Site Survey Document

For Connected Factories

Ganesh R

ABSTRACT
This document is an initial questionnaire for the site study for the Scope of Implementation of
SmartSense in Connected Factories

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Table of Contents

Overview 3
Project Objective 3
Site Overview 4
Infrastructure Overview 5
Stakeholders 6
Team from Client 6
Team from Ecolibrium 6
Sample SCADA Architecture (Share here or separate file) 7
SITE SLA/KPI 8
Dependencies 10

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Overview
● Date of Filling: 5th July 2021

● Data filling by (Name) : Shijith K N

● Contact Details (Phone and Email): shijith.kn@cpmjk.jkmail.com

Project Objective
Please state the objective of the project

Objective Priority Yes No Good to Have

Labor and Maintenance Cost P2 Yes

Reduction

Asset Efficiency improvement P1 Yes

(Through reduced Energy, fuel,
compressed air consumption)

Asset Downtime reduction P1 Yes

Improving Throughput P1 Yes

Others (Please mention here) P1 Yes

Reduction in water consumption

Increase in Return condensate P1 Yes

Additional information on the objective the needs to achieve would help design the solution better.

1. Connectivity with SAP

2. Auto load shedding.
3. What if scenario

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Site Overview

Description Site 1 Site 2 Site 3

Name of Company JK Paper Limited,

Unit : CPM

Total Area (in Sqft)

Product being manufactured Writing & Printing Paper

& Duplex Board

Annual Maintenance costs ACCONTS DEPT

(Manpower and repairs)

Annual Energy FY 2020-21

(in kWh / USD)
138273874 kwh

Annual Downtime hrs PM1 -4626 hrs To be vetted with PK

affecting production PM2 -1562 hrs Mittal
BOARD -1441 hrs

Current Reject % Finishing +Break (20-21) To be vetted with PK

PM1 -15.68 Mittal
PM2 – 11.67
BOARD -10.34

Energy Meters installed (Nos) ELECTR. DEPT ANNEX -1 EM LIST No Further list will be
ofm meters likely to shared (MEP area)
increase minimum by
2 to 3 times so as to
monitor energy
section wise/
equipment wise. Now
it is monitored plant
wis only.

Motors (# and make) ELECTR. DEPT ANNEX- 2 – MOTOR Further list will be
LIST PAPER PLANT shared (MEP area)
AND BM4

Pumps (# and make) NEERAJ NILMANI

Water Cooled Chiller (# and NEERAJ NILMANI

make)

Air Cooled Chiller (# and NIL

make)

Transformers (# and make) ELECTR. DEPT ANNEX -3 Further list will be

TRANSFORMER LIST shared (MEP area)
PAPER PLANT,

Compressors (# and make) 3 NOS SCREW

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COMPRESSORS
MAKE ATLAS COPCO

2 NOS CENTRIFUGAL
COMPRESSORS MAKE IR

Boilers (# and make) DETAILS AS PER

ANNEXURE 1

GearBox (# and make) 2 NOS TRIVENI MAKE

GEAR BOX FOR NEW
TURBOGENERATORS

DG (# and make) NIL

Fans (# and make) NEERAJ NILMANI

Cooling Tower (# and make) TG#3 CT – GEA

TG#4 CT - SHRIRAM
OLD EVAP. CT - HIMAGIRI
TG#5&6 CT – NORTH
STREET
PROCESS CT – NEW
PLANT- NORTH STREET

Flowmeters (# and make) NEERAJ NILMANI

Furnace (# and make) NA

UPS (# and make) JARNAIL YADAV

CNC Machine (# and make) NA

Other – Specialized critical

manufacturing machine ( List
Type, # and Make)

Type 1 Paper Machine 1

Type2 Paper Machine 2

Type 3 BOARD MACHINE

MAKE –SAPI
RETROFIT BY VOITH

Type 4

Infrastructure Overview
Description Facility 1 Facility 2 Facility 3

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Make & Model of Production NO PRODUCTION

Management systems MANAGEMENT SYSTEM
(SCADA, MES, etc) INSTALLED

QMS FOR MACHINES

AVAILABLE

PM 1&2 – ABB (QCS)

BOARD – HONEYWELL

Functional Status ( Working, WORKING

non functional)

Protocol Available for NEERAJ NILMANI

communication with existing
systems (List all by systems)

Internet Connection Available YES

on site ?

ERP System make and APIs SAP HANA S4

available

CMMS Details (if used on site) No

do we have single Line ANNEX -4 – ELECTRICAL DONE

Diagram Available SLD

Do we have the SCADA, MES NO

Architecture Available –
Please share architecture

PM Schedule available – YES –ANNEXURE 2

Please share list NEERAJ NILMANI

Are the sensor Meters DCS –

connected to the SCADA? AVAILABLE SENSORS &
METERES CONNECTED

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Equipment Overview
(Attach the relevant Architecture / Document to support the data)

Description Quantit Rated Controller type Communic Parameters to be Expectation

y Details (PLC/SCADA/ ation shown on from
DCS/OPC detail Dashboard Algorithm
Analogue/Port) Protocol &
Port &

Energy ANNEX ANNEX - PORT 485 ELECT ELECT DEPT Warning/

Meters- DEPT KW/KWH/PF Alram for
ELECT DEPT 485 ACTUAL/
over
TARGET/HIGH/
LOW/AVG comsumpti
on/trip for
very high /
settable/sel
ectable
UPS – ANNEX ANNEX Potential free 485 INV Algorithm to
ELECT DEPT contacts/ port VOLTAGE/HZ/LO give warning
AD/ALARM/WAR about UPS
485
NING FOR loading/overlo
TRIP/ALT / ading and Will
BATTERY save UPS
VOLTAGES/ROO failure.
M AND
BATTERIES TEMP/
ALARMS/

Chiller 8 NEERAJ/ PLC NEERAJ

CHINTU

Pumps NEERAJ NEERAJ EFFICIENCY

Cooling NEERAJ EFFICIENCY

Tower

AHU CHINTU CHINTU CHINTU MITRA CHINTU CHINTU MITRA CHINTU MITRA
MITRA MITRA MITRA

Air 5 ANNEXU PLC AIR

compressor RE 3 CONSUMPTION
BREAK UP.
POWER/NM3

Turbine ANNEXURE 1 NEERAJ NEERAJ STEAM AUTO LOAD

CONSUMPTION SHEDDING.
BREAK UP.
STEAM/MWH, WHAT IF
HEAT RATE SCENARIO.

BEST
EFFICIENCY
OPERATION

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DISPLAY TO
GUIDE
OPERATORAND
CLOSED LOOP
BASED ON
ACTION TAKEN

Boiler NEERAJ NEERAJ BOILER BEST

EFFICIENCY EFFICIENCY
OPERATION
DISPLAY TO
GUIDE
OPERATORAND
CLOSED LOOP
BASED ON
ACTION TAKEN

Motors ANNEX ANNEX Potential free Potential Load in Algorithm to

ELECT DEPT contacts free KW/Amps/Volts/ give warning
motor body about motor
contacts
temparatures, loading/overlo
/RTDs Ambient temp. ading and Will
for save motor
motor failure,
temp/ improve
load in efficiency.
amps/K
W
Transformer ANNEX ANNEX Potential free Potential Load in Algorithm to
s contacts free KW/Amps/input give warning
ELECT DEPT and output about
contacts
Volts/Transforme transformer
/for r oil and body loading/overlo
Alarms/ temparatures, ading and Will
warning Ambient temp. save
s/Analog transformer
ue failure,
inputs improve
efficiency.
for Body
and oil
temp

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Stakeholders
Team from Client- GS Govindraj

Name Designation Mobile No Email ID

Plant -1  

Team from Ecolibrium

Name Designation Mobile No Email ID

Naman Gupta Consultant - Connected Naman.gupta@ecolibriumenergy.c
Factory om

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Sample SCADA Architecture (Share here or separate file)

(this is an Example)

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SITE SLA/KPI
(Below is an Example ) – List attached –Annexure 4

S.No Desired Outcome Parameters Devices Monitored

1 Electrical Power distribution - Energy Meters (Distribution Network),

Transformers, Panels

UPS Power system

Centralized HVAC System - Chillers, AHU, Pumps, CT, Temperature (Run & Trip Status)

OEE -

(Availability and productivity)

2 Reject % Rejects%

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3 Energy Performance Index POWER IN KWH/MT OF PAPER,

POWER IN KWH /MT OF BOARD
POWER IN KWH/MT OF PULP

STEAM MT/MT OF PAPER,

STEAM MT/MT OF BOARD
STEAM MT/MT OF PULP

WATER M3/MT OF PAPER,

WATER M3/MT OF BOARD
WATER M3/MT OF PULP

AIR NM3/MT OF PAPER,

AIR NM3/MT OF BOARD
AIR NM3/MT OF PULP

CONDENSATE RETURN -%

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Dependencies
(This will be filled by the Ecolibrium Team post the site survey)

Dependencies Action Owner Remarks

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