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Remote Monitoring Solutions for

Effective Plant Management

deploying M2M technology

Do you face these challenges?

The lack of right information to the right people, at the right place, and time, leaves plant managers and personnel struggling to meet these challenges. Expansive plants and geographically distributed plant locations only compound these challenges. The solution to these issues is to provide a centralized on-line, real-time, decision support system that can empower personnel with concise information on the device of their choice i.e. laptop, mobile phones, or tablets.

Such a system will involve:

1. Continuous monitoring of remote plant assets for real time information on: a. Production b. Productivity c. Availability d. Losses e. OEE

2. Continuous tracking of critical process parameters that help: a. Identify and address deviations quickly b. Track equipment health / condition to instill and manage predictive/condition-based maintenance

3. Real-time reporting of KPIs such as specific resource consumption, OEE, Plant Load Factor, batch change time etc. that help keep track of operational effectiveness and performance

4. Alerts intimating plant users about critical plant conditions before they get out of hand

The solution

TMA.T.E. Enterprises Pvt. Ltd. (EcoAxis – Business Unit) has developed SUPERAxis which is a machine-to-machine (M2M) technology platform for continuous remote monitoring and analytics of discrete batch and continuous process plant & equipment and also utilities such as energy, air, and water/waste water. EcoAxis is a pioneer of such technology in the country.

TMSUPERAxis is a complete suite of hardware and software products integrated into a total solution. This includes embedded data logging gateways, a data warehouse and software engine to deliver analytics in the form of reports, dashboards on web or mobile interfaces, notifications over emails and SMS, and bridges to enterprise applications.

The solution has been implemented for a number of applications including energy, power, heating and cooling, water and TMwastewater plants for processes, effluent, chillers, cooling towers and boilers. SUPERAxis has also been implemented

in process plants such as textiles, sugar, printing and packaging, and discrete equipment such as air compressors, boilers, chillers and, injection/blow molding machines.

EcoAxis value proposition

The business scenario today, ever-demanding customer needs of high quality products at highly competitive prices leave plant owners with many challenges to meet the top and bottom lines, such as:

1. Continuous and aggressive management of: a. Operations and maintenance practices to maximize Overall Equipment Effectiveness (OEE) b. Quick response to deviations from standard operating conditions to minimize revenue loss and ensure effective use of skilled man-power c. Optimisation of specific resource consumption (air, water, steam, electricity, fuel etc.) to reduce operating costs d. Maximize equipment life while minimizing Total Cost of Ownership (TCO)

2. Complex nature of industrial plants and equipment requiring in-depth technical expertise on one side and limited pool of experts on the other, to manage these assets.

Plant & Equipment & Data Acquisition

CustomerScope

Utility Equipment

Process Plant

Central Supervision

OPC Server

OPC Client

AxislogData Logger

Organisation

• Process IOs supported through external AI, DI modules• 100 modbus parameters through selectable interface (RS232/RS485/RS422)• Modbus (RTU, ASCII 7 &8 bit support) master & slave• Data transfer through FTP over Ethernet, broad band, PSTN, GSM (GPRS) • Modbus TCP (SCADA), SD-card, snapshot on SMS, logging of critical parameters• 24 VDC external power supply

Hardware for data acquisition

• Process IOs supported through external AI, DI modules• 40 Modbus parameters over fixed RS232 OR Rs485• Modbus (RTU, ASCII 7 & 8 bit support) Master only• Configuration through local file download over serial port Data transfer through FTP over GSM (GPRS) • Operates on 9-30 VDC external power supply

KPI & Advanced AnalyticsData Management

Define user roles

Create users

Functionality

EcoAxis Solution

Trending Tabular

Data

Export

to Excel

Export

to Pdf

a isx EYE

a isx EYE

a isx GURU

a isx NOTIFYAlerts & Notifications

Application

Server

Database

Server

Configuration

Users Sites Equipments

• End User

• O & M

• OEM

• Operator

• Maintenance Team

• Management (KPI’s)

SuperAxis software framework is deployed on in-plant or remote servers and is available for authorized users over a web browser. The extensive software framework has the following modules:

Software connectors for data acquisitionEcoAxis' software connectors help collate data from a variety of PLC / DCS / EMS systems over a variety of protocols like OPC, Modbus, Profibus etc.

Data historian for data storageData historian provides for: • Configuration of the customer's world including

its organization, customers, users, customer locations, customer's users, installed base details such as models, parameters, etc.

• Rich algorithms to efficiently store big data coming in through software connectors or data-loggers in the data-base

Software offering • Serving the data through internet browser to authorized users

Analytics, alerts and acts for data visualizationEcoAxis' software solution provides for framework for: • Customized reports and notifications that can be accessed over the web • Customized notifications which are delivered through SMS and emails

EcoAxis develops and publishes these at a one-time development cost after preparation of functional specifications in consultation with the users.

The solution can be easily deployed very rapidly across a multitude of applications and verticals, which help users maximize these benefits.

The solution architecture of the system is depicted in the picture below:

Solution architecture

EcoAxis' Machine-to-Machine (M2M) based monitoring solutions tracks critical parameters of power plant operations (such as boiler temperature profile, turbine vibration parameters, equipment operations, run-hours, stoppages, and water chemistry), performance and maintenance on a programmable time interval (minutes / seconds as needed by the process). EcoAxis has implemented its remote monitoring solution at an enterprise-level covering multiple power plant sites, to achieve the following objectives:

• Manage the operation of the plant through advanced supervision and diagnostic tools to reduce power plant operating and maintenance costs

• Achieve greater flexibility in power plant operations and performance

• Enable better scheduling of power generation as per grid demand along with load-based performance monitoring (instead of capacity-based), thereby giving a better indication of power plant performance

• Help power plants attain peak operational efficiency through real-time integration of fuel management accounting systems• Reduce maintenance cost through condition-based / predictive maintenance• Continuous condition monitoring helps detect defects early on and carry out predictive maintenance• Increase plant availability by controlling and effectively

managing unscheduled stoppages. Plant reliability is also improved through vibration and temperature profile monitoring of various rotating parts in the power plant

• Track coal in real-time in the coal handling plant, to avoid slagging. Slagging can reduce plant efficiency, cause costly outages, and dangerous working conditions. Continuous monitoring helps decide when and in what quantity reagents like ammonia, sodium bisulphate, and calcium carbonate are to be added.

• Monitor continuously boiler water chemistry such as dissolved oxygen content, pH and conductivity of feed water and improve de-aeration effectiveness and minimize boiler corrosion risk, thereby enhancing the life of the boiler.

In the solution described here-in, over 3000 parameters are captured on-line from a multitude of sources viz. DCS systems, smart meters, sensors etc. Facility to manually enter parameter values on the portal is made available for parameters that are not captured from-line instruments, but are manually measured in the lab for over 50 odd parameters. Smart device based entry forms can also be deployed for ease of use.

Glimpses of the implemented solutions are visible in the following sections.

Sample implementation of EcoAxis solution for power plant

• Personalized dashboard published as web pages

• MIS reports with meaningful analytics• Operations control screens made available to experts remotely for viewing in real-time

• Smart device based dashboards available anytime, anywhere

• Asset framework based approach• Configuration of alerts & email notification & escalation

Plant process monitoring

Waste watereffluent disposal

monitoring

Continuous Measurement& Verification (CMV)

Discrete equipment monitoring

Facility monitoring

Utilities monitoring

EcoAxis is an end-to-end solutions provider for IoT based remote monitoring for sustainable business practices. Such solutions are deployed for the following applications:

About EcoAxis

Our Vision:We will deliver Internet of Things (IoT) based continuous monitoring and automation solutions to customers in diversified industrial segments, significantly impacting the way they manage their assets.

Our Mission:We will achieve this by addressing our customer's key need of continuous resource optimization, through an in-depth We will achieve this by addressing our customer's key need of continuous resource optimization, through an in-depth understanding of processes and applications, and strategically engaging with domain experts.

EcoAxis (a business unit of A.T.E. Enterprises Pvt. Ltd.) has an IoT based system for continuous remote monitoring of industrial plant & equipment as well as energy and environmental resources.

This system called – SUPERAxis™ – consists of hardware & software connectors for logging data from machines, instruments and sensors. Using cloud-based computing, it delivers analytics and alerts in the form of reports, dash boards, emails and SMS – on any device, anytime, anywhere.

SUPERAxis™ has been implemented for complete plant monitoring covering applications such as textile process houses, power plants, printing and packaging units, sugar complexes, facilities, etc. as well as for utility equipment like boilers, heaters, chillers, compressors, gasifiers, cooling towers, DG sets, water and waste water treatment plants etc.

OEMs and O&M service providers have packaged EcoAxis' remote monitoring solution to monitor their installed base of equipment for improving service revenue and service processes, reducing warranty costs and for field validation of their product and technology designs.

The solution has benefited end users in improving production, productivity and availability, reducing losses, as well as effectively managing energy & resource utilization and improving plant maintenance.

Here are some examples of EcoAxis' solutions in IoT based continuous monitoring:

Ÿ Installed base consisting of several hundred units of heat exchange equipment of a large OEM, sending equipment data across geographies to a central control room for remote service delivery by the OEM.

Ÿ Management of a multi-plant sugar enterprise given access to data on online production, productivity, availability & losses while on the move (via ergonomically designed dashboards) on smart devices.

Ÿ Remote monitoring of several facilities.

Ÿ A role-based decision support system built for various stakeholders of a multi-fuel, multi-site power plant enterprise, with remote access of critical operations and maintenance data to experts at a centralized location.

As of January 2015, EcoAxis’ solutions delivered across the globe have analyzed over 4.5 trillion data points and is growing at 1 trillion

data points every year.

A.T.E. ENTERPRISES PRIVATE LIMITED

T-126, T Block, MIDC, Bhosari, Pune 411 026T | +91 20 3088 1100 E | contact@ecoaxisindia.comW | www.ecoaxisindia.com / www.ateindia.com

(Business Unit: ) EcoAxis