Centralized Energy Management: 147 Meters Connected, 5 Pipelines Digitized (Leading Oil & Gas Corporation)

@Faclon Team

November 14, 2025

2min read

About the Company

A leading government-owned oil and gas corporation with $50 billion market cap as of 2024, holding a leading regional position in petroleum refining and marketing with 34% contribution to domestic petroleum sales. The organization operates 30+ pipelines for delivering crude oil and end products to various locations for processing or dispatch, employing over 32,000+ actively employed personnel. With extensive operations across multiple regions, the company maintains 7 pumping stations and 11 delivery locations ensuring continuous supply of petroleum products, focusing on implementing advanced energy management systems to optimize operational efficiency and cost-effectiveness across its pipeline network infrastructure.

Problem Statement

Critical operational challenges threatening manufacturing efficiency

Manual report generation complexities Collating reports manually from various business units and pumping stations creating high challenges due to errors and variance in SEC analysis procedures
Tariff optimization limitations Data standardization requirements for different pumping stations to track maximum demand and ensure optimal utilization during low tariff periods based on time-of-day pricing
Lack of live analytics capability Critical need for real-time energy and electrical data access across 13 pumping stations to ensure operational reliability and continuous monitoring
Preventive maintenance gaps Requirement for proactive insights on pumping operations to identify overloading conditions enabling pump switchover to prevent failures, damage, and wear & tear
Geographic distribution challenges Managing energy consumption across dispersed pumping stations spanning vast geographical areas requiring centralized monitoring and control systems
SEC analysis standardization Need for consistent specific energy consumption tracking across various pipelines and power sourcing methods to enable accurate performance benchmarking

How Faclon Solved the Problem

I/O Sense Platform: Comprehensive Industry 4.0 deployment for energy management and process optimization

Pipeline-wise SEC Tracking

Implemented energy consumption monitoring per metric tonne of product pumped across various pipelines tracking power sourcing from multiple sources (kWh/MT pumped)

Dynamic Single Line Diagrams

Created pinpoint understanding of individual pumping stations enabling identification of electrical anomalies and asset overloading for cyclical operations management

Comprehensive Alerting System

Provisioned real-time alerts and alarms enabling proactive measures for power quality, power factor, current/voltage imbalance, and other critical parameters

Automated Reporting Platform

Established reporting schedulers ensuring generation of highly detailed daily, weekly, and monthly reports for various stakeholders across organizational hierarchy

Multi-Location Integration

Connected 7 pumping stations and 11 delivery locations across 5 digitized pipelines using 147 connected meters with ST-54 gateway architecture.

Advanced Analytics Deployment

Implemented I/O Lens dashboard development capabilities enabling strategic management dashboards without coding requirements for comprehensive operational insights.

The Outcome

Comprehensive results across operational efficiency

147 meters connected

Complete integration of energy monitoring infrastructure across all pumping stations and delivery locations enabling comprehensive data collection

7 pumping stations digitized

Full automation of energy tracking across all critical pumping facilities ensuring continuous monitoring and operational oversight

11 delivery locations integrated

Comprehensive coverage of destination points enabling end-to-end pipeline energy management and SEC analysis capabilities

5 pipelines digitized

Complete pipeline network coverage enabling detailed energy consumption analysis per metric tonne of product transported across different routes

Centralized CEMS implementation

Successful deployment of Central Energy Management System enabling remote tracking and thorough SEC analysis across geographically distributed operations

Real-time analytics achievement

Implementation of live energy monitoring and electrical data access ensuring operational reliability and enabling data-driven decision making

Behind the Scenes

Advanced technical implementation and strategic deployment considerations

Gateway networking architecture

ST-54P gateways looped across entire geographical span via OFC networking ensuring reliable data transmission and communication with on-premise CEMS server

Multi-parameter monitoring integration

Comprehensive coverage of energy meters, gas flow meters, DG meters, and solar meters using Modbus RS-485 connectivity supporting 10-15 meters per gateway

Advanced platform capabilities

I/O Sense platform deployment with no-code dashboard development, single line diagram creation, live analysis dashboards, and drill-down analytics using I/O Matrix

Alert and reporting framework

Real-time alert generation for voltage anomalies, overcurrent, high SEC, high maximum demand, and increased harmonics with customized stakeholder notification

SEC analytics methodology

Specific energy consumption tracking implementation measuring kWh per metric tonne pumped with power source diversification analysis and pipeline-specific benchmarking

Centralized control architecture

CEMS server deployment enabling bird's eye view of critical metrics, hierarchical access control, Excel-compatible reporting tools, and conditional formatting capabilities

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