• Analyze data in conjunction with sludge handling volumes and relevant process data
• Help assess equipment scheduling and treatment efficiency

Chemical Dosing Systems:

• Track chemical usage and operating data from related equipment
• Analyze changes in chemical consumption alongside treated water volume and available water quality data
• Provide a basis for evaluating dosing strategies and controlling chemical costs

The specific analysis indicators depend on equipment type, metering conditions, and the data available on site.

5. Abnormal Energy Consumption Detection and Alerts

Use historical energy data, operating status, and preset thresholds to flag abnormal changes in energy consumption, helping managers identify potential issues promptly.

Key functions include:

• Alerts for energy consumption exceeding limits or fluctuating abnormally
• Detection of abnormal energy consumption per unit of water produced
• Alerts for equipment running for unusually long periods or abnormal operating durations
• Correlation analysis between equipment status and energy consumption data
• Comparisons with corresponding periods, historical baselines, and target values
• Querying abnormal-event records and tracking their handling

Alert rules may use fixed thresholds, historical baselines, or project-specific analysis rules. More advanced anomaly detection and predictive analysis can be configured as needed and must be validated against actual data.

6. Energy-Saving Optimization Recommendations

Use energy data, equipment operating status, and process requirements to help managers identify energy-saving opportunities and develop targeted optimization recommendations.

Optimization areas include:

• Optimizing pump combinations and operating schedules
• Matching blower loads to backwashing requirements
• Optimizing operating parameters for variable-frequency equipment
• Reviewing chemical dosing equipment schedules and chemical consumption
• Optimizing operating plans for sludge dewatering equipment
• Prioritized monitoring and maintenance recommendations for high-energy-consuming equipment
• Comparing energy consumption under different operating plans

Optimization recommendations must be assessed against treatment processes, equipment performance, effluent requirements, and on-site safety constraints. Energy consumption must not be reduced at the expense of necessary backwashing, adequate chemical dosing, or water treatment effectiveness.

7. Energy-Saving Evaluation and Report Management

Compare energy data before and after energy-saving measures are implemented to help evaluate their actual effectiveness.

Key functions include:

• Management of energy-saving targets and energy consumption baselines
• Comparison of energy data before and after optimization
• Analysis of changes in energy consumption per unit of water produced
• Statistics on energy-saving performance of major equipment and process units
• Summaries of energy trends and abnormal conditions
• Generation of daily, weekly, monthly, and customized reports

Evaluations should account for factors such as treated water volume, influent water quality, process load, season, and operating conditions wherever possible. Differences caused by changing operating conditions should not automatically be attributed to energy-saving measures.

8. Integration with Automatic Control Systems

According to project requirements, the system can integrate with PLCs, SCADA, and intelligent process analysis modules so that energy analysis results can support operating strategy optimization.

A phased implementation approach can be used:

• Phase 1: Energy monitoring. Establish energy data collection, itemized statistics, and trend analysis.
• Phase 2: Energy analysis. Combine throughput, equipment status, and process data to identify anomalies and energy-saving opportunities.
• Phase 3: Strategy optimization. Develop equipment operation optimization plans based on analysis results and on-site assessment.
• Phase 4: Automatic optimization for specific scenarios (optional). After reliable data, control interfaces, process validation, and safety protections are in place, connect validated optimization strategies to the automatic control system.

The on-site PLC remains responsible for equipment start/stop commands, interlocks, protection, and critical control logic. The energy analysis system provides data analysis and optimization support and must not bypass on-site protection logic to control equipment directly.

3. System Architecture

The Energy Management and Energy-Saving Analysis System typically consists of the following components:

Energy metering and field equipment → Data acquisition and communication → Energy management platform → Analysis and optimization applications → Management personnel

1. Energy metering layer: Smart electricity meters, flow meters, and other project-specific metering instruments.

2. Field equipment layer: Raw-water intake pumps, treated-water delivery pumps, blowers, backwashing equipment, chemical dosing equipment, sludge handling equipment, and other major energy-consuming equipment.

3. Data access layer: PLCs, SCADA, equipment communication interfaces, and energy data acquisition systems.

4. Data management layer: Energy data storage, itemized statistics, indicator calculations, historical trends, and anomaly records.

5. Analytics application layer: Energy analysis, anomaly alerts, optimization recommendations, energy-saving evaluation, and report management.

6. System integration layer: Integration, as required by the project, with the Smart Visualization Platform for Water Treatment Plants, intelligent process analysis systems, and automatic control systems.

The actual system architecture is determined by on-site metering instruments, equipment interfaces, network architecture, and project management objectives.

4. Applicable Scenarios

• Municipal water treatment plants: Analyze plant-wide electricity consumption and major energy-consuming processes such as raw-water pumping, backwashing, and sludge handling.
• Industrial water treatment plants: Track energy consumption across different treatment processes and equipment to help control operating costs.
• Rural water supply stations: Consolidate energy statistics and compare consumption across distributed sites.
• Water supply pumping stations: Analyze the relationship between pump operating hours, water volume, and electricity consumption.
• Centralized multi-site management projects: View energy indicators across sites in one place and identify abnormal sites and opportunities for energy-saving improvements.

5. Customized Services

Provide system integration and customization based on the water treatment process, on-site instrumentation, equipment types, and energy management requirements.

• Establish itemized energy consumption and equipment classification based on the plant's process layout.
• Integrate smart electricity meters, flow meters, PLCs, SCADA, and other available data interfaces.
• Configure statistical indicators such as energy consumption per unit of water produced and equipment energy consumption according to project requirements.
• Customize energy dashboards, trend analysis, anomaly alerts, and management reports.
• Configure specialized analysis for pumps, blowers, chemical dosing, and sludge handling according to available site data.
• Integrate with 3D visualization platforms and intelligent process analysis systems according to project conditions.
• Design solutions, conduct on-site validation, and implement in phases for scenarios requiring automatic optimization.

Specific functions, metering scope, analysis models, and automatic control scope are subject to the project technical proposal and on-site conditions.

6. Application Benefits

• Understand energy consumption: Gain insight into energy use across the entire plant and each process unit.
• Identify abnormal consumption: Detect anomalies promptly by comparing historical trends, equipment operating data, and energy indicators.
• Support operational optimization: Provide data to support adjustments to pumps, blowers, backwashing, and other energy-consuming equipment.
• Evaluate energy-saving measures: Compare energy indicators before and after optimization to help determine whether measures are effective.
• Improve management transparency: Establish consistent energy data, statistical indicators, and management reports.
• Support refined operations: Provide a data foundation for controlling water treatment costs and long-term energy management.

7. Product Notes

The Energy Management and Energy-Saving Analysis System focuses on energy data collection, itemized metering, energy indicator analysis, anomaly detection, and evaluation of energy-saving performance. It can work alongside a water treatment plant's real-time monitoring system, intelligent process analysis system, and PLC control system.

The accuracy of energy data depends on on-site metering instruments, data acquisition, and statistical definitions. Energy-saving results depend on actual operating conditions, equipment performance, process requirements, and implementation of optimization measures. Automatic energy-saving control functions must be configured on a project basis after on-site assessment and validation of control strategies.

The system can be deployed as an independent functional module of the Smart Visualization Platform for Water Treatment Plants, deployed independently, or integrated with existing systems according to project needs.