plantconnect presentation
TRANSCRIPT
www.plantconnect.net
An ISO 9001:2008 company
PlantConnect®
Presentation
Features
About AIPL
Applications
Case Studies
PlantConnect®
Overview
Internet of Things (IoT)
Platform
for
Monitoring & Control
of
Industrial Devices
Monitor
Devices• Same or different types of devices
Location• Located in a single or multiple plants (sites)
Time and place
• Anytime (24x7)
• From anywhere
Frequency• Continuous OR Need-based
Packaging m/c
Test Beds
Wire drawing / cutting m/c
Any PLC controlled m/c
Devices fitted with a Controller / PLC / HMI
Plastics m/c
(Injection moulding,
extruders)
Boilers
Pumps
Chillers
Gas Analyzers
Weather Stations
?
Other Devices
Which Devices
Connect with Sensors
Connect directly with field sensors through PlantConnect integration with 3rd party IO
modules
IO Modules from
- National Instruments
- Renu Electronics
- Other vendors
Business Drivers
Perform proactive
maintenance
Use skilled
manpower
more effectively
Get a ‘differentiator’
in support and
service
Monitor plant
KPIs
Get plant
health alerts
via SMS and email
Integrate plant
data with enterprise
systems
Real time
reports
Improve resource
Utilization by reducing
downtime
Build traceability in
production
Energy Monitoring
Components
Data Acquisition Module (DAM)• Installed at each site
• Connects to devices, polls data and sends to PlantConnect server
PlantConnect Server • Web server located anywhere on
internet / intranet
• Receives data from all DAM
• Provides functions to clients for real time monitoring, reporting, analysis
Browser based client• PC
• Tablet
• Mobile
• PlantConnect DAM
installed on each site.
It collects data from
equipment in real time
• PlantConnect Server
on customer premises
/ cloud
• The data from each
site is sent to
PlantConnect server
over internet
• PlantConnect server
processes the
data…tops it up with
intelligence…and
presents it to different
types of users like
Support Team,
Managers, Top
Management
• Each user sees what
is relevant to him/her
Deployment
Real time data acquisition using protocols like Modbus, OPC etc.
About AIPL
Applications
Case Studies
Features
PlantConnect®
Overview
Functional Modules
Visualization
Alarm Management
Historian
Asset Management and Maintenance
Data Analysis and Reporting
Integration
Configuration
Visualization
• Device tree
• Hierarchical view of complete installation
• Device status icons
• Role based dashboards – System level and Device level
• Drill down to individual devices from the dashboard
• Real time data values / trends
Visualization
• Real time data trend
• Real time data values
• Android application
• Access device status, real time data and alarms from anywhere using your smart phone or tablet
Alarm Management
• Parameter limit based alarms
• Conditional alarms (see details
on next slide)
• Alarm alert on browser client,
mobile app
• Alarm alert by SMS, email
• Alarm escalation
Historian
• View / print historical data values
• View / print historical data trend
• View / print alarms archive
• Rollup data views
• Apply simple functions like avg., min., max.
• Export data to CSV / SQL / Custom format
• Send exported data to other systems via FTP, web service etc.
• Schedule data export
Condition Based Processing
Define conditions
• Based on multiple parameters
• Multiple conditions joined by AND / OR
• Attach periodicity / number of occurrences to the
condition
Examples -
(Pressure1 < 68 AND Valve1 = OFF )
If this occurs 5 times in 30 minutes, then set condition true
(Abs(Zone1Temp – Zone1SetTemp) >= Zone1TempTolerence OR
Abs(Zone2Temp – Zone2SetTemp) >= Zone2TempTolerence )
If this condition occurs and stays for 10 seconds, set condition true
Condition Based Processing
Condition ProcessingAttach condition to one of following
Condition
Based Alarms
Generates an alarm
when condition
occurs
Condition Based
Maintenance
Generates
maintenance workflow
State change
Records a state
change for device /
process when
condition occursExecute logic
Executes custom
logic when condition
occurs. Used for
performance /
efficiency calculations
Execution of Custom Logic
• Plug-in custom logic modules. These are
executed
– Time based
– Every polling cycle
– Based on condition evaluation
Asset Maintenance
• Maintenance scheduling – condition based / running hours based / periodic
• Maintenance alerts
• Maintenance logging
Asset Maintenance
• Maintenance Due Report
• Maintenance Logs
Maintenance Reports
back
• Define asset health conditions
• Raise alerts when the condition occurs
• Send SMS / Email for each alert
Data Analysis & Reporting
• Standard as well as customized reports
• Automatic report scheduling and delivery as file, email, hard copy
Reports
• Trends
• Charts (X-Y chart, pie chart, bar chart etc.)
Charts
• Data entry engine – Define and generate data entry screens, for manual data
• Any report / chart can contain manual as well as automatic data
Data Entry Engine
back
Report Builder
Report Definition
Define reports consisting of raw data, configuration,
processed data, expressions etc.
Data grouping by interval
Functions like avg, min, max, sum etc. on detail and
summary sections
Publishing
Publish reports for specific devices and user roles
Once published, users can use the report like any
standard report
Reporting power in your hands
Integration
• Get Data Interface
• Integration with different data sources
• Devices / OPC HDA / SQL / Custom sources
Downward Integration
• Put Data Interface
• Integration with Enterprise Applications
• Data stored as binary files / CSV files / SQL / XML / Custom format
Upward Integration
back
Configuration
• Extensive configuration tool to configure sites, devices, parameters, users etc
• Remote configurable DAM
Configuration
• User authentication – password + IP address
• Role based authorization
• Device – User matrix for access rights
• Secure data storage
Access Control and Security
back
Device Drivers
Generic AQMS Plastics Others Modbus RTU
Modbus TCP
OPC DA
OPC HDA
OPC UA
Euromap 63
GSI – Generic
Serial Interface
Thermofisher
Teledyne API
Forbes
Marshall Codel
MetOne
Eco Physics
Bayren Hessen
protocol
(Horiba and
others)
File based
drivers
Envidaq
Selogica –
Arburg
machines
MC3F –
Krauss Mafai
machines
MC4 - Krauss
Mafai
machines
Euromap 63
NI Compact
DAQ
FX2N –
Mitsubishi
PLC
Omron PLC
Fanuc CNC
Controllers
About AIPL
PlantConnect®
Overview
Features
ApplicationsCase Studies
Smart Factory Solution - SFactory
SFactory Value Proposition
sFactory– Sample Widgets / Reports
Remote Asset Management (RAMS)
After Market Service (AMS)
- Faster & better service
- Remote Support
- Reduced AMS costs
Collaboration with customers
- Troubleshooting
- Condition based maintenance
- Equipment usage best practices
- Remote monitoring platform
Analytics
- Performance analysis
- Breakdown patterns & statistics
- Valuable data for product improvement
Sales
- Customer satisfaction
- Repeat business
- Spares requirements
Give VOICE to your Equipment
Remote Asset Management Solution for Capital Equipment Manufacturers
Allows OEM to monitor assets installed on customer sites
RAMS – Sample Widgets / Reports
• Web based Environment Quality Monitoring System
• Applications
– Ambient Air quality monitoring
– Stack emissions monitoring
– Water quality monitoring
– Effluent monitoring
• Connectivity to gas analyzers, SPM analyzers, water analyzers, weather
stations from various manufacturers
Compliant with Indian Pollution Control Board (PCB) requirements
EnviroConnect®
EnviroConnect® – Sample Widgets / Reports
PlantConnect® Insights
Plant Connect Insights
Data Management Solution for
Process Plants
Data historian
Report Builder –define and
publish reports on the fly
Custom reports and dashboards
developed as per your needs
Plant / equipment
performance calculations
PlantConnect® Insights
Report Builder
Real time reporting solution
Define and publish reports on
the fly
Custom reports and
charts developed as
per your needs
Collects real time data from
plant DCS, other devices
Reports basis
machine data +
manual data
Reports over
intranet / internet
On demand reports +
scheduled reports
Standard Reports for Dairy
32 standard reports. Some of these are -
• Cream Pasteurizer Report
• Mass Balance Report
• Equipment Master Report
• Equipment Running Hrs Report
• Lab Milk Testing Report
• LYE Uploading Report
• Milk Closing Report
• Milk Pasteurizer Report
• Process CIP Report
• Product Transfer Report
• Silo Testing Report
• Tanker CIP Report
• Utility Consumption Report
• Economizer, Cond and Accumulator Parameters Report
• Power Monitor Data Report
About AIPL
Applications
PlantConnect®
Overview
Case Studies
Features
SFactory Case Study - Energy
Power Plant Sub-Station
Energy Management
- Energy consumption
analysis
- Peak load management
- Circuit overload / trip
alerts
SFactory Case Studies - Plastics
German plastics company
Integration with MES
- Data Acquisition from Injection Moulding Machines of Arburg and
Demag
- Integration of data in Customer’s Manufacturing Execution System via
SQL Server
Multiple plants of a plastics company in India
Production Monitoring
- 3 plants – total 40 injection moulding machines
- Plant / shift / machine performance monitoring
- Condition based maintenance
- Reporting
RAMS Case Study
OEM manufacturing Paper Processing Machines
Remote monitoring of machines installed at customer sites
DAM installed on machine controller More than 60 machines monitored
round the clock System used by OEM and machine users
Objectives- Improve customer
service
- Reduce AMC /
warranty costs
- Ensure increased
machine life by
Just In Time (JIT)
maintenance
- Production data
collection for R&D
EnviroConnect - CPCB Server for FM
EnviroConnect server installed in CPCB on behalf of Forbes Marshal
• Real time CEMS and ETP data collection from various plants throughout the
country
• Around 300 devices connected
• Largest environment data server in India in terms of number of devices
connected
• Same system accessed by industries and regulators
PlantConnect Insights
A Dairy in Gujarath, India - Connected to 7 devices
DCS for milk plant DCS for refrigeration
plant Milko scan - 2 Titrator - 2 Weigh bridge
- Objectives Real time
reporting, 38 reports
Maintenance alerts
Customers
Features
PlantConnect®
Overview
Applications
Case Studies
About AIPL
A little bit about company…
Ascent Informatics (India) Pvt. Ltd.
Software Solutions for Industrial Automation
Thought leader in convergence of
Industrial Automation &
Information Technology
About AIPL
People
Our customers, employees and
associates
Processes
• ISO 9001:2008
• Process driven, but agile approach
Products
Innovative IT solutions in Industrial Automation
We believe in….
USPs
We work beyond technology
Hardware neutral solutions
Mix of product and custom development
Flexible and sensitive to client’s needs
Optimum Quality Management System certified by
ISO
Resources continuity and retention
Involvement of top management in projects
Cost effective and great value for money
Industrial Automation Applications
Types of applications developed
Web based monitoring and control
Plug and play instrumentation platform
Data loggers / Data Acquisition Servers
Web enabling of hardware
SCADA
Device Drivers
Many more…
Our customers are saying…
We would absolutely recommend AIPL to other firms looking for a
good partner, and would give them the highest recommendation.
- Steve Drevik, CEO, Agilaire LLC
We are delighted to have been able to work with AIPL and strongly
believe that their flawless execution was a key factor to our project
success.
- Director, Motion Business US & Asia, A Public Company in CA, USA
Everyone at AIPL is proactive, flexible, energetic and capable to
accept and meet new challenges.
- Mahesh Washikar, CEO, FuturePath
Thank You!
Dr. Arvind Tilak, Jt. CEO
Mr. Anand Taparia, Manager – Business Dev.
Or call us at +91 20 6500 4608
Ascent Intellimation Pvt. Ltd.‘Dnyanamayi’, 1, Shreeniketan Society,
Kothrud, Pune 411038, India
www.plantconnect.net