1

Making Industries Smarter

“In our vision to make our factories smarter, SmartSense is a key tool to help us take early
action in managing our power consumption & critical assets such as Motors. In just one plant,
actions from SmartSense predictive insights have led to savings of nearly INR 10 Million”

Snehashish
Plant Manager– Pepsico India
 Predictive Maintenance for Buildings 3

JLL is managing nearly 72 million square feet of real estate in India. In our vision to create the future of
work, we have partnered with Ecolibrium to help generate insights for transitioning from planned
preventive maintenance to data oriented predictive maintenance.
We are helping our clients optimize their maintenance and Energy costs using the powerful insights
provided by SmartSense.

Rajat Malhotra
COO – Integrated Facility Management (West Asia)
 4

Empowers Enterprises to Improve their Asset Efficiency with IoT powered

Predictive Analytics

70 % 30 % 10 %
Reduction in unplanned Downtime Improvement in Energy and
Reduction in Maintenance Costs Production Efficiency

Eliminate Production losses and increase Life of Eliminate Manual Data collection, and convert Dumb Data (EMS, BMS,
Equipment with PowerGenome® Analytics SCADA) into Automated Actionable Insights for Smarter Maintenance and
Energy Optimization
SmartSense: A Proven Solution.. 5

700+
Installations Globally over 300+ Organizations

Incubated and Supported by Global Recognitions

Energy Management
International Best Practices Award– 2016
Lighthouse Activity
Ashden Award

Global Climate
Most Innovative Energy Efficiency Product Solver Award
 6
…Across verticals
FMCG Government and Utilities

Engineering and Automobiles Commercial Buildings and Facilities

Pharmaceutical & Chemical Other Manufacturing

Partners
PowerGenome® Predictive Analytics 7

Pathbreaking Predictive Maintenance

Algorithms using Energy Signatures for early
detection of faults as compared to other
methods

1. Minimal need of sensors reducing

cost and time of implementation by ~
50%
2. Independent of Brand of Equipment
3. Applied to all critical equipment such
as Motors, Compressors, Pumps, Fans,
Chillers, Transformers etc.

12000 Sensors 200 Million

Being Analyzed over 4000 Data Points Analyzed daily over
equipment > 8000 equipment
The SmartSense Approach 8
 A1: Acquire 9

City Buildings Industries

Plug n Play Ready Integration Modular and Secure

Ready retrofit with > 200 types of sensors and 12 Industry 3rd Party Integration with systems such as SAP, Secure Cloud hosted infrastructure with multitenant
protocols – Wireless deployment with minimum cabling BMS, IoT Platforms, etc. capabilities
 A2: Analyze 10

AI Pipeline:
Convert unstructured data into
contextualized data in real time by
using our unique expert systems and
Machine learning

Plant Digital Twin Asset Digital Twin

Create a Digital Twin of CREATION OF Create a Digital Twin of the
your plant or building to DIGITAL TWIN critical assets using
identify any anomalies proprietary SmartSense
or leakages in Energy or models using its ‘Sensor-
Production light” approach

Customized to sectors Ready Models for Motors,

and Processes Chillers, Transformers, Fans,
Boilers, etc.
A3: Act 11

Automated Recommendations with Root Cause Analysis

Predictive and Anomaly algorithms identify Energy and asset
optimization Opportunities .Alerts in case of impending Asset
failures

Customize Dashboards for your Industry Needs

Sectoral Dashboards for more than 10 leading verticals with
customized KPIs. Dashboards for CXOs, Plant heads, and Line
manager

Easy customization using ‘widget-maker’ Dashboard

Get automated reporting and custom alerts

Excel based reporting engine, and Advanced Rules engine alert
builder

Control Assets remotely

Ability to control equipment from dashboard – Also able to
upload production data from App.
12
 The SmartSense Journey 13

Asset Condition Monitoring and predictive

insights to avoid inefficiencies and downtime

Integrate Energy data with production data Condition Predictive

and identify inefficiencies in Specific Monitoring Insights
energy in shifts or products

Productivity
Insights

#FullStack solution with Hardware and Software

Track Energy Costs and automatically identify o Ready Integration with any 3rd Party Systems
optimization from Bill or energy sourcing from Exchange
or Renewables o Plug n Play Wireless Deployment in days
Enterprise
Insights o Scalable Multi-Tenant Solution
Automated Anomaly detection of idle consumption
of network or process health issues
#Low cost Software as a Service (SaaS) Solution
Modular Analytics with no upfront costs
o

Enterprise
Dashboards

Acquire data to get a Real Time custom dashboard with Automated Reports and Alerts
SmartSense Impact Stories: A Peek
Enterprise Analytics identifies
Billing and consumption (Load
factor and power factor)
Industries optimization ~ Rs. 4 Lakhs per
month. Demand Optimization
leads to avoided Capex
investment of Rs. 5 Crores
Enterprise and Asset insights identify
Buildings & savings of nearly Rs. 5 crores per
Commercial year from demand optimization,
Infrastructure trading feasibility, and chiller
inefficiencies improvement. Expands
scope to cover its tenants
14
Asset Insights identify Motor
inefficiencies using predictive algorithms
– Identifies saving opportunities of
nearly 20% in energy consumption. Also
monitors drug storage with temperature
alerts to avoid stock wastage.
… and 300 more!
Asset Insights of Chiller helps
perform predictive maintenance–
identifies potential breakdown due to
refrigerant leakage costing more than
Rs. 60 lakhs a year
Join the SmartSense Journey 15

Primary Proposal, Scope

Site Survey Questionnaire to SmartSense Commissioning
Finalization and Order
be filled and discussed and ongoing analytics
Processing

3 days Depending on Scope

1- 10 Weeks
SmartSense Costs

SmartSense Services:
a. SmartSense secure Hosting, Dashboard, Reports, Alerts,
Yearly analytics as per Applicable Package
Subscription b. Remote support and Domain Expert Advisory
c. Link+ Gateway with communication (for India only)

One • Meters, Sensors & Convertors (If not present or

Time Retrofit not possible)
Cost • Installation and 3rd Party Integration (SAP, BMS, etc)
charges
 16

The SmartSense Journey: A Deep Dive

The SmartSense Journey Packages 17

Asset Modules

• Transformer
• Motor
Condition Predictive • Chiller
Monitoring Insights • Pumps
• UPS
• DG
• Compressor
Productivity
Insights
Production Insights Module

Sourcing Insights Module

Enterprise
Insights

Enterprise Analytics Package

• Enterprise Dashboard
• Network Insights
Enterprise • Billing Insights
Dashboards
Develop a Customized Enterprise Dashboard 18

1. Track custom KPI trends on My Dashboard

Widgets based Dashboard – For easy customization of
tracking energy, water, gas, Fuel, production, etc.

2. Automate MIS Reports/ Critical Alerts

Customized SMS/ Email alerts on critical situations as per
site and automated reports as per requirements

3. Monitor distributed facilities

GIS Map View For Centralized
monitoring

4. Track Asset performance in

Network View: To see
architecture of all assets in the
facility with energy contributions
and trends
 Optimize Energy costs with Billing Insights 19

2. Identify and Avoid

Penalties due to Demand
1. Monitor Real Time Overshoot, Low Power Factor,
Energy Costs etc. with alerts
• Performance
against Target
• Historical
• Current Month 3. Act on cost saving
• Anticipated bill opportunities (What if Scenario’s)
• Time of Day costs • Demand
Analysis • Power Factor
• Demand and Power • TOD
Factor Charges Tracking • Renewable sources mix
• SPV Capacity
Optimize Power Purchase costs with Sourcing Insights 20

1. Monitor Real time cost benefits

from Trading
Rooftop
• Dashboard of 15 min slot
Solar
Power consumption to track overtraded and
Bilateral
Exchange under traded units
• Automated Net Benefit Analysis
report daily to track benefits and
Grid
Power Diesel losses against Utility charges
Purchase Genset

2. Identify Potential Losses and get

Sourcing the Cheapest Power Automated Alerts and reports
Alerts on overbidding and underbidding
situations.

3. Act to increase Benefits from

Trading by Optimizing Bid
by up to 20% on exchange using analytics
keeping into account sourcing from various
options
Automated anomaly detection using Network Insights 21

Anomaly Detection Algorithms using AI

• Unusual Energy Consumption

• Power Health
Enterprise Insights • Sector Specific Parameters: Temperature,
Pressure, Flow, and other KPIs
 Network Insights Dashboard
1. Identify Network
Anomalies
Health
• Voltage & current
Variations
• Power factor issues
• Harmonic Issues
Unusual Energy
Consumption
• Non- working hours
• Non-Working days
• Idle running
22
2. Track Potential Savings
and get customized
Recommendation
Best Practice identification and
savings if issue brought under control
3. Act on Issues and
maintain activity & Impact
log
Track the complete life cycle of issue
and resolution status
Automate Specific Energy Monitoring with Production Insights 23

Integrate SmartSense with Production data to track productivity on a live dashboard, and track anomalies to
generate actionable insights

Option 1: SAP Integration

• Production planning module

• Planned maintenance module ERP

Option 2: Mobile App

Manual Entry

Smart sense Production Mobile App

Production Insights
Option 3:
Manual Production Monitoring
Upload in Excel sheets
Manual Entry

Limit Switch/ PLC

Option 4. GPRS/ Wi-fi
Automated Production
Monitoring
Link+
Assembly Line Production Sensor / Convertor
 24
Production Insights Dashboard on

Track Energy trends for each

product on a real time basis by
integrating SmartSense Energy and
Production data

Track Specific Energy

consumption of producing each product in
each plant - Integrates PP module with
IoT data

Track OEE performance against

targets

Anomaly Detection of
productivity deterioration - Identify
shifts or areas causing issues
 25

The SmartSense Journey: Asset Insights

Asset Insights make Predictive Maintenance possible 26

SmartSense help identify early signs of Asset deterioration - leading to increased uptime, and savings in
Energy and Maintenance costs!
Prevent Asset breakdown with SmartSense Insights 27

Early detection of Asset Fault

Centralized Asset Issue Dashboard

Asset Insights

Track Consumption increase due to impending faults

Protect Motors with SmartSense Predictive Insights 28

3. Act

2. Analyse
Neural network using FDD Automated Identification of Mechanical or
Electrical Issues

1. Acquire • Rotor or Stator Faults

• Bearing faults
• Power Quality issues (THD, Imbalance)
• Loading ( Underload / Overload)
• Any other Anomalies

SmartSense Motor Insights is done using a patented PowerGenome approach using only Electrical
Data for predictive maintenance – eliminating need for vibration or MCSA tests – thus saving upto
50% on motor maintenance costs
 SmartSense protected Chillers 29

2. Unusual Trends identified using Chiller Analytics

Engine

1. Real Time Tracking

of KPIs
• Running IkW/TR
• Running COP
3. Act on Automated recommendations to
save Running costs and prevent downtime
Chiller Issues
• Refrigerant Leakage
• Condenser or Chilled water Flow Deviation
• Condenser or Evaporator fouling/Scaling
• Compressor Motor health/Efficiency (Fault detection in motor)
• Pumping unit Efficiency including Pump Motor health/Efficiency
• Cooling Tower system health Issues
• AHU Motors Health/Efficiency

SmartSense Chiller Insights is done using a patented PowerGenome approach using which does not
require expensive flow meters for predictive maintenance – thus making predictive maintenance
possible with minimal data
 SmartSense protected Transformers 30

2. Track Unhealthy patterns in KPI’s

1. Track Transformer
Health KPI’s
(Loading, power quality, Running
losses/ oil temperature and voltage
levels)

3. Automated Alerts for Improvement

Opportunities
• Loss Increase due to connection or internal faults
• Loading Optimization possibility:
• Under/ overloading
• Harmonics/ Phase balance issues
• Power Factor Issues
• Predictive Maintenance of:
• OLTC Defects
• Oil Quality or quantity issues

SmartSense Transformer Insights track mechanical issues such as OLTC problems using a patented
PowerGenome Approach using which does not require extra sensors – thus making predictive
maintenance possible with minimal data and costs
Other SmartSense Asset Analytics Packages 31

SmartSense Asset Condition Monitoring Packages

• Elevators
• UPS
• DG Sets
• Heat Exchanger
• Furnaces
• Boilers
 32

504, Venus Atlantis,

Anandnagar Road,
Ahmedabad 380015

info@ecolibriumenergy.com +91 79 4016 5151 www.ecolibriumenergy.com

 33

Annexure: The Need for Predictive Insights

Industry 4.0 has arrived.. 34

…and here to stay

Big Data
Connected
Energy
Machines
Analytics

Enhanced Predictive
Productivity Maintenance

20 billion + connected devices by 2020.

As per a Mckinsey Survey - 82% of Business and technology decision makers feel adopting IoT analytics improves
business process efficiency, and allows for a stronger position in the marketplace
The Organizations who ‘opt-out’ of this Industrial revolution face an uncertain Future’
 .. Producing opportunities to optimize Productivity 35

IoT and Predictive Intelligence can help plug in

the gaps in productivity and dramatically
increase OEE Scores of the Company

Planned Unplanned Lack of Capacity OEE Loss

Downtime Downtime Demand Utilization
Loss 43%
business and technology decision makers
Optimize with
lack of IoT technology will affect product
PdM
quality and customer satisfaction

Production Actual
Capacity Production
(Hrs) (Hrs) USD 7mn
Potential savings per company year due to
predictive Intelligence – saves 30min per
technician per day
 36

.. and reduce Energy and Maintenance costs with predictive insights

Reactive maintenance Preventive maintenance Predictive maintenance

Energy and Maintenance Costs

120

100 50% Reduction in Costs Energy and Maintenance costs

15 % contribute to nearly 50% of Running
80
$$ costs in Enterprises - Transition from
60
Reactive to predictive Maintenance
40
45 %
can help reduce nearly 50% of OpEx
20 5050% 36
21
13
0 5 10 %
Year 1 Year 2 Year 3 Year 4 Year 5

Year 1 Year 2 Year 3 Year 4 Year 5

20x ~ USD 24,000

Cost of sudden repairs as compared to Per minute wastage in running a large
scheduled maintenance defective machine
 37

504, Venus Atlantis,

Anandnagar Road,
Ahmedabad 380015

info@ecolibriumenergy.com +91 79 4016 5151 www.ecolibriumenergy.com