Issue no 2

Case study of EMS in Tynor Orthotics, Chandigarh

Tynor Orthotics Pvt. Limited is the largest

manufacturer and exporter of orthopaedic
appliances and fracture aids in India with
export base to 50 countries. Being one of
the fastest growing company in
Orthopaedic appliances in India, the
requirement for energy is also high.

Problems faced by Tynor:

1. 190KW Solar panel was
installed recently. The
energy manager wanted to
track Solar and EB
consumption daily. One
technician had to spend time
to note down the readings manually which was cumbersome and prone to inadvertent
errors.
2. Difficult to track wastage of energy. Eg: Energy consumption of lights in shopfloor
during lunch time or inadvertently the worker used to keep the machine ON were
examples when these loads were supposed to be switched off.
3. Electricity is billed by EB in kVAh hence maintenance of PF is of utmost importance.
Daily tracking of energy generation at multiple points of time was difficult and
cumbersome.
4. Energy manager required to cross check the data seen in the software provided by Solar
panel manufacturer for the energy exported. No bi-directional meter was available for
this requirement at site.

EAIC | ESP | PMM | Energy Management Solutions

 Solution from L&T
L&T’s SmartComm EMS with 30 meters were installed.
1. L&T SmartComm EMS solution has helped in better
visibility of energy consumption from Solar and EB on
daily basis. Energy bill from PSEB is received next month,
but with SmartComm EMS proper daily energy consumption report is generated and
received by email next day morning. Manual data logging is completely eliminated.

2. Advanced bi-directional meter WL5010 meter was installed to help to cross check of
solar energy delivered. This meter has separate energy registers for EB and Solar
consumption thus helping in better tracking. The Energy manager receives Daylog
book report by email everyday mentioning the energy units received and delivered. On
Sundays and holidays, internal load consumption is negligible hence solar energy is
exported back to the grid. The report helps in proper monitoring.

3. Sometimes it was observed that inadvertently few machines were kept ON in no load
condition thereby consuming energy. SmartComm EMS helped in identification of such
loads and assisted the Energy Manager/Production Supervisor to guide the operator
properly to avoid repeated mistakes. For eg: During non-production hours if kW level
is above a threshold it means some machines are running at no load.

EAIC | ESP | PMM | Energy Management Solutions

 4. On hourly basis, kW of main feeders through SmartComm EMS’s Dashboard Matrix
feature is used by Energy manager to see any abnormal spike in consumption.

5. Using SmartComm EMS, it was found that Current THD% is above permissible limits
due to high usage of non-linear loads for manufacturing.

THD Amps=52.71%

6. Shift wise Energy report is used to monitor energy consumption of all feeders in every
shift.

EAIC | ESP | PMM | Energy Management Solutions

 7. HVAC is one of major energy guzzlers. Monitoring it by sub group basis helps in
maintaining proper level of temperature compared to external one especially during
summers. Temperature controller of HVAC is within arm’s reach of Energy Manager.

The energy manager has determined the wattage level threshold for different seasons,
thereby adjusting the temperature required within the plant accordingly without any
loss of comfort for personnel.

Conclusion:
L&T’s SmartComm EMS has empowered Tynor Orthotics for effective Energy
Management by increasing visibility of energy guzzlers. Energy wastages can
now be tracked easily by the Energy Manager along with automated
reporting.
Proper tracking of EB, Solar, and DG energy has helped in better asset
resource management.

Scan this QR code to experience

SmartComm EMS benefits

EAIC | ESP | PMM | Energy Management Solutions