Hierarchical multilevel smart energy monitoring system

Energy management in industrial facilities requires the integration of operational data, utility systems, and enterprise-level decision-making processes. Although ISA-95-based architectures are widely used for enterprise-control integration, practical deployment of energy-focused monitoring frameworks across large industrial environments remains insufficiently documented. This paper presents a hierarchical multilevel smart energy monitoring system developed for industrial energy management based on ISA-95 principles and OT-IT integration. The proposed architecture integrates field instrumentation, PLC/SCADA systems, Manufacturing Execution Systems (MES), and Enterprise Resource Planning (ERP) platforms into a unified energy monitoring environment. The framework was implemented across more than 15 manufacturing facilities and integrated approximately 1,476 electrical analyzers, 214 compressed-air flowmeters, 126 gas correctors, 73 water meters, and nearly 30,000 operational data streams. The architecture enabled centralized monitoring, plant-level benchmarking, utility-system integration, and enterprise-wide visibility of energy performance. Evaluation using energy datasets obtained from 21 glass manufacturing facilities revealed that furnace systems accounted for approximately 73% of total energy consumption, while furnace and waste heat recovery projects represented 34.7% of identified energy-saving potential. The integrated architecture enabled systematic identification of energy-intensive assets, elimination of fragmented data structures, and improved cross-functional energy performance evaluation. The study demonstrates how an ISA-95-based energy monitoring architecture can support industrial energy management through scalable data integration, hierarchical decision support, and enterprise-wide energy visibility. Hierarchical ISA-95-based architecture enables OT–IT convergence for industrial energy management. Centralized platform integrates multi-utility monitoring across more than 15 industrial facilities. Approximately 15,000 field devices and 30,000 operational data streams were integrated. Sankey-based analysis identified furnace systems as the dominant energy consumer (≈73%). Enterprise-wide benchmarking and decision support facilitate identification of energy-efficiency opportunities.