Digital factories - Tata Communications · Distribution panel, Sub Distribution Panel, Motorised...
Transcript of Digital factories - Tata Communications · Distribution panel, Sub Distribution Panel, Motorised...
Digital factoriesTop 10 LoRaWAN solutions for industrial IoT
Toxic Gas Monitoring SolutionCO, CO2, Temp, Humidity, PPM,
PM2.5
Temperature and Humidity
Monitoring SolutionHeat Loss, Measurement,
Threshold breach (Boilers, Ovens),
Surface monitoring at various
places viz Bus Bars, Transformers,
Induction Motors, Data Centres
Plant Energy Monitoring with
Machine DataModbus to LoRa Converters, Data
Extraction and Transmission from
machines
Machine Trip Status
Monitoring Solution – NONCMonitor Industrial O/P via NO-NC,
VFD Tripping, CNCs, Compressor
Tripping, Breaker Tripping
Pressure MonitoringDifferential Pressure
(atmospheric) Monitoring,
Weight Sensing
Gas and Water/Fluid Flow
Monitoring Solution Flow Monitoring, Gas Pressure
and Consumption Monitoring,
Fluid (Oil, Water, Chemical
fluids) level monitoring
Load Monitoring Solution-
Load Protector DeviceTransformer Monitoring, Main
Distribution panel, Sub
Distribution Panel, Motorised
Control Panel etc.
Smart Plant Lighting – Single
or Group Controlling Scheduling, Dimming,
Astronomical Calendar Sync,
Luminosity Control etc.
Movable and Immovable
Assets TrackingTrack asset location, monitor
temperature and anomalies
remotely
Manual Call Point / Service
Request ButtonEmergency Alarms, Repeat Orders,
Maintenance and Support
Requests, Pantries, Customer
Experience Centres
Worker Safety Watch – People
Tracking
Fall detection, Body temp,
Indoor Tracking, Idle time
Access Tracking
Manage & Monitor Your
Plant Area Access
Digital factories, powered by Tata Communications
Use case 1 : Plant energy monitoring with machine data (MODBUS to LoRa)
The Challenge
• Distributed energy meters across the plant
• No control over energy usage & maximum demand
• Energy planning depends upon electricity bill at the end of
each month
• Difficulty in energy accounting
• Low System Power Factor at load ends
• Inability to study the load characteristics/profiles
• No data to figure out Transmission & Distribution (T&D) loss
Solution
IoT based Energy Monitoring Solution with Modbus to LoRa
Converters
• Wireless Modbus RS 485 to LoRa Converters fixed onto
traditional energy meters
• Energy management application on IoT Platform
• Custom energy monitoring reports and dashboards
Benefits
• Benchmarking energy consumptions
• Specific level Energy Consumption Accuracy
• Reduction in Distribution Loss
• Reducing Peak Demand
• Eliminating equipment Idle Time Operation
• Predictive Maintenance
• Root Cause Analysis
• WAGES Monitoring (Monitors non-electrical parameters like
Water, Air, Gas, Electricity & Steam Generates specific energy
consumption data)
Module technical specification:
Power Supply 85 ~ 280 AC/DC 50Hz
Power consumption <3VA(230VAC/50Hz)
RS485 Input Modbus RTU Protocol
No. of energy meter
supportUpto 10
Module dimensions 108mm(W) x 73mm(H) x 61mm(D)
EnclosurePolycarbonate White/Grey color,
DN Rail mounting
Operating
temperature0-60oC
Energy meters
MODBUS to LoRa Converter
KLGCC Electricity Demand Profile
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Date & Time
Ele
ctr
icit
y D
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an
d (
kW
)
East Course outgoing feeder West Course out going feeder Driving range outgoing feeder Club House MSB 1 Club House MSB 2 Total demand
Friday MondaySundaySaturday Tuesday Wednesday
Peak demand
Use case 2 : Smart plant lighting with single/group control
Benefits
• Save Money & Energy
• Ease of maintenance & reduce maintenance cost
• Remotely control of street light & monitoring
• Automatically adapt luminosity to needed conditions
• Centralized operations
The Challenge
• Optimize energy consumption, ensure savings , observe
trends
• Centralized control of street lights through application
• Easier management of individual LED warranty
• Street lights should be adaptable with dimming feature as
per requirement
• Street lights should have on and off feature based on the
environmental Sunlight intensity
Solution
• The street lights are factory fitted with LoRa module.
• The module communicates with Tata communications
IOT network.
• The module enables with sharing of power
measurement parameters e.g. Ampere, Voltage, Kilo
Watt Hour (KWH), Kilo Watt (KW), Power Factor.
• The module takes command web portal via IOT platform
to switch ON/OFF or Dim the concerned street light(s).
• The controlling commands can be scheduled for
group(s) of street light(S).
Individual light control
Group light
control
Analysis ParticularsSodium
vapourLED
LED with on/off
automation
LED with On/Off +
Dimming
Voltage 250V 230V 230V 230V
Current 1.6A 0.91A 0.91A 0.91A
Wattage 400W 210W 210W 210W
Working hours 12 12 9 6.75
Units consumed per 12 hrs 4.8 2.52 1.89 1.42
Unit rate ₹ 12.00 ₹ 12.00 ₹ 12.00 ₹ 12.00
Consumption cost per 12 hrs ₹ 57.60 ₹ 30.24 ₹ 22.68 ₹ 17.04
Annual consumption cost per lamp ₹ 21,024.00 ₹ 11,037.60 ₹ 8,278.20 ₹ 6,219.60
Annual consumption cost per 100
lamps
₹ 21,02,400.00
₹ 11,03,760.00 ₹ 8,27,820.00 ₹ 6,21,960.00
Savings wrt Sodium vapour ₹ 9,98,640.00 ₹ 12,74,580.00 ₹ 14,80,440.00
Appx. first time cost15 lacs(18 month payback period)
5.5 lacs(14 months payback period)
Recurring maintenance costs from
2nd yearNil 15-17% - 2 months payback period
Use case 2 : Smart plant lighting with single/group control
47.5% 60.0% 70.4%
Use case 3 : Worker safety and tracking
The Challenge:
• Lack of visibility in worker movement across the plant
• Traceability of employee during emergency evacuation
• Employee movement in hazardous/ restricted area
• Attendance of employees
• Safety of women employees during transportation
• Alert for unexpected accident
Solution:
• Tracking of employee/worker
• Detection of abnormal conditions
• Fall and Immobility detection
• Alert indication for access to unauthorized area
• Heart Rate Monitor
• Skin temperature Monitor
Tata Communications IoT Employee Health
and Safety watch
Use case 3 : Worker safety and tracking
Benefits:
• Improve worker safety
• Help in quick emergency response
• Provide alerts if worker in hazardous/radiation/restricted
area
• Reduction in operating cost by delivering timely
information
• Improve employee satisfaction index
OFF
NO
ENTRY
ON
SOS
45o
SUPERVISOR PROXIMITY BEACON
HAZARDOUS AREA
SKIN TEMPERATUREWEARABLE
ENTRY BEACON
HEART RATE
NO ENTRY
Use case 4 : Moveable and immovable asset tracking
The Challenge
• Higher turn around time for material shipments
• Lost assets - difficulties in locating
• Idle assets - reduced productivity
• Real Time tracking of asset movement
• Alerts for breaching geofence
• Pay per Use of Assets
• Asset Health Monitoring Challenges
Benefits
• Less time spent tracking assets
• Save money from inventory shrinkage when a lost asset
must be replaced
• Optimum utilization of resources or asset
• Low maintenance costs thanks to LoRa sensors low
power operation, ensuring batteries can last longer
• Employee safety
• Monitor Asset condition remotely
Solution
• GPS, Accelerometer, BLE, WiFi, AGPS, Temperature &
Humidity
• Longer battery life
• Geo-fence & POI
• Facility to integrate analogue or digital sensors
• Asset Tracking history
A,B,C are LoRa based asset tracking devices
(A)
(B)
(C)
Use case 5 : Toxic gas monitoring solution
The Challenge
• Wired Infrastructure for connecting sensors
• Higher installation and infrastructure maintenance costs
• Large plant area difficulties in cabling across the plant
• Requires immediate alerts on poisonous gases outbreak
Solution
• Wireless Environment Sensors
• Industrial Grade Gas Detectors – Detects various
Hazardous Gases
• Central Monitoring Station with Alarms
• Detects - CO, NO2, H2S, Propylene, Combustibles,
Sulphur Dioxide, Phosphine and Others
Benefits
• Monitors and Alerts Poisonous Gas outbreaks instantly
across the plants spread across few sqkms
• Central monitoring hub for health status of each sensor
and the alarm status is displayed
• Complete wireless system for easier installation and
maintenance
• Fewer single boosters or routers due LoRa technology
advantages
Cloud based dashboard application
Use case 6 : Temperature and humidity monitoring solution
The Challenge
• Manual Temperature and Humidity readings
• Distributed Temperature and Humidity sensors across
plants
• Delayed alerts on thresholds breaches and alerts
generation
• Costlier wired infrastructure across the plant
Solution
• Measurement range -40°C to + 85°C Accuracy ±0.5°C• Measurement range 0%RH to 100%RH Accuracy ±2%RH
• Battery Enabled
• Plug & Play device
• Low Powered
• Light weight & easy
• to mount
Benefits
• Monitors and Alerts Temperature and Humidity changes
instantly across the plants spread across few sqkms
• Central monitoring hub for health status of each sensor
and the alarm status is displayed
• Complete wireless system for easier installation and
maintenance
• Fewer single boosters or routers due LoRa technology
advantages
Live installation of
environment sensors
Tata
Communications’
environment
monitoring
device
Use case 7 : Gas and fluid flow monitoring solution
The Challenge
• Need for a completely automated reading, monitoring,
alerting metering devices with less infra and operating
costs
• Need for Automated Billing and consumption analysis
• Need for directed demand and supply planning
• Easy tampering and theft of meters
• Meters have been removed and updated in the system as
under repair, but water consumed
• Faulty meters, thus faulty readings or no readings
Solution
• Billing Management —Payment information, service
connects and disconnects, tariff units of measure,
load control signals, and fraud detection
• Data collection and Geo map integration
• Device and application controls, standard protocol
support
• Monitoring and diagnosis
• Data analytics based consumption & many other
parameters
Benefits
• Provides real-time billing information, reducing estimated
readings and re-billing costs
• Monitors Tampering, Theft and Alerts
• Increases cash flow by allowing quarterly or semi-monthly
accounts to be converted to monthly billing
• Reduces customer complaint calls and increases customer
satisfaction
• Helps in Demand Forecasting and Supply planningFluid flow monitor and cloud based dashboard application
Use case 8 : Machine trip status monitoring solution
The Challenge
• VFD, CNCs, Compressor, Breaker Tripping Monitoring
• Remote Industrial Alarm Monitoring
• Remote Transformer Trip Monitoring
Solution
• Status change report – Reporting based on port
change state.
• Periodic Report - Report current status of ports
every
• Self-test report – Self-diagnose ports if they are
functional
• Self-test seconds – Self-diagnostic time period in
minutes.
Benefits
• Proactive Monitoring of NONC Switches
• Quicker resolution of Tripping in Machines
• Higher continuity of operations
Use case 9 : Remote monitoring and control of machines
The Challenge
• Lack of control on machines – no view on idle time,
production time
• No voltage and current consumptions monitoring
• No automatic switch off or on based on threshold
• Send alerts on the power fluctuations
• Higher infrastructure costs of the wire based controls
Solution
• Simple solution for remote control applications where
faulty wire maintenance is not possible or practical
• Controlled through application remotely
• Devices available for Single Phase and 3 Phase
Applications
Benefits
• Remotely control machines through web or mobile
application
• Instant view of machine idle time and production
time data
• Instant alerts on power failures
• Minimal infrastructure setup costs due to wireless
plug and play feature
LoRa based smart switch
Use case 10 : Load monitoring and protection solution
The Challenge
• Machine failures with short circuits due to higher load
fluctuations
• No automatic on-off of machines due to load imbalances
• Lack of instant alerts during voltage, current, earthing
leakage and temperature threshold breaches
Solution
• LoRaWAN based Load Protector device
• Load/Machine/AC protection features – Under
Voltage/Over Voltage, Under Current/ Over Current,
Open Neutral, Earth Leakage and Temperature Monitoring
(Upper Limit/ Lower Limit)
• Load Cut off – Has inbuilt relay to cut off
load/machine/AC
• Fire retardant Device casing
Benefits
• Remote control of any Load/Machine/AC or other
equipment’s via application
• Protection against any mis-happenings due to power
fluctuations
• Accurate Energy/Power consumption monitoring and
accounting
• Built in Temperature Sensor with extended half meter
cable with thermostat
• Inbuilt Relay – Trips and protects/saves your device from
any failures
MODBUS converter
Transformer
sensor
aggregator
More use cases
Fluid level monitoring Pressure monitoring Access tracking
Manage & Monitor Fluid Levels
in your Machineries
Monitor the Pressures data of
Machines’ differential Pressure
(atmospheric) Monitoring. We
can also provide Weight
Pressure Sensing solutions.
Manage & Monitor Your Plant Area
Access
Tata Communications is building an IoT ecosystem on LoRaWANTM. Here is why
Flexible deployment and customization of LoRa®
network at remote manufacturing plants
LoRa® uses license free 865-867 MHz ISM bands
LoRa® has very wide coverage range about 5 km in
urban areas and 15 km in suburban areas
LoRa® consumes less power and hence longer battery life
Each LoRa® Gateway device is designed to handle 1000s of end
devices or nodes
Longer Battery Life for
wireless sensing devices –
More than 1-5 years
(based on data frequency
set) for a non-
rechargeable battery
Private customized LoRa
IoT Network setup
exclusively for IoT
applications across the
manufacturing plant.
Long Range – Sensing
devices can communicate
with LoRa base stations
installed 5-10 sq. kms
across the plant without
any signal boosters.
NO SIM Card – Embedded
LoRa RF Module
communicates with the
base station on license
free band (865 MHz -867
MHz) in India
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