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Every kilowatt traced to the line that used it.

Energy is one of a factory’s largest costs and emissions sources, yet most plants know only the bill. Submetering of electricity, gas, steam, compressed air and water by line and machine, with production data, shows where energy goes, where it is wasted and what each saving was worth.

Industry

Industry

Measurements

4

Sources cited

3

1. Industry · Factory energy management

   Only the bill

   Energy is one of a factory’s largest costs and emission sources, yet most plants see only the monthly bill. Without knowing which line, machine or utility uses what, savings are guesses. Energy audits and management systems ask for measured data, and submetering supplies it.

2. What is measured

   Every utility, by line

   Submeters at distribution boards and machines measure electricity every minute, flow meters measure gas, steam, compressed air and water on main branches, and line counters bring in production output, so energy can be set against what it produced. Every instrument keeps its calibration and position with the site record.

   Instruments

   Electricity submeters · Flow meters · Production counters

3. The base node

   Energy per unit

   The node computes energy per unit of output for every line, detects base load between shifts and compressed air leaks at night, forecasts the next peak and verifies each saving against a baseline normalised for output and weather. Every value is signed at the node before it leaves.

4. Radio and links

   On the plant network

   Most plants have a network, and metering joins it through the edge node. Remote sites and utility buildings without the plant network use cellular. Production data join from the production system for normalisation. When one path fails, the other carries the data.

   Links

   Fibre · Public cellular

5. How it works

   From a night flow to a fixed leak

   Compressed air flow stays high every night with the lines stopped. The node flags a base load equal to a large compressor. Maintenance walks the network with an ultrasonic detector, finds and fixes a dozen leaks, and the next month’s verified saving is recorded against the baseline.

6. From order to operation · Order

   Scope the energy flows

   The scope reads bills, single-line diagrams, utility schematics, production data and existing meters. Nexus Observatory Inc. returns the metering plan by significant energy use, the analysis, measurement and verification design and a price per plant and per year. The scope is agreed before any site work begins.

   Plan a deployment

7. From order to operation · Survey

   Survey boards and branches

   Crews survey distribution boards, utility branches and production lines with the energy manager: meter points, current transformer sizes, flow meter positions and network access. Significant energy uses are confirmed. Findings shape the kit for each site before anything is built.

8. From order to operation · Permits

   Electrical safety

   Work in live boards follows the plant’s electrical safety rules and permits, usually in planned windows. Utility branches are isolated for flow meter fitting. Every permit is kept with the plant record. No crew goes to site before its approvals are in place.

9. From order to operation · Build

   Build and configure

   Meters and gateways are configured with the single-line diagram, nodes enrolled with their identities and loaded with line and production mappings. The system is tested together before shipping. Nothing ships until the whole kit has passed its tests together. Test results travel with the kit to the site.

   Open the Station Builder

10. From order to operation · Install

    Install in planned windows

    Crews fit meters and current transformers in boards, flow meters on utility branches, and gateways and the node, connecting the production system. Every meter is labelled with its board and circuit. Crews follow the site safety plan throughout the work.

11. From order to operation · Commission

    Commission against the bill

    Each node proves its identity. Submeter totals are reconciled with the utility meters, flows with the utility plant, and baselines for each significant use are set from weeks of data normalised for output. Acceptance is recorded with the owner before handover.

12. From order to operation · Operate

    Find and prove savings

    Energy managers see energy per unit of output, waste between shifts and peaks. Leaks are fixed, idle machines switched off and peaks shaved, and each saving is verified against its baseline for audits and certification. Every alert and action is kept on the record.

13. From order to operation · Maintain

    Verify and recertify

    Meters are checked against utility meters, baselines updated when production changes, software updated in rings, and records prepared for audits and recertification. Every change is kept with the plant record. Maintenance history stays with each site for its whole life.

    Book field services

14. Data products

    For energy, maintenance and finance

    Energy managers and line managers receive energy per unit of output; maintenance teams receive waste and leak alerts; finance and auditors receive verified savings; sustainability reporting receives energy and emissions records, each tied to line, meter and period. Every product can be traced back to its readings.

    See the data products

15. Evidence

    Measured and verified

    The programme follows the energy management system standard, savings follow the measurement and verification standard, and records support the audit and management duties of the energy efficiency directive. Every meter, baseline and saving is kept for auditors and certifiers. The record is kept for as long as the duty lasts.

    Drawn against

    ISO 50001 · ISO 50015 · Directive (EU) 2023/1791

16. What you get

    Mine, plant and port site monitoring

    Slope radar, tailings monitoring, dust and water, and site connectivity for operations and closure. Delivered as managed service and hardware + software, for mining, heavy industry, ports. Scale: Site portfolios. Service levels are written as numbers you can measure on your own dashboard.

    Talk to sales

17. Next step

    Plan factory energy management with us

    Tell us the site, the measurements and the rules it answers to. We reply with a survey proposal, a design and a scope for factory energy management. An engineer replies with a survey proposal and a scope, and the plan grows from one site to the network you need, at your pace.

    Plan a deploymentOpen the Station BuilderOpen the Studio

01The place and its hazards

Where it runs, and what can go wrong.

Operating contextEnergy management systems follow the international standard, savings are measured and verified to its companion standard, and large enterprises must carry out energy audits or run a certified energy management system under the energy efficiency directive. Submetering makes both possible.

Hazards

• Bills that show totals but not causes
• Compressed air leaks running day and night
• Machines left running between shifts
• Savings claimed without measurement
• Peak demand charges from coincident loads

02What must be measured

What, where, how often, and under which rules.

Each measurement names where it is taken, how often, and the public standard or regulation behind it. Numbers in the sources column open the cited source below.

03The observation stack

From one base unit to a network.

The same blocks at every scale: instruments and a base node, a site with its radio, a fleet run as one, and a network federated on the open protocol.

1. 01

   Base unit

   A metering point: electricity and flow meters on an industrial gateway.

   Build a station →
2. 02

   Site

   A plant: every board, line and utility branch on one node, with the production system joined.

   Plan a site →
3. 03

   Fleet

   Every plant of a company on one energy view.

   Managed offers →
4. 04

   Network

   Energy and savings records reach auditors, certifiers and reporting through open standards.

   The open protocol →

• 01Energy and power-quality meter
• 02Flow meter
• 03Compact weather station
• 04OT gateway (OPC UA, Modbus)
• 05Edge node (Wedge)
• 06Cellular modem/router
• 07Fibre terminal

Radio and links

Fibre

Most plants have a network; metering joins it through the edge node.

Radio and links

Public cellular

Remote sites and utility buildings without the plant network use cellular.

Edge computeThe node computes energy per unit of output for every line, detects base load between shifts and compressed air leaks at night, forecasts peaks and verifies each saving against its baseline.

PowerMeters run from the boards they measure; the gateway and node run from the plant supply.

04How it works

From the instrument to the product.

One observation’s path, tier by tier, with the interface on every link and a bill of materials below; then how the one node grows to a site, a fleet and federated networks.

05From order to operation

Every step, from the first call to a running site.

The same crew and the same record carry the work from scope to maintenance.

1. 01 Order

   Scope the energy flows

   The scope reads bills, single-line diagrams, utility schematics, production data and existing meters. Nexus Observatory Inc. returns the metering plan by significant energy use, the analysis, measurement and verification design and a price per plant and per year. The scope is agreed before any site work begins. 13

2. 02 Survey

   Survey boards and branches

   Crews survey distribution boards, utility branches and production lines with the energy manager: meter points, current transformer sizes, flow meter positions and network access. Significant energy uses are confirmed. Findings shape the kit for each site before anything is built. 1

3. 03 Permits

   Electrical safety

   Work in live boards follows the plant’s electrical safety rules and permits, usually in planned windows. Utility branches are isolated for flow meter fitting. Every permit is kept with the plant record. No crew goes to site before its approvals are in place.

4. 04 Build

   Build and configure

   Meters and gateways are configured with the single-line diagram, nodes enrolled with their identities and loaded with line and production mappings. The system is tested together before shipping. Nothing ships until the whole kit has passed its tests together. Test results travel with the kit to the site.

5. 05 Install

   Install in planned windows

   Crews fit meters and current transformers in boards, flow meters on utility branches, and gateways and the node, connecting the production system. Every meter is labelled with its board and circuit. Crews follow the site safety plan throughout the work.

6. 06 Commission

   Commission against the bill

   Each node proves its identity. Submeter totals are reconciled with the utility meters, flows with the utility plant, and baselines for each significant use are set from weeks of data normalised for output. Acceptance is recorded with the owner before handover. 2

7. 07 Operate

   Find and prove savings

   Energy managers see energy per unit of output, waste between shifts and peaks. Leaks are fixed, idle machines switched off and peaks shaved, and each saving is verified against its baseline for audits and certification. Every alert and action is kept on the record. 23

8. 08 Maintain

   Verify and recertify

   Meters are checked against utility meters, baselines updated when production changes, software updated in rings, and records prepared for audits and recertification. Every change is kept with the plant record. Maintenance history stays with each site for its whole life. 1

06Data products and integration

What it delivers, to whom, and into which systems.

Data products

• Energy per unit of outputEnergy managers and line managers
• Waste and leak alertsMaintenance teams
• Verified savingsFinance and auditors
• Energy and emissions recordsSustainability reporting

Integration

• Production systemOutput data join from the production system for normalisation.
• Building and utility controlsPeak forecasts reach controls that shed load.
• ReportingRecords feed audits, certification and emissions reporting.

Exchanged through OPC UA, Modbus, ISO 50001 records.

07Questions buyers ask

Before you scope it.

Will it help with the energy audit?

Yes. Measured data support the audit and certification.

How are savings proven?

Against baselines normalised for output and weather.

Can it find compressed air leaks?

Night and weekend flows show them.

Do we need new networks?

No. It joins the plant network or uses cellular.

08Resources

The sources behind this page.

Public standards, regulations and guidance, cited where they apply. Each applies only where its jurisdiction or scope does.

1. 1ISO 50001: Energy management systemsInternational Organization for Standardization
2. 2ISO 50015: Measurement and verification of energy performance of organizationsInternational Organization for Standardization
3. 3Directive (EU) 2023/1791 on energy efficiencyEuropean Union · 2023

09Related

Use cases and solutions.

10Industry: specialized fields

Other fields of this industry.

Bring us the site.

Plan a deployment, configure a station, model it in the Studio or talk to sales. The form names who receives your details.