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Smart Technology and Service Suite Equipment Monitoring - Diesel Gensets

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Smart Technology and Service Suite Equipment Monitoring - Diesel Gensets

  1. 1. Smart Technology & Service Suite
  2. 2. Smooth & efficient utilisation of the valuable industrial assets is one of the keys to success in any business. Moreover, in order to meet customers' needs and service demands in a cost-effective manner, the operating staff needs to optimize & utilize the available resources effectively. EcoAxis (a business unit of A.T.E. Enterprises Pvt. Ltd.) offers remote monitoring solutions for effective management of the industrial assets thus improving the productivity and reliability. What can the RMS monitor? Solution Architecture Astandard management axiom states that “you cannot manage what you cannot measure”. Thus for efficient management of valuable facility assets like DG sets, it is essential to measure critical parameters such as : ŸEnergy generated ŸElectrical quality parameters like voltage, current, power factor, etc. ŸFuel consumption and fuel tank level ŸCritical engine parameters like battery voltage, coolant temperature, exhaust temperature, lube oil pressure etc. ŸCritical alternator parameters like harmonics, winding temperatures etc. ŸCritical ambient parameters like ambient temperature & humidity, canopy temperature, canopy door open/close status etc. ŸRun hours of each DG set ŸMaintenance schedule and periodic checks ŸLoad on DG sets and load patterns EcoAxis has a proven Internet of Things (IoT) based solution based system has been widely used by end users as well as OEMs for analyzing critical operation & maintenance processes of their products/ processes through use of big data analytics. This Remote Monitoring System (RMS) helps in collating data & analyzing the various parameters related to the performance of DG sets. The critical parameters can be monitored continuously on a near real-time basis. The continuous monitoring and analysis of these parameters is helpful in managing operations as well as scheduling maintenance activities of different subsystems to ensure effective availability of the plant to meet the demand. RMS helps OEMs / users in following ways: ŸProvides a platform for monitoring a global installed base of DG sets – any device, anytime, anywhere ŸProvides authentic information to take corrective actions & helps for root cause analysis ŸMonitors critical parameters and performances across multiple locations ŸMonitors service due based on run hours, evaluates its adherence and effectiveness of service through comparison of performance pre and post service ŸCompares against benchmarks / norms ŸInitiates notifications & escalate them to ensure follow-through, if needed ŸProvides alerts & notifications on smart devices through SMS & e-Mail ŸIntegrates with smart devices like iPad, android phones, etc. thus providing platform of your choice ŸImproves reliability & uptime of DG set and reducesTotal Cost of Ownership (TCO) ŸProvides a platform for managing deployment of service personnel & spares
  3. 3. Examples Monthly DG set Overview Operating Efficiency Summary 0 4 8 12 16 20 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Trip Hrs Stop Hrs Run Hrs Hrs Days 0 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3.5 3.0 2.5 2.0 0 kWh/Lit Days Total Running Hours Total Stop Hours Total Trip Hours 1498 203 19 Minimum kWh/litre Maximum kWh/litre Average kWh/litre 2.9 3.8 3.25 * These figures are for representation only * These figures are for representation only Historical Efficiency Analysis Specific fuel consumption is higher in the month of Jan, Mar & Nov which corresponds to lower efficiency. 0 0.5 1 1.5 2 2.5 3 3.5 4 Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 kWh/Lit Days Operating Cost Analysis Cost per kWh, Rs/kWh Specific energy output, kWh/Litre 2.800 2.900 3.000 3.100 3.200 3.300 3.400 3.500 3.600 3.700 3.800 11.00 11.50 12.00 12.50 13.00 13.50 14.00 14.50 15.00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Hrs Rs/kWh kWh/Lit Data Minimum Maximum Average kWh/Litre 3.12 3.70 3.47 Rs/kWh 12.43 14.74 13.27 Ÿ Automated logbook of critical parameters Ÿ Listing of critical events Ÿ Facility for operator comments Do away with painful manual log books Ÿ Trend of key parameters Ÿ Facility to pan & zoom * These figures are for representation only Operating Parameter Trending e-Logbook 0 20 40 60 80 100 120 140 0 200 400 600 800 1000 1200 1400 1600 1800 Hrs. 08:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 CURRENT (AMP) VOLTAGE (V) POWER (kW) LUBE PRESSURE (kg/cm2) LUBE OIL TEMP. (°C) WATER TEMP. (°C) Hourly average kWh generated Vs litre/hr of diesel consumed trending Data Minimum Maximum Average Liters/hr 153 173 162 kWh 470 595 547 * These figures are for representation only Diesel consumed, Litres/hr Power generated, kWh 100 200 300 400 500 600 700 800 900 1000 140 145 150 155 160 165 170 175 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Lit/hr kWh Hrs
  4. 4. Monitoring of Multi-located DG Sets DataAcquisition: EcoAxis deploys hardware data-loggers and software connectors for collection of field information through sensors, smart instruments like energy meters, DG set controllers, AMF controllers, PLCs, etc. and streams the data thus collated over the web using either in-built GPRS modems or Ethernet LAN to cloud server. Data Management: The cloud server provides for a data historian for collating & managing field information in a structured format. KPIs &AdvancedAnalytics: The cloud servers also provides dashboards, notifications & alerts for important information through email or SMS. DG Set Overview Indicative list of the parameters which are measured & analysed Ÿ Electrical power: Voltage, Current, Power factor, kW, kWh Ÿ Diesel consumption Ÿ Diesel tank level & available quantity Ÿ Cooling water Temperatures Ÿ Equipment run hours Ÿ Individual equipment efficiency Ÿ Total DG plant load Ÿ Alerts & notifications Ÿ Critical water parameters: pH, TDS, Conductivity, ORP Ÿ Electrical distribution Dashboards & Reports
  5. 5. Regionwise Spares Requirement Q3 FY13-14 SMS & e-Mail Alerts Region Diesel filter (012-321-056) Air filter (011-411-312) Coolant (023-614-005) Oil (416-918-050) Hose (561-032-146) Belt (049-310-980) O-Ring Kit (213-056-722) North 33 27 66 52 29 78 65 South 66 52 32 98 36 45 30 East 32 98 76 62 12 59 47 West 76 62 45 73 41 44 86 Benefits for End Users Benefits for OEMs Ÿ Remotely monitor and manage multiple DG sets at multiple sites Ÿ Use role based analytics for crisp and actionable information - empower key stake-holders in operations, maintenance, top management etc. for quick redressal of impending issues. Ÿ Aggressively manage operations and maintenance through monitoring Ÿ Continuously track KPIs like capacity utilization, plant load factor and specific fuel consumption to maximise efficiency and minimise total cost of ownership Ÿ Maximize availability through tracking of service compliance and service effectiveness in terms of critical parameters Ÿ Perform quick root cause analysis through tracking frequently occurring faults and key associated parameters Ÿ Integrate easily with engine control units and AMF controllers Ÿ Remotely monitor installed base of DG sets Ÿ Customized dashboards & reports over PC, laptop & smart devices Ÿ Important alerts/ notifications via email & SMS Ÿ Region wise/model wise/dealer wise classification of information Ÿ Condition based maintenance – track maintenance due of remotely based on equipment run hours Ÿ Accordingly manage service man-power deputation and spares logistics Ÿ Achieve first visit resolution - minimize service costs and maximize service revenue Ÿ Benchmark DG set performance and evaluate performance against benchmark Ÿ Remotely evaluate performance of new designs and design changes in the field Ÿ Remotely evaluate capacity utilization, loading patterns and identify cross and up-selling opportunities Ÿ Track frequently occurring faults - improve equipment availability Ÿ Track critical parameters and perform root cause analysis of frequently occurring faults Ÿ Track specific fuel consumption continuously and manage efficiency Ÿ Integrate easily with engine control units and AMF controllers Ÿ Delight your customers – help them to enhance equipment life cycle * These figures are for representation only
  6. 6. A.T.E. ENTERPRISES PRIVATE LIMITED T-126, T Block, MIDC, Bhosari, Pune 411 026 T | +91 20 3088 1100 E | contact@ecoaxisindia.com W | www.ecoaxisindia.com / www.ateindia.com (Business Unit: )EcoAxis Waste water effluent disposal monitoring Continuous Measurement & Verification (CMV) Analytics for renewable energy Discrete equipment monitoring Facility monitoring Utilities monitoring Plant process monitoring Understand your most critical challenges Setup systems to collate the most pertinent data Data acquisition & historization Build advanced analytics Generate insights for better decisions Cloud based platform EcoAxis Solution Manual Entry Trending Tabular Data Export to Excel Export to Pdf ax si EYE - Historian EcoAxis Hardware OPC Client Process 1 Process 2 Process 3 Process n Basic Functionality Additional Information Any device, Anytime, Anywhere Alerts & NotificationsAnalytics GURUax si NOTIFYax si Your Scope Our Solution Process 4 Data Acquisition Data Management Advanced Analytics

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