Automation and Power KLG

Automation and Manufacturing Solutions

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A variety of market trends are driving manufacturers toward the next generation

of automation and manufacturing solutions. Producing the right product at the

right-quality, right-price and at the right-time to meet market needs remains

among the most essential need of any company. However, each of these measures

of what is “right” has ever-higher benchmarks. Customers are now demanding

shorter lead times, customized products, and better quality, while comparing

prices freely. The Internet empowers customers with more information for

negotiation.

The agility to accurately promise and quickly deliver increasingly customized

products or new products requires synchronization across a broad scope of

manufacturing activities performed by multiple organisations.

KLG, for the last 10 years, has been offering IT enabled business optimisation

solutions in the manufacturing space. These solutions have evolved from a Human

Machine Interface and Shop Floor Scheduling solution to a complete Plant

Intelligence and Supply Chain Optimisation application framework. In this space,

KLG has served some of the most reputed manufacturing organisations across

various industry verticals in India. These include names like Asian Paints, Bharat

Petroleum, Essar, Glaxo, HLL, Maruti, Nestle, Pepsi, Reliance and TISCO.

KLG now offers integrated solution for Industrial Automation and Supply Chain

Planning and Optimisation. KLG Manufacturing Execution Systems provide

complete solutions to analyse the data captured from a wide variety of data

sources over multiple sensors, plant organisation – to improve uniformity, increase

yields, maximize productivity and decrease maintenance costs. KLG assists

customers to achieve these goals by delivering information and analysis tools that

organise and deliver plant intelligence, which is accessible throughout the

organisation – from the ‘Sensor-to-Boardroom’. As a result, the organisations are

able to make better-informed decisions about their business.

Real-time production information enables and empowers decision makers through

web based dashboards and seamless flow of information between ERP systems.

KLG works closely with Wonderware, a division of Invensys PLC, Microsoft, IBM,

Oracle and SAP to deliver solutions. KLG integrates diverse Automation Platforms

from ABB, Allen Bradley, Areva, Foxbro, Honeywell, Siemens, Yokogawa and Sensor

Manufacturers.

ERPEnterprise Integration

Device Integration

ApplicationModels

Functi

ons

Pre

senta

tion

PLANT FLOOR

Common

Services

Name Services

Security

Messaging

Config. & Deployment

Events & Alerts

High Availability

Plant & ProductionModel

CustomerStandards

SupervisoryControl

Process Management

ProductionManagement

PerformanceManagement

Process &Production

History

HMIAnalysisClients

NotificationReports

An open Enterprise Integration Approach for Driving Manufacturing Performance

SAP J D Edwards

MicrosoftBusinessSolutions

ORACLE

S95 / B2MML / XML HTTP

Data / Events

Manufacturing Execution Systems

Realtime Database

IndustrialApplication

Server

MercatorMicrosoft MQNetWeaver

TibcoWebSphereMQ Series

Enterprise Integration ApplicationManufacturing Systems

Multiple Message / Transactional Systems

Multiple Business Systems

Database

Schedulers, Enterprise Asset Management, Manufacturing Execution Systems, Programmable Logic Controllers,

Distributed Control System..

3rd Party Manufacturing Systems

Web Services SQL

2

Plant Shop Floor

ERP

Ability to PromiseSupply Chain

Planning & Scheduling Dynamic

Production Planning/Schedulng

Simulation / Optimization / Maintenance

Manufacturing Execution Systems

MMI / SCADA / Control SystemsPlant Information

Market

! Customers determine price, quality, quantity, time, and place of delivery.

! Organization has to compute profitability of deals, basket of deals in short term and long term.

! Negotiate prices of input, transportation and ware house logistics.

! Decision to sell or decline.! ERP system uploaded with order data.

! Plant does Monthly, Weekly, Daily, Hourly planing to meet schedules.

! MES application simulates various production scenarios.! Optimization in use of raw materials, energy consumed and

accommodation of maximum production batches.! MES application orchestrates manpower, machines,

maintenance, quality, recipes, sequence and schedule of plant.

Market Forecast and Ability to Promise

Planning and Scheduling

Manufacturing Execution Systems

! HMI visualizes plant/ machine status.! Visibility of plant parameters across shop floor and

Human Machine Interface / Plant Information

Programmable Logic Controller, CNC Machines, Sensors

Sensor to Board Room Pyramid1

4.1

SBU

Note: *

* Source: Wonderware Website

Nestle

hWorld’s Leading food company

hSwitzerland’s largest industrial company

Nestle India Ltd. has adopted technology offered by KLG Systel Ltd. for their Supply

Chain Management Manufacturing and Execution Systems. Nestle’s plants

manufacture popular brands like Nescafe, Milo , Lactogen, Fruit’N Dahi, Kit Kat, etc.

Business Challenges

hMilk powder manufacture requires handling of large quantity (150 MT) of

milk on a daily basis.

hWith a turnover of over US$ 590 Million, 35 brands manufactured in 15

plants. Nestle has a major SCM challenge to produce more & move goods

based on demand to thousands of location.

hLactogen manufacturing needs different recipes based on quality of raw

material.

hManufacture of coffee and chocolates need proper handling of proteins

and other nutrients in appropriate proportions.

hManufacturer of Fruit’N Dahi (Yogurt) requires proper batch processing.

KLG Solution

hKLG’s CHAOS technology, using Heuristics and Multi Integer Linear

Programming, optimises the daily supply chain for 35 Brands, 15 Plants, 550

SKU’s and 60 Depots.

hOptimal operation of Egron and Evaporation has resulted in savings of upto

10% milk usage done by reduction in spoilage and enhanced quality.

hCapability to handle 75 recipes was attained and transition time for

change in recipe was reduced by 400% resulting in use of various milk

varieties and optimal purchases.

hIntroduction of animated 3D graphics gave a more realistic look and feel of

the plant to the operators. Process Control Engineers could have an

overview of the process parameters of the whole plant from a centralised

location.

Nestle is implementing our solution for all other upcoming units and are also

engaging services of KLG Systel Limited for SARC nations.

Automation and Manufacturing Solutions - Nestle India Ltd. Case Study

Stage A: Supply Chain Management System

2 60 Depots 3 100’s of Locations 4 Happy Customers

Stage B: Manufacturing & Automation

Login to the project Nestle Egron Plant1

Login to the project - Nestle Fruit’N Dahi Plant

1

Login to the project - Nestle Kitkat1

2 Egron Plant View2

Fruit’N Dahi Plant Overview22

2Kitkat process overview2

3 Nestle product - Fruit’N Dahi

Nestle product - Lactogen3

3 Nestle product - Kitkat

4.2

1 US $590 Million Turnover, 15 Plants, 35 Brands550 SKU’s

Case Study

Essar Steel Limited - The second largest private sector steel

producer in India has an integrated steel complex at Hazira, Gujarat.

Plant comprises Hot Briquette Iron (HBI) - Electric Arc Furnaces (EAF)

- Continuous Caster (CC) - Hot Strip Mill (HSM) route to strip making.

The plant is capable of manufacturing high value added non-

commercial flat products. With regard to its product quality and

specifications, the plant offers tremendous flexibility in charge mix,

lot size and product mix / range. Operations are highly automated to

improve operational efficiency and productivity. It has high level of

automation for both process and business applications. It has a state-

of-art hot rolled coil (HRC) plant with a capacity of 2MMPTA. It is the

only mill in India capable of rolling up to 2000-mm wide coils.

Business Challenges.

hHigh Volume and a large variety of product types.

hChanging market demand and prices required plant

management to change product mix and schedule in near real

time to improve profitablity.

hAutomation and technology at different levels was a major

challenge. Technology was sourced from various

suppliers globally resulting in data islanding.

Solution offered

hSolution as a step towards establishing an integrated real

time information system on the plant floor using Windows

platform.

hSolution to Integrate with wide variety of Process

Controllers like Cegelac, GeFanuc Honeywell, Siemens,

Allen-Bradley, L&T and Siemens was offered and technology was

brought on a single unified platform.

�Information was logged without any manual interventions

and errors.

�Timely corrective actions were ensured and much needed

co-ordination between various departments was achieved.

�Satisfied by the performance and support by KLG, Essar has

offered a MES (Manufacturing Execution System) system

study and prototype project for material and ladle tracking

in Ladle Furnace, VD & Ferro Alloy Store Area.

Automation and Manufacturing Solutions - Essar Steel

Nozzle Gas System5Alloy Addition System 4

HOT BRIQUETTE IRON

VOD - VACCUM OXYGEN DECARBORISATION

ELECTRICAL ARC FURNACE

LABEL REFINING FURNACE

CONTINUOUSCASTING

LAMINAR COOLING

COIL BOX

HOT STRIP MILL

FINISHING MILLDESCALERDESCALER

WALKING BEAMFURNACE

REVIERSINGROUGHERWITH EDGER

CROP SHEAR

SHEAR LINE

PLATE

DOWN COILER

SERVICE CENTER

VD - VACCUMDEGASSING

Steel Production Process 1

RH Furnace 2 Factory Floor Integration3

Essar Steel

Vacuum System6

4.3

Steel Production Process

Case Study Automation and Manufacturing Solutions - Tata Iron & Steel Company Ltd.

Tata Iron & Steel Company Ltd.(TISCO)

Established in 1907, Tata Steel is Asia's first and India's largest

integrated private sector steel company. With its captive iron

ore, coal mines and one of the world's most modern steel

making and finishing facilities at Jamshedpur in eastern India,

which includes a state-of-the-art Cold Rolling Mill complex,

Tata Steel is among the ‘lowest cost’ producer of steel in the

world. The 4 million tonne Jamshedpur plant produces

both flat and long products.

Business Challenges

hIslands of legacy automation from diverse vendors.

hNo integration between processes and plants.

hPlant floor not integrated with IT system.

hPoor visibility for managers of plant activities and plant

operation.

hLack of tracking, control, scheduling and optimisation

systems.

hNo interface with business system.

KLG Solution

hContinuing collaboration over last seven years to devise a

Manufacturing Executing System (MES) linking Plant Floor

to SAP ERP system seamlessly over 12 mills.

hProduction simulation and real-time scheduling of

continuous casters.

hMajor improvements in plant operation and profitability.

Dynamic Scheduling of Slab Caster & Melt Shop. 1 Gantt Chart Showing Status of Heats2

1 Status of Wire Rod Mill Machinery

Online Inspection System42 Discharging System

Finished InventoryManagement

5Mill Order Screen3

4.4

Reliance Infocomm - Historical Trends8

Reliance Infocomm’s - network is a high-capacity, integrated

(wireless and wireline), convergent (voice, data and video) digital

network. The network is designed to offer services that span the

entire Infocomm value chain-infrastructure, services, both for

enterprises and individuals, applications, and consulting. The

network is designed to deliver services and applications that will

change the way Indians live. Installed Infrastructure is capable of

supporting 14 Million subscribers without incremental installation.

Business Challenges

lMonitoring of the entire network on 24 x 7 basis and 100%

Redundancy for telecom stations in 426 locations.

lFault & Performance Management.

lTraffic Monitoring.

lOperation Support System (NEMS,Clarity).

lRemote configurable architecture.

KLG Solution

lApplication for realtime monitoring of operating parameters of

network.

lEscalation of alarms & resolution of issues.

lPerformance measurement.

l Control from one center for the entire network

l Unlike most other network operations centers around the world, which

are designed to support a specific product, service or geography, the

network of Reliance is unique in the sense that it controls a range of

products, services and geographies.

lThe NOC could monitor the pan-India network on a 24 X 7 X 365 basis by

employing state-of-art digital systems to track, display and maintain

the complex network.

Case Study Automation and Manufacturing Solutions - Reliance Infocomm

Reliance Infocom

Reliance Infocomm All India NetworkReliance Infocomm Network in the State of Maharashtra1

2 Reliance Infocomm - National Network Operation Center

Reliance Infocom - Process Parameters4 5 Diagnostic Screen

Reliance Infocomm MCN DieselGenerator 1, Energy Unit Generator and Tank Fuel Level overview

6

Reliance Infocomm - OSP SCADA Alarms7

3 Reliance Infocomm MCN Communication Status

7 Reliance Infocomm - Historical trends

4.5

Client List Automation and Manufacturing Solutions

Sectors

lOil & Gas

lAutomotive

lMetal

lPower

lProcess Industries

Breweries

Cement

Chemicals

Cigarette

Fertilizer

Paint

Pulp & Paper

Sugar

lFood & Beverage

lPower

lEngineering Procurement & Construction

lTextile

lConsumer Packaged Goods

Key Customers

KLG’s customer base includes reputable

Indian companies across a wide spectrum of

industries.

Godfrey Phillips India Ltd. is primarily a tobacco product company. Well known for its Four Square, Red & White, Cavander’s, Jaisalmer, etc. brands of cigarettes. Godfrey Phillips is today the second largest player in the Indian cigarette industry with an annual turnover of over US$ 265 million. Godfrey’s Chakala Factory is a regular user of solutions developed and offered by KLG. This time they wanted to have automation on the plant floor where they had multiple Metler Toledo Weigh Scales and LNI systems which are primarily used for weighing of Cigarettes during manufacturing process. Based on the weight and other factors for the cigarettes they define the Quality of the running batch.

KLG provided a solution and the following features and benefits were available after implementation:l Automatic recording of weight data,

eliminated incorrect data entry, more time for operators to focus on productivity.

lOnline details about the Produced Weight, Production Standard Deviation, Light / Good /Heavy Cigarette, Stop Times, efficiency and rejects resulted in better quality and lower production costs

lUser could get the details of which Maker is running which Brand, the latest weight, the Min & Max. 30 Cig. Wt, Average Cig. Weight, Average Density, Standard Deviation, etc.

IOCL - The IOC group is the leading producer of various Petrochemicals & LPG in India. Wonderware InTouch is being used for the Terminal Automation of the LPG filling station. Wonderware InTouch runs on a 486/75 PC linked to an Allen-Bradley S5 series PLC via 1784-KT cards running at 9600 baud. The system monitors the Pre-weighing Stage of an empty LPG cylinder & the actual filling as well as the Post-weighing stage indicating various valve outputs, conveyer positioning & the weight of the LPG at pre & post filling stations.

Godfrey Phillips India Ltd.

Indian Oil Corporation Ltd.

Sectors

Food & Beverage

Colgate Palmolive

Nestle India

Pepsi Foods

Titabhi Sugar

Consumer Packaged Goods

Duracel

Godfrey Phillips India Ltd.

ITC Ltd.

Automotive

Amar Raja Batteries

DGP Hinoday

Maruti Udyog

MRF Tyres

Metal

Essar Steel Ltd.

Hindalco Industries

Tata Steel

Oil & Gas

British Gas E & P

BPCL

Indian Oil Corporation Ltd.

Chemical

Asian Paints

Castrol India

Galaxy Surfactants

Indofill Chemicals

Rallies India Ltd.

Syngenta

EPC and Other Industries

ABB

Alstom

Areva

Bhabha Atomic Research Center

BHEL

HEG Ltd.

Human Machine Interface/scada

Manufacturing Execution Systems

Plant Information Management

Plant-to-Business Integration

4.6

Power Systems Solutions SG61 Technology

l30% to 50% loss of power in distribution sector total of 30,000 MW costing US$ 10 Billion in cash loss and another US$ 20 Billion in residual losses

lCost of new 30,000 MW capacity - US$ 30 Billion, Cost of additional transmission & distribution system - US$ 20 Billion. Total investment US$ 50 Billion, time taken 3-6 years

lInformation and Automation expenditure of US$ 50 per consumer for 100 million consumers can result in savings of 15,000MW at a cost of US$ 5 Billion in 1.5 to 2 years

lGovernment of India actively pursuing this routelKLG has worked with 5 million consumers of 8 utilities in India for past 5 yeas in the

areas of Meter Reading, Billing, Energy Accounting, GIS and Revenue Management and shown reduction of 3% to 5% losses

lKLG has developed proprietory hardware and software technology SG61 backed by 9 patents (applied for) which has a business potential of US$ 10 Billion in developing countries

lKLG has teamed up with Autodesk, IBM, Singapore Technologies and SAP to use their core technologies and hardware

lKLG has developed its application on IBM software and is the only premier ISV for utilities in India

KLG Business Model - India, Asia and developing countries

SG61TECHNOLOGY

TM

Remote controller and communication hardwareusing GPRS /CDMA

Theft prevention hardware

Automatic meter reading

Automation and communication backbone software

TCP/IP Broadband backbone for multimedia applications

business application software

Implementationof

IT Backbone

--Consumer

Indexing

Meter ReadingSpot Billing

Energy

Accounting

Loss

Diagnostic

Study

Feeder

Renovation

Automation

(SCADA)

GPS Survey /GIS Mapping

6.1

SBU

Automatic

Meter

ReadingHighlight - India

Revenue Collection

COMMERCIAL SECTOR

INDUSTRIAL SECTOR

132kV

66/33/11kV

OSH PPING

COFFI

E

11/0.415 kV

N

RIAL

IDUST

L

COM

MER

ACI

D

ESIC

OM

T

RRUAL

B

T

DST

IU

IO S

M

IR

TN

YSE

POWER DISTRIBUTION NETWORK

POWER DISTRIBUTION

·Power is distributed at 0.4 kV level after being stepped down from 11 kV

·Total Distribution capacity is about 250000MVA; total number of consumers is over 130 million

·Distribution sector is managed by state owned distribution companies / boards / corporations or private companies

·Indian Electricity Act 2003 have made distribution companies more accountable and opened up privatisation

·Average annual compound growth rate of electricity consumption since 1950 has been 8.9 %

·Electricity consumption in different sectors Agriculture- 24.9%Industries - 33.9%Domestic & Commercial-32% Others - 9.2%

APDRP and subsequently DISTRIBUTION RELATED ISSUES·Inefficient / poorly designed

and managed network/equipment·Metering - not 100%· High Aggregate Technical and

Commercial Loss- 30% to 50% · Distribution companies are

financially stressed · Tariff structure based on

subsidising agricultural sector at the expense of Commercial and Industrial sector; resulting in theft and /or shifting of Commercial and Industrial sector to own captive generation

· Weak Revenue Management and Energy Accounting. Lack of Load Forecasting - Long Term and Short Term

D TI

ISR IBUT NO M

YOC PAN

POWER SECTOR IN INDIA

GENERATION RELATED ISSUES·Installed Capacity - 120000 MW Peak Shortage - 12.6%

Base Energy Shortage - 7.5%

·Sources of Power Generation Steam - 57%, Hydro - 26%Nuclear - 2.4%, Wind-1.7% Gas - 10%, Diesel - 1.0%

·Plant Load Factor Improvement

·Low Quality, high ash content coal as primary source of fuel

·Alarmingly low participation of private sector in capacity augmentation

POWER GENERATION

·Alternates to Thermal in Hydro and Nuclear have not picked up as per expectation

·Peak and Energy Shortages still remain ; hence no possibility of spinning reserves

·Environmental pollution

POWER TRANSMISSION

·Transmission System comprises 400kV network for Main & Bulk transmission. Total Transmission network is about 22000 km

·Power Grid Corporation is responsible for transmitting electricity at 400 kV and 220 kV

TRANSMISSION RELATED ISSUES

·Grid Discipline, with overdrawals resulting in grid collapse

·Enforcement of Availability Based Tariff (ABT)

·Weak Reactive Power Management resulting inpoor voltage regulation High Switching Transients

·Interconnection of regional grids for transfer of bulk power from one part of the country to another

AGRICULTURAL SECTOR

·Highly subsidised or free power to agriculture sector; with flat rate tariff in many states·Main use of electricity is for pumping ground water for irrigation; total number of electricity

driven pumps is about 141 lakh with compounded annual growth rate of 13.3 %·Share in overall electricity consumption is about 30%·Agriculture supply is predominantly high loss due to longer HT/LT line and misuse of single

phasing period·Extensive scheduled and unscheduled load shedding·HVDS is being implemented in many states

USERS OF POWER

·shortage of power availability

·Energy charges may be partially subsidised for this category in some states·Non-technical losses including theft, tampering of meters, billing and collection errors are

common·Variance between Sanctioned load vs. Connected load is high; with middle class

consumption patterns changing rapidly, especially in Metros and Class A cities

Compounded annual growth rate reduced from 13% in 1984-85 to 5.0% in 2002-03 due to

DOMESTIC SECTOR

BA KN·Compounded annual growth rate reduced from 9% in 1984-85 to 5.4% in 2002-03 due to shortage of power availability

·Quality and Reliability of supply is of major concern to this sector· Most commercial buildings opt for own in-house generation for continuous supply relying

on expensive diesel·Energy charges to this sector are comparably high because of cross-subsidy resulting in

theft

·On the receiving end of the cross-subsidy policy, this sector has the highest tariff among all users with unit charges as high as Rs 5/- per unit

·8.6% compound growth rate per annum·Lack of reliable and good quality power supply to this sector has led to own captive

generation by many industries, hence reducing revenue share of utilities

6.2

Power Systems SolutionsSBU

Power System Solutions Vidushi

GIS based Reliability & Load Flow analysis

Generation of Unique Consumer Identification Number

Distribution Network Manager - Hierarchal representation of network up to end consumer

Collection of detailed information of different assets owned by Utility

Electrical network tracing

Capturing of meter details and online status updation

GIS based simulation and on screen analysisfor better decision making

Automation of New Connection release process

On-spot Meter Reading and Bill Generation

Vidushi-Transmission & Distribution Information Management System

Mass Bill Generation at billing center

Generation of Exception Report

Utility Distribution Management System

SAP ERP SAP ISU

Consumer & Asset data

Meter Data

Meter Reading

Consumer Indexing

EnergyAccounting

MeterReading

SAP NetWeaver Web Application Server

SAP Netweaver XI

Vidushi Plug-ins

(Powered by

SAP NetWeaver )R

6.4

SBU

SBU Power System Solutions Vidushi

1. Generation of MIS reports 3. Technical loss calculation and analysis2. Trend analysis for better decision making

4. Graphical representation of loss analysis on GIS map 5. Commercial loss calculation 6. Detailed consumer information on a single click

7. Consumer complaint registration 8. Load forecasting 9. Use of mobile devices to improve process efficiency and performance

6.5

Power System Solutions

SG61 Automation and Communication comprises:

Distribution Management System! Substation automation! AMR integration and real time visibility from consumer level up to HT Network! Online energy audit! Remote connection and disconnection activities of

substation, feeders, transformers, consumers! GPRS / CDMA, PLC based meter reading! Prepaid metering! Load Forecasting! Load Scheduling, load shedding, planning ! Revenue Optimisation

KLG has developed hardware for:! GPRS / CDMA based meter reading! Remote controller and communication hardware

for data collection and switching on/off HT /LT feeders

! Theft prevention hardware

These are TCP/IP based, integrated with KLG software.

3. SLD of electrical network2. Substation SLD with Asset details1. Online energy data analysis and reconciliation

5. Real time energy trend of substations, feeders, distribution transformers & consumers

4. Electrical network status at LT level

7. Revenue management using financial audit

9. Alarm status in control room

13. Load analysis

6. Substation wise energy auditing 8. Real time energy trend at Feeder level

10. SG61 theft detection system 11. GPRS/CDMA meters for online data analysis and MIS

12. Integration of PLC (Power Line Communication

Meters) of Singapore Technologies

14. Optimum load scheduling and planning 15. Revenue maximization using load scheduling 16. Load shedding schedule

SG61

6.6

SBU

Services offered:

! Vidushi Implementation

! GPS Survey

! GIS Mapping

! Consumer Indexing

! Asset Survey

! Asset Database preparation

! Meter Installation

! Meter Reading

! Bill Generation

! Bill Distribution

! Spot Billing

! Automatic Meter Reading (AMR)

! Energy Accounting

! Load Flow Studies

! Technical Loss Analysis

! Feeder Renovation

! HVDS Installation

! Load Scheduling

! Load Forecasting

UPPCL, Lucknow

GIS Mapping, Consumer Indexing, Database preparation,

Bill generation, Bill Distribution, Disconnection,

Reconnection, DT wise Energy Accounting for Lucknow,

Varanasi, Bareilly, Gorakhpur, Moradabad and Allahabad

city for 8.5 Lac consumers.

SBU Power System Solutions Client List

6.7

UPCL, Dehradun

GIS Mapping, Consumer Indexing, Load flow studies,

Energy Loss calculation, Meter Reading, Bill Generation,

Bill Distribution for Dehradun, Rudrapur circle covering

3,29,312 consumers.

BEST, Mumbai

Business process Automation System including

Distribution Information Management System

(Connection management, Billing, Asset Management,

Network manager, Consumer Indexing, energy Audit,

Meter Management, Consumer Information System)

covering 10 Lac consumers, Automatic Meter Reading for

feeders, Distribution Transformers and consumers, Load

Forecasting, ABT Metering, IVRS based Call Centre and

Camera based Spot Billing for 2 Lac consumers etc.

JDVVNL, Jodhpur

Spot billing for 10 Lac consumers for a period of 3 years

and Supply, installation and commissioning of Web based

software covering 100 sub-divisions connected on WAN.

JVVNL, Jaipur

Geographical Positioning survey, GIS, Consumer

Indexing, Asset Coding for 5 Lac Consumers, integrated

web based software covering 50 locations on WAN having

GIS, consumer Indexing, Asset Management, Energy

Accounting, CRM, Consumer Billing, Analysis, collection

and linkage of spot billing / camera based billing system

and Interface with SCADA system.

JVVNL, Jaipur

Monthly Meter Reading along with load survey, logging

of tamper events, wiring verification and their analysis

using CMRI and web based software for analysis and

generation of MIS reports for various categories of 5,000

no. of consumers in seven circles of Jaipur Discom for a

period of 3 years.

MSEDCL, Maharashtra

Digital Camera based photo meter reading for 13.5 Lac

consumers.

MVVNL, Bareilly

Meter reading, spot billing, revenue realization,

disconnection, reconnection, DT wise Energy

Accounting for 89,601 consumers.

WBSEDCL, Kolkata

Spot Billing for 10,45,959 consumers covering 3 zones,

11 circles, 20 divisions, 50 supply stations and web

based software for MIS.

Torrent Power

Meter reading of 2,200 Distribution Transformers of

Bhiwandi circle using CMRI and data analysis using

software.

DHBVN, Haryana

Digital Camera base photo meter reading for 50,000

consumers.

PSEB, Patiala

Meter reading and billing for AP 53,000 consumers.

The Ahemdabad Electricity Co. Ltd.

Mapping of Transformers and Consumer Indexing for

2,20,000 consumers.

BSES Rajdhani Power Limited

Survey, Electrification, Meter reading / Bill

distribution.

NDPL

Survey, Mapping, Sequencing, marking / painting of

poles, Meter Reading Energy audit for loss tracking and

Revenue Management.

Reliance Energy

Survey, design, engineering, BOQ generation with

complete project report of LT clean up system.

EPC Projects

PSEB, Patiala

RGGVY works covering 17 Districts of Punjab.

JdVVNL, Jodhur

RGGVY works for Hanumangarh and Sriganganagar

Districts.

AVVNL, Ajmer

Urban Focus Programme for Banswara and Chittorgarh

circles.

AVVNL, Ajmer

Feeder Renovation Programme for Banswara and

Chittorgarh circles.

JVVNL, Jaipur

Feeder Renovation programme for Bayana division

under Bharatpur circle.

DHBVN, Haryana

HVDS / LVDS works under “OP” circle Gurgaon

DHBVN, Haryana

Feeder Segregation Programme under “OP” circles

Hisar and Gurgaon.

Engineering Procurement and Construction

7.1

Engineering Procurement and Construction

After six decades of independence, India has been able to establish a relatively good infrastructure in generation and transmission to cater to the country's requirements. But electricity distribution still does not deliver as per the expectations. Only 56% of Indian households have access to electricity and in the rural areas, the figure drops to 44%.

The Rajiv Gandhi Grameen Vidyutikaran Yojana (RGGVY) has a mission to electrify all villages and habitations, ensure all households in India have electrification by the year 2010, and provide free of cost electricity connection to Below Poverty Line (BPL) families. In addition, special attention is being given to augmenting and modernizing rural electrification infrastructure. This is being made possible by developing a Rural Electricity Distribution Backbone (REDB) with at least one 33/11 kV (or 66/11 kV) sub-station in each block; Village Electrification Infrastructure (VEI) with at least one distribution transformer in each village/habitation; and DDG Systems where the grid’s supply is not feasible.

The state electricity utilities have also taken proactive steps to improve distribution efficiency under the Feeder Renovation Programme. This is being done with a view to utilities achieving turnaround by the year 2011-12.

KLG being already active in the Indian Power Industry, has entered the programme and is carrying out Feeder Renovation Programmes (FRP) in Rajasthan. The company is also undertaking construction of 33/11 kV line/substations, BPL Connections and HVDS/LVDS activity in the states of Madhya Pradesh, Maharashtra and Haryana. KLG also has plans to begin work in Feeder Segregation under the Feeder Renovation Programme.

Energy Today – The Startling Reality

The earth is facing a severe crisis. On the one hand we lack adequate secure supplies of affordable electricity and on the other we are faced with the environmental harms of generating and consuming too much of it.

Added to this, power loss occurs at all levels of production, transmission, distribution and consumption. At a macro level as a result of disconnected islands of energy and peak load scenarios and numerous other variables that result in peaks and troughs that are difficult to cater to. And at the micro level, power wastage results from negligence, convenience or simply a lack of manpower resources, for e.g. machines and equipment idling, lights that remain burning in broad daylight.

Personal or commercial, power wastage occurs regularly; you only need to look around to see it. We urgently require an efficient system to conserve such waste. After all, this waste directly impacts us in the form of inadequate power supply, higher bills, higher tariff or even concern about our future energy security.

connectgaia.com – Intelligent Electricity

connectgaia.com is the enabler for the Intelligent Grid. At one level of the grid is the Power Highway, which flows from Power Plants, Transmission Towers, through Substations and Transformers to the End User. When this is superimposed with the IT Highway with Intelligent Meters and Sensors, Remote connect/disconnect of Power and the World Wide Web, it gives birth to an intelligent system.

FUEL RESERVES

ESCALATINGPRICES

SUPPLY RELIABILITY& QUALITY

CAPACITY

TECHNOLOGY

INNOVATION & EFFICIENCY

COMPETITIVEPRICING

POLLUTION ENVIRONMENTIMPACT

PRESERVINGECOSYSTEMS

ENERGYCONCERNS

CLIMATIC CHANGES

SUST

AINAB

L DEV

ELOP

NT

E

ME

NR

EU

RY

EE

GYS

CIT

connectgaia.com works through one or more intelligent devices installed at user premises based on an organisation's business requirement. There is no software to install or maintain nor do you need to become an energy management expert. connectgaia.com can be operated from an internet browser anywhere, just login to your secure account at any time and view concise charts that pinpoint energy consumption trends quickly.

connectgaia.com's unique Virtual Network allows you to group & label 'metering & controlling points' in a logical manner to suit your requirement, regardless of how your buildings or plants are wired. connectgaia users can also compare energy use across several facilities, from a single account. With this solution, users can switch on or off electrical/electronic equipments from remote locations through their secure web page, effecting 50% saving worldwide.

The intelligent device installed at user premises communicates with thousands of sensors – Temperature, Pressure, Flow, CO level, Humidity, etc. Hence, the power advantages of this 2

device are just the tip of the iceberg; it shall be the user's first step in reaping the advantages that a sensor network offers.

How does the connectgaia.com solution work?

connectgaia.com is a low cost web based solution that allows power consumers to MEASURE, TMVISUALIZE, ANALYZE, CONTROL AND SAVE electricity in Real-time, Anywhere, Anytime –

across the Enterprise. The solution leverages advanced metering, sensor, proven IP communication technologies and a robust IT backbone to bring intelligence into electricity consumption.

connectgaia.com

8.1

BUILDING 2 BUILDING 1

OFFICE C

BUILDING FACILITIESMANAGER

INTERNETCLOUD

OFFICE A

OFFICE B

CAFETARIA

GYM

8.2

connectgaia.com

AT THE HEART OF THE connectgaia.com solution are the gaiaeco (mother) and gaiacell (child) units, which are installed on a customer's existing electricity network. gaiaeco is the nodal device that puts all the power related problems of a consumer in perspective. Containing inlet & outlet connectors, GPRS and ZigBee antennas, this water resistant unit incorporates state-of-the-art microprocessor-based technology and digital switching. A gaiaeco unit is installed on the user's premises. Then depending on the business requirement, geographical / administrative entities or equipment to be monitored, the gaiaeco unit connects to a network of gaiacell units to draw information about power consumption in the premises, at different locations, areas or by individual consuming points. connectgaia.com enables remote sensing and access of metered data and allows the customer to remotely manage electricity consumption on his premises.

connectgaia.com with Demand Response capabilities arms consumers with information on their electricity usage that allows them to realign consumption patterns. By curbing their power use during peak periods, they can not only save money but also help to ease the demands on power plants and distribution lines. Utilities, in turn, can avoid buying expensive power on spot markets or generating their own during peak times.

Though not an energy efficiency device in itself, connectgaia.com enables power users to set up informed energy efficiency & conservation measures by using state of art technology and sensor networks. connectgaia.com is the platform that will make possible an era of energy efficiency, where better energy management is institutionalised and sustainable among electricity customers.

How the connectgaia solution distributes itself across a customer's premises?

This diagram illustrates how connectgaia intelligent devices are installed on a customer's electricity network in a commercial or industrial setup. With the connectgaia.com system in place the Factory Head or Facility Manager can access the connectgaia.com platform through the web using a secure account and can view, monitor and control power utilization on the premises.

intelligently electricity

With the connectgaia.com network in place the Intelligent Grid works to the advantage of all stakeholders :

! Consumers can participate in optimising power and saving.! Each Power Station, Transmission Network, Distribution Network and all component of consumers can collaborate online by sharing power information for an optimised Demand

Response System.! Blackouts in some areas are fed energy from energy surplus areas – till there are no more blackouts and each unit in the network receives optimum energy.! Lower electricity use in peak periods creates benefits by reducing the amount of generation and transmission asset required to provide electric service.! Lower demand in response to high prices reduces the cost of electricity production for peaking power and holds down prices in electricity spot markets.! Reduced demand enhances an operator's ability to manage the electric grid and reduces the potential for forced outages or full-scale blackouts.

Portal features

connectgaia.com enterprise portal is built on the latest IBM SOA platform and offers the following features:

TMMEASURE, VISUALIZE, ANALYZE, CONTROL & SAVE

MEASURE:

Dashboard: lets you customise all the important reports, which you would like to view at regular intervals, on ONE SCREEN.

VISUALIZE:

Reports & Graphs: connectgaia.com solution offers following reports, which will help you v i sua l ize the energy requirements of your organisation and plan accordingly.

8.3

Accessing the connectgaia.com portal

connectgaia.com solution can be accessed over the internet anywhere and anytime. You simply need to create a username and password once the solution is installed at your premises. Visit www.conectgaia.com and login with your username and password and get connected! It's that simple!!

connectgaia.com portal integrates the data collected in the data warehouse and presents it to the user. connectgaia.com core application handles device provisioning, package subscription and other back office functionality.

connectgaia.com

Instant Parameters

Energy ConsumptionLoad Profile

8.4

connectgaia.com – a holistic solution

Empowers you, enriches your life

connectgaia.com enables users to:

From simple benefits to the efficient management of complex power consuming businesses, to wide ranging environmental benefits, connectgaia.com translates into different advantages for different people. It means:

! Better management of available power! Real time monitoring and measurement of usage! Circuit level measuring and pinpointing wastage! Identifying energy efficient measures! Remote switching on and off of equipment, machinery or appliances! Reducing customer's energy bills, without drastic changes in lifestyle! Programming schedules for remote management

! Allows for rule and event based scheduling! Supports real time generation of alarms and user prompts! Monitors and protects against power theft! Communicates with temperature, pressure, light and over 1000 types of sensors! Increases worker productivity! Ensures utilities comply with power delivery service levels! Presents a case for discrepancies in billing

! Participate in Demand Response with utilities and power network! Make choices on the time of day tariff based incentive programmes! Depend less on captive power plant generation! Realise the economic development of an organization! Practice saving energy resources! Help reduce global warming! Be a proud member of the clean, 'Gaia friendly' energy family–by lessening carbon emissions

& in fact earning carbon credits

connectgaia.com gives a clear individual, environmental and civilisational advantage in averting the impending energy crisis.

ANALYZE:

CONTROL:

SAVE:

! Tariff calculation and cost analysis with inbuilt tariff logic; ! Trend Analysis helps analyze their electrical problems to enable corrective action; ! Energy Consumption comparison over time period, similar machines and benchmarks; ! Control High Electricity Bills with demand optimisation, managing power factor, analysing

quality of power and peak load consumption; ! Analyze Phase Imbalance, DG performance and avoid Idle Operations.

Remote Switch On/Off (Digital Switches): Controlling your devices was never so easy.

Logic based Schedulers: With the web based scheduler option, you are now able to schedule remote switch on/off of your equipments.

Using connectgaia.com, users can save up to 50% of their electricity bill. connectgaia.com empowers customers to closely monitor and thereby control electrical and process parameters tightly, optimise energy consumption and minimise the scope of wasteful practices. All this directly impacts electricity bill in terms of savings.

Trend Monitors

Energy Distribution

connectgaia.com

8.5

Intelligent Lighting Unit

connectgaia.com ePOD

Street-lighting Management - BEST, Mumbai

Programme overview:Pilot project for automated operation of 10 SLPs of Dadar, Mumbai

Programme objectives:Operation Management: Automatic operation/ remote management of street lights through time based or calendar based scheduling. Asset Management: Online Health Monitoring of equipments enabling quick fault detection.Power Supply Monitoring: SLP wise monitoring of energy consumption, voltage fluctuations, frequency profile, load profile pattern, power factor etc.

Programme design and implementation strategy:Out of the many solutions proposed to BEST, was the chosen one for its capabilities in the following domain:

connectgaia.com

! Asset Management

- Online health monitoring- Enables Quick Fault

Detection! Power Supply Monitoring

- SLP wise electricalparameters

- Voltage fluctuations

! Operation Management- Calendar Based Scheduling- Astronomical Scheduling- Need Based Scheduling –

ON/OFF operation- Remote Management

Centralized operation Convenience of operation and flexibility of

monitoring

Calendar/Time Based

Scheduling

Allow to operate the network as per the

astronomical conditions

Remote Operation Provides ease accessibility, usability,

management & control

In-built power and

data transmission

No separate cabling to implement

connectgaia.com solution

Automatic mal-function

notification online

Enhanced service

Power conditioning &

voltage regulation

Saves energy consumption hour – hours

during low traffic time zones

Flexibility of operation Anywhere, anytime, precise control

Historical logs Provides trend analysis, load forecasting,

etc.

Quick fault

identification and

restoration

Improved system uptime & customer

satisfaction

Asset management Better capacity utilization, reduced

maintenance costs

! Single phase metering (16, 20 and 25 Amp.)! Compatibility with European, US, South East Asian and Indian Sockets! Remote On/Off! Wireless communication - WiFi/Zigbee! Acts a child to connectgaia.com mother unit! Scheduling and Alarms

A green switch providing real time monitoring & control of electrical equipments

connectgaia.com

Features Benefits

Conclusion: Before the installation of connectgaia.com intelligent street lighting system, the average operation hour of street lighting system was approximately 11.23 hours and annual energy consumption of each SLP 35000 kWh but with the installation of connectgaia.com, BEST could manage their street lighting and public area lighting network better leading to considerable annual energy savings of 56852 kWh/ annum. This has provided BEST with an intelligent system enabling optimization of its manpower and assets leading to savings.

Plot No. 70A, Sector - 34Gurgaon - 122004 ( India )

Tel: +91-(0) 124-412 9900Fax: +91-(0) 124-412 9999Email: [email protected]: www.klgsystel.com

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