The document describes a smart manufacturing suite called SUPERAxis developed by A.T.E. Enterprises to provide real-time plant monitoring and analytics. The suite involves continuous monitoring of remote plant assets and critical process parameters. It provides real-time reporting of KPIs and alerts to keep plant users informed of critical conditions. The solution includes hardware for data acquisition and a software framework for data storage, visualization of trends, reports, alerts and notifications to empower plant personnel.

1. Smart Manufacturing Suite
for Effective Plant Management

2. 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
TM
A.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.
TM
SUPERAxis 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
TM
wastewater 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 minimizingTotal 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.

3. Plant & Equipment & Data Acquisition
Customer
Scope
Utility Equipment
Process Plant
Central Supervision
OPC Server
OPC Client
Axislog
Data Logger
Organisation
• Process IOs supported through externalAI, DI modules
• 100 modbus parameters through selectable interface (RS232/RS485/RS422)
• Modbus (RTU,ASCII 7 &8 bit support) master & slave
• Data transfer through FTPover Ethernet, broad band, PSTN, GSM (GPRS)
• ModbusTCP(SCADA), SD-card, snapshot on SMS, logging of critical parameters
• 24 VDC external power supply
Hardware for data acquisition
• Process IOs supported through externalAI, 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 FTPover
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 NOTIFY
Alerts & 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 acquisition
EcoAxis' 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 storage
Data 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 visualization
EcoAxis' 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.
Solution architecture

4. 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.
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
Sample implementation of EcoAxis solution for power plant
Configuration of alerts & email notification & escalation

5. 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