End To End P lant Automat ion

C O M P A N Y P R O F I L E

Autosys EnginEEring Pvt Ltd

T: +91 44 4353 3555 F: +91 44 4353 3556

E: ael@ael-india.net W: www.ael-india.com

Unit ii: 142, 1st Main Road, Developed Plots Estate, Perungudi, Chennai 600096, INDIA

Unit i: 167 Developed Plots Estate, Perungudi, Chennai 600096, INDIA

Section 1.0 OVERVIEW

Autosys provides end to end plant automation and turnkey project execution in a wide variety of industries and processes. Autosys combines its multi-disciplinary engineering expertise (mechanical, electrical, electronics, PLCs, SCADA, computers and software) with its deep domain knowledge to undertake fixed price contracts for projects costing Rs(INR) 100 lacs to Rs(INR) 100 crores. Modernization of existing plants and automation of specific processes are also undertaken. (Rs(INR) 10 lacs to Rs(INR) 100 Lacs).

The leadership team at Autosys have been working together for 20+ years, and have a cumulative experience of over 100 years in Industrial Process Control and Automation. The team has executed over 400 projects for industry leaders and global MNCs, exceeding customer expectations every time, on performance, reliability and quality.

1.1 COnSulTIng SERVICES

AEL can provide consulting services in areas such as:

This includes Engineering, Documentation, Procurement assistance, Vendor management, Verification of supplies, Quality checks, Standards and Testing compliances, Supervision of erection and commissioning, Integration of vendors and Project management.

By engaging AEL, clients achieve cost reduction, improved quality and timely completion.

1.2 FIxEd PRICE EPC COnTRaCTS and BOT COnTRaCTS

AEL, offers EPC turnkey contracts on fixed price basis with guaranteed performance, quality and throughput. AEL will source, manufacture, integrate, deliver and commission everything required for a project across multiple disciplines - mechanical, electrical, electronics, controls, instruments, PLCs and software – except land, power and civil works.

BOT (Build – Operate – Transfer) model is also offered on select verticals such as Refractories.

Section 2.0 CaPaBIlITIES and dOmaInS

2.1 CaPaBIlITIES

2.2 dOmaInS

Section 3.0 Bulk maTERIal handlIng – TuRnkEy PROjECTS

Autosys team has experience in building bulk material handling plants on turnkey basis for industries such as refractories, cement, mining, friction material, coffee, tea, animal feed, poultry feed etc. This is a sample list of equipment that we supply and commission for a turnkey project.

• OEE Improvement and De-bottlenecking• Automated Material handling (IN gate to OUT gate)• Automatic Weighing and Batching

(Grams to Tons, Solids & Liquids)• Automatic Dosing Systems

(up to 1 gram accuracy, BD upto 0.15)

• PLCs & SCADA• Reporting and MES Software• Networking and Remote management • Instrumentation & Telemetry• Project Management & Turnkey contracts

• Ferro Alloys• Refractories • Abrasives • Rubber • Brake shoe

• Food• Pharma• Pesticides• Infrastructure• Water and Waste water

• Ceramics & Insulators • Animal / Poultry feed • Power

(Sub station Automation)

• OEE improvement• De-bottlenecking• Material handling

• Batching, Weighing, Dispensing and Dosing

• Control and Instrumentation• Telemetry

• Process control • Control and MCC Panels• Process optimization • MES software

Section 4.0 PaRTnERS

aEl is an authorized System Integrator of Rockwell Automation for PLCs, SCADA, Drives and Software.

AEL provides MCC and Control panels incorporating switchgear components from various reputed vendors like Rockwell, Siemens, Schneider, L&T and ABB

AEL provides weighing solutions from world leaders such as Metler, Diniargeo and Vishay.

Instruments like flow meters, level transmitters, pressure transmitters, special purpose instruments, analyzers, vibration equipment etc. are sourced from world’s leading manufacturers.

AEL choses the right vendor and models based on the unique requirements of each application, without being biased towards any one vendor. So customers get the best solution for their needs.

Section 5.0 ExPERTISE

5.1 aREaS OF ExPERTISE

• material handling–Lean management, Automated raw material handling and semi-finished goods handling, Finished goods handling, Specialized conveyors for material storing and retrieval. ASRS based systems, AGVs, Mobile weighing, Automatic dispensing systems etc.

• Weighing and Batching of liquids, solids, light weight and low bulk density materials. Process guarantee on accuracy and speed of batching.

• Turnkey solutions – Complete plant including structural construction and design of process layouts. Includes all material handling, process control and utilities as required for the plant.

• Power Panels : MCC Panels, LT switch gear panels, DG synchronization panels, APFC panels, AMR Panels, Bus Ducts, MV panel, PCC panels etc.,

• Control Panels – PLC panels, Control panels, Desk panels, Junction boxes, Relay panels, MIMIC panels, Large screen displays etc.,

• Water and Waste Water Instrumentation : Flow meters, level sensors, pressure transmitters, GPRS / VSAT communications, Cloud based remote data collection and aggregation. Experience in large projects related to water distribution and pumping, ETP and WTP plants.

• heating and Furnace control –Closed loop systems with guaranteed performance on heating control accuracy and process parameters

• mES software with ERP integration

• Power plant automation – Balance of plant automation, Sub-station automation, Protection panels, Bay controllers, DNP and IEC standard systems

• Back to Back Supply and Support for Infrastructure companies and Consultants.

• Structurals • Silos/Hoppers • Sieves • Bowl feeders • Dust collection equipment • Conveyors• Screw conveyors • Vibro-feeding systems

• Skip hoist Systems • Bucket elevators • Box feeders• Rotary airlocks • Bucket elevators • Pneumatic conveying systems • Custom equipment as per

process needs

• Loadcell based weighing Systems with weigh hoppers

• Motors and drives • MCC & PCC control panels• Control desks • PLC control systems • SCADA software with MIS • MES software

5.2 ChallEngIng aPPlICaTIOnS In WEIghIng

• Accurate weighing and precise dosing of liquids / powders as low as 0.02gms within time limits.• Weighing under dynamic conditions with stirrer and vibrating tank in formulation systems• Mobile weighing • Weigh feeders • Batch weighing with screw feeders and Vibro feeders• Monorail weighing • Weighing with compliance to S88 Standards• FDA regulated traceability standards in batching and weighing• Batching and dosing of difficult to flow materials with very high bulk density or very low bulk density• Custom design of multi-speed feeders after determining flow characteristics of materials

5.3 InduSTRy SPECIFIC ExPERTISE

• Ferro alloy : Batching system for quartz, silica, manganese, chrome ore, charcoal, lignite etc., Weighing in the range of 100 Kg to 1000Kg with speed of 20 to 35 batches per Hour. Furnace control and auxiliary systems monitoring and control.

• Refractories :Batching and weighing system for various grain sizes of alumina, quartz, felspar, zirconia etc. Weighing capacity in the range of 300 kgs to 3000 kgs with speed of 1,000 Kgs / Hr to 30,000 Kgs / Hr. 30 to 40 different raw materials are handled within a small area, with complete automation. Complete plant with Vibro sieves, EOT cranes, Bucket elevators, Storage silos, Structurals, Mixers, Blenders, Bagging, Stitching, Jumbo bag handler, Robotic Palletizer etc.

• abrasives : - Batching and weighing of silica, zirconia etc. with various grit sizes and color combination for both large volume and small volume materials. Silos, batch weighing system, cum flows, barrel mixers and press distribution systems. 30 to 40 materials handled within a small area. 100 kgs to 300 kgs batches with 20gms to 50 gms tolerance. High speed systems of upto 30 to 40 batches per hour.

• Rubber : Weighing, Batching, Dispensing of various oils, chemicals and various types of rubber with bar code and RFID interfaces.

• Brake shoe :Semi automatic batching system with bar code, RFID, mixer interface, storage and retrieval system with horizontal carousel and vertical carousel for large number of raw materials (Typically between 80 to 120). Low capex - Semi automatic process in a controlled environment to ensure FIFO, Poke-Yoke, traceability and accuracy.

• Food, Pharma and Refractories :mobile Trolley Batching- Collection of material stored in Jumbo bags, mobile trolley based weighing and feeding with integrated dust collection system.

• Food - mono rail Weighing - Dynamic weighing of material when moving on monorail. Dispensing control to meet the set feed rate.

• Pharma , Pesticides - Formulation systems - Reactors, kettles and storage tanks are weighed and fed with accurate quantities of material. Control of the process inside reactors and kettles for temperature, stirrer RPM, pressure and time. Weighing under very adverse conditions like vibration due to agitations, high tare weight, very low material weight, steam / hot water jacketing etc..

• Pharma Industry - Tank weighing system

• Ceramic & Insulators : Weighing, batching, material handling and instrumentation for liquid batching systems

• Water and Waster water : Infrastructure companies, Public and private sector companies with requirement of Instrumentation and Telemetry systems. AEL provides pre tendering and post tendering support as well as turnkey solutions.

SECTIOn 5.4 WaTER and WaSTE WaTER PROjECTS

Autosys has extensive experience in control and instrumentation projects related to Infrastructure, Water and Waste-water.

• Reservoir monitoring and control • Canal automation• Lift and piped irrigation • Industrial water pumping & transmission• Water treatment & distribution • Effluent treatment • Sewage pumping & treatment

the technical expertise includes :

InSTRumEnTS COnTROl TElEmETRy ITFlow meters Motorised Valves GPRS – 2G – 3G Web enabled SCADALevel instruments Actuators RF-Radio Servers & NetworksPressure instruments VFD Drives VSAT Large Video displaysAnalysers (Example Chlorine) Panels* Fibre Optics

Condition monitoring & Sequence of Event monitoring

• Vibration (Example pump thrust bearing, motor axis)• Temperature (Example Motor coils)

ChallEngIng aPPlICaTIOnS

the Autosys team has executed projects with :

• Flow measurement upto 1600 mm dia.• Piped water transmission up to 120 Km.• Dual redundant systems with 1/ 2 instrument voting philosophy.• Remote monitoring and control of 300+ locations.

5.5 PanElS

AEL provides design, engineering, documentation, load testing, FAT & SAT for supply of MCC panels and control Panels.All panels are CPRI certified for 65KA isolation and IP protection up-to IP55. For specific requirements we can also supply IP65 certified panels.

Section 6.0 PEOPlE and InFRaSTRuCTuRE

6.1 InFRaSTRuCTuRE

Our factory and head Office is located at Perungudi in Chennai. The factory has an integrated 10,000 SFT fabrication workshop with all required facilities.

• MCC panels – fixed type (Compartment and Non-Compartment type)

• Intelligent MCC panels • PCC panels• Draw-out MCC panels

• Drive panels (LT and MV drives)• Bus ducts• Control desk (Mild steel constructions

and stainless steel construction)• Control panels (Air conditioned and

Non-air conditioned panels)

6.2 ExECuTIOn

More than 90% of our employees have technical / engineering background in disciplines such as Electronics, Instrumentation, Software and Mechanical.

The following are the various processes that we follow in executing a project.

6.3 SERVICE SuPPORT

We not only provide end to end plant automation, integrating multiple disciplines from mechanical to software, we also provide complete and comprehensive service support for all these sub systems. We have well trained engineers at our head office as well as engineers co-located at project sites. Online remote support is provided to customers within 1 hour of complaint registration through internet.

First year support, AMC support and On-call support contracts are offered with committed response time and guaranteed performance.

6.4 PROduCT dIVISIOn

Our product division (www.xeleer.com) focuses on standardized products for industrial automation applications. Automatic dosing systems for fibres and fibrous composites used in roofing sheet, concrete and friction material industry is one such example. These dosing systems deliver high accuracy (+/- 20 Grams for 3 Kgs and +/- 2 grams for 300 grams) and excellent throughput (30 second cycle time 30-60 doses per hour).

6.5 TEam SIzE (aS OF nOV 2013)

Leadership team : 5Permanent employees : 45On demand contract : 35Supplier data base : 400+Onsite Contracting firms : 25+ (can deploy more than 150 to 200 staffs on demand)

6.6 FOundERS and lEadERShIP TEam n kIShORE Managing Director

30 years’ experience in manufacturing, operations and business management. Before joining hands with the Autosys team as a cofounder, KISHORE was the President and SBU head of USD 100 Million business unit of a leading South Indian industrial group. He brings with him rich experience in leadership development, business management, technology intensive manufacturing and material science. He has a wealth of expertise in spearheading aggressive growth through expansion, green field projects, overseas collaborations, acquisitions and integration.

• System Study• Design Engineering & Detailed Drawings• Procurement• Manufacturing / Integration • Inspection & Testing

• Installation • Commissioning• Training• Service & Annual

maintenance contracts

V.jayakumaR Director Operations 22 years’ experience in automation solutions,15 years in project management and operations, Has executed many turnkey projects in the area of Refractories, Ferro alloys Ceramics and Foundries. g. PIChaIPIllaIDirector Projects

30 years’ experience in design, engineering, manufacturing and site erection of mechanical, hydraulic, pneumatic and electro-mechanical systems including structurals and material handling equipment.

V.ThandayuThaPanIDirector Engineering

16 years’ experience in control systems engineering and software development in microcontrollers, PLC’s and SCADA. Expert on PLCs and SCADA of AB, Siemens and GE.

anuP Raj gaunIDirector Customer Support 17 years’ experience in project Execution, customer support and commissioning. Specialist in design and implementation of control, instrumentation and telemetry systems.

RamkumaR R SConsultant Marketing

25 years’ experience in Techno-marketing of capital equipment, projects and products.

6.7 hISTORy / BaCkgROund

Before founding Autosys, Jay, Pichai, Anup and Pani were leading the Automation business of MELSS Automation Ltd and were instrumental in growing MAL 10X times between 2002 and 2012. Before MAL, they worked together as a team at the Industrial Automation Division of Murugappa group. Kishore has worked with them as a customer for many years.

Panels / Water Project

Section 7.0 PanElS

Section 8.0 SamPlE COnTROl SySTEm COnFIguRaTIOnS

Instrumentation, Control and Remote monitoring for Water and Waste water projects with telemetry.

Section 9.0 WaTER and WaSTE WaTER PROjECTS

Iso / cpri

Section 10.0 QualITy CERTIFICaTIOnS

Autosys EnginEEring Pvt Ltdunit I : 167 Developed Plots Estate, Perungudi, Chennai 600096, INDIAunit II : 142, 1st Main Road, Developed Plots Estate, Perungudi, Chennai 600096, INDIAT: +91 44 4353 3555 F: +91 44 4353 3556 E: ael@ael-india.net W: www.ael-india.com