The first condition for bringing factory energy costs under control is to make consumption visible. A well-planned energy monitoring system installation makes a facility’s electricity, natural gas, water and compressed air consumption measurable at line and machine level. In this article we cover how an energy monitoring system is installed in factories, the steps involved and what to watch out for during installation. If you want to understand the basics first, see our article on what energy monitoring is and how the system works.
Before Installation: Needs Analysis and Selecting Measurement Points
A successful installation begins at the desk, before going to the field. The first step is to map the facility’s energy: main inlet, distribution panels, high-consumption machines and critical lines are identified. The aim is to achieve the highest visibility with a limited budget, so the points that make up most of total consumption are monitored first and the system is expanded later.
If an energy audit has already been carried out, the improvement areas it revealed are turned directly into a monitoring plan.
Step 1: Selecting and Mounting the Measurement Hardware
Measurement accuracy determines the accuracy of the entire system. Energy analyzers, smart meters and current transformers (CTs) are placed at the selected points, and relevant flow meters and sensors are added for natural gas, water and compressed air. Choosing the correct device class and CT ratio is critical; a wrong choice makes all the data unreliable. We explain this in detail in our guide on choosing an energy analyzer.
Step 2: Setting Up the Communication Infrastructure
For field devices to talk to the central platform, a communication infrastructure is established. The most common methods in industry are Modbus RTU (RS-485) and Modbus TCP (Ethernet). Wireless IoT solutions are preferred where cabling is difficult. Gateway units that collect and transmit data come into play at this layer.
Step 3: Commissioning the Software Platform
Collected data is processed in an energy monitoring software. At this stage, measurement points are defined, the consumption hierarchy (facility, building, line, machine) is created, and performance indicators such as energy per unit of product are set up. Live dashboards, reports and threshold alarms are configured.
Step 4: Verification and Go-Live
After installation, measurements are validated against reference values. The consistency of meter readings, the accuracy of phase connections and the continuity of data flow are tested. Skipping this step leaves you with a system that appears to work but produces incorrect data.
How Long Does Installation Take?
Depending on the size of the facility, the number of points and the existing infrastructure, it ranges from a few days to a few weeks. With a modular approach, critical lines are commissioned quickly and the remaining points are added gradually without disrupting production.
Common Installation Mistakes
- Wrong CT selection: A CT ratio incompatible with the load corrupts measurement from the start.
- Ignoring power quality: Harmonic distortion affects both measurement and equipment and should be included in the scope.
- Not monitoring reactive power: Unmonitored reactive consumption turns into penalties.
- Not planning for scalability: The system should allow new lines to be added later.
Turnkey Installation with Atasayın ATS
Atasayın Energy and Engineering manages the entire process, from needs analysis and hardware selection to installation and software commissioning, with its ATS Energy Monitoring System. For an installation plan tailored to your facility, get in touch with us.
Frequently Asked Questions
Can the system be installed with my existing meters?
Existing meters and analyzers that support protocols such as Modbus can in most cases be integrated. Suitable measurement devices are added at points that do not support them.
Does installation stop production?
Most of the work is done without disrupting production. Only some panel connections may require short, planned interruptions.
Which energy types can be monitored?
Electricity, natural gas, water, steam and compressed air can all be monitored through the same system.