Automation & SCADA

  • Client Name: MES, Bangalore
  • Manual Operation Due to plant air demand variation multiple centrifugal air compressors were operating at an unequal load pattern Inefficient operation due to imbalanced equipment loading and excess air blow-off situations.
  • Automation Solution PLC-based Energy Efficient Control system with an equal load sharing logic resulted in reduced cost of maintenance, managed preventive maintenance schedule, higher Reliability.
  • Project Value: INR 0.11 Crores (ROI approx. 9 to 12 months)
  • Manual Operation
    • Combined various Utility equipment data not available in one place for MIS purposes.
    • Need to refer multiple systems (compressors, dryers, chillers, pumps, motors, etc.) to assess health, maintenance schedules, and efficiency which resulted in reliability and efficiency issues.
  • Automation Solution
    • Collected all data for all equipment at one central location using logic from OEMs and built logic to ensure the safety of the equipment.
    • Designed SCADA system with real-time efficiency and health of the utility system over and above Daily, Weekly, Monthly, and Annual reports covering all important parameters of all utility equipment.
  • Project Value: INR 0.20 Crores (ROI approx. 12 to 15 months)
  • Client Name: Maruti Suzuki, Rohtak (R&D Centre) + Hero Motorcycles, Jaipur
  • Manual Operation Due to plant air demand variation multiple centrifugal air compressors were operating at an unequal load pattern Inefficient operation due to imbalanced equipment loading and excess air blow-off situations.
  • Automation Solution
    • Designed a complete system with the supervisory controller to integrate all the equipment of HVAC.
    • Monitor and control the entire HVAC system from a single point.
    • Customized reports for energy calculations
    • Controller runs systems based on performance and sequencing.
  • Project Value: INR 0.25 Crores
  • Client Name: Ultra Denim, Surat
  • Manual Operation
    • Manual Data Logging: Logbook not accurate, discipline issues, cost of manpower, stationary, inventory, record keeping etc.
    • Interpretation issues with different shift operators/manpower
    • Alarms missed/ignored to take preventive measures/maintenance.
    • Reporting was mostly on Break Downs or Purchase Requisitions!
  • Automation Solution
    • Data Logging of values with time stamping up to one year in SCADA
    • System provides historical trends, sensitizes and escalates alarms, prepares reports, and provides preventive maintenance schedules!
    • Customized reports for energy calculations
    • Controller runs systems based on performance and sequencing.
  • Project Value: INR 0.11 Crores (ROI approx. 9 to 12 months)