SBU Automation and Manufacturing Solutions

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
Note: *
among the most essential need of any company. However, each of these measures Market Forecast and Ability to Promise
of what is “right” has ever-higher benchmarks. Customers are now demanding ! Customers determine price, quality, quantity, time, and
place of delivery. ST
OM
ER
S

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

! Organization has to compute profitability of deals, basket of

Market deals in short term and long term.
prices freely. The Internet empowers customers with more information for ! Negotiate prices of input, transportation and ware house
MA
N
CO UFA
LLA CTU
BO RIN
RA
TIO G
N

logistics.
negotiation.
SUPPLIERS

! Decision to sell or decline.

ERP ! ERP system uploaded with order data.
PLA
NT 4
& MA VEL

The agility to accurately promise and quickly deliver increasingly customized Ability to Promise
Planning and Scheduling SC NAG
HED E
UL MEN
ING T
LE

Supply Chain
! Plant does Monthly, Weekly, Daily, Hourly planing to meet
products or new products requires synchronization across a broad scope of Planning & Scheduling
Dynamic schedules.
PR
OD
UC
TIO
N SU
PE
RV
ISIO
LE
VEL
3

Production Planning/Schedulng N

manufacturing activities performed by multiple organisations. Manufacturing Execution Systems PR

OC LE
VEL
2

ES
SS
UP
ER

Manufacturing Execution Systems

! MES application simulates various production scenarios. VIS
I ON

! Optimization in use of raw materials, energy consumed and

KLG, for the last 10 years, has been offering IT enabled business optimisation Simulation / Optimization / Maintenance
accommodation of maximum production batches. DIR
EC
TC
LE
VE
L1

ON
! MES application orchestrates manpower, machines, TR

solutions in the manufacturing space. These solutions have evolved from a Human maintenance, quality, recipes, sequence and schedule of
O L

0
VEL
plant.
Machine Interface and Shop Floor Scheduling solution to a complete Plant
LE

MMI / SCADA / Control

Plant Shop FloorSystems TH
EP
RO
Plant Information C ES

Intelligence and Supply Chain Optimisation application framework. In this space, Human Machine Interface / Plant Information S

HMI visualizes plant/ machine status.

KLG has served some of the most reputed manufacturing organisations across !
! Visibility of plant parameters across shop floor and
various industry verticals in India. These include names like Asian Paints, Bharat
Programmable Logic Controller, CNC Machines, Sensors
Petroleum, Essar, Glaxo, HLL, Maruti, Nestle, Pepsi, Reliance and TISCO.

KLG now offers integrated solution for Industrial Automation and Supply Chain 1 Sensor to Board Room Pyramid
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
Multiple Business Systems Manufacturing Systems
organise and deliver plant intelligence, which is accessible throughout the Enterprise Integration Application

Enterprise Integration
organisation – from the ‘Sensor-to-Boardroom’. As a result, the organisations are ERP
Manufacturing Execution Systems

able to make better-informed decisions about their business. J D Edwards

Presentation
SAP

Functions
Microsoft ORACLE Supervisory Production Analysis
HMI
Business
Solutions
Realtime Industrial
Application
Control Management Process & Clients
S95 / B2MML / XML HTTP Web Services SQL Database
Production
Real-time production information enables and empowers decision makers through Multiple Message /
Server
Process Performance History
3rd Party Manufacturing Systems Reports Notification
Transactional Systems Management Management
web based dashboards and seamless flow of information between ERP systems.
Application Plant & Production Customer
Models Model Standards
KLG works closely with Wonderware, a division of Invensys PLC, Microsoft, IBM, Mercator Tibco
Data / Events Database
Schedulers, Enterprise Asset Management,
Microsoft MQ WebSphere Manufacturing Execution Systems,
Commo Name Services Messaging Events & Alerts
Oracle and SAP to deliver solutions. KLG integrates diverse Automation Platforms NetWeaver MQ Series Programmable Logic Controllers,
Distributed Control System..
n
Security Config. & Deployment High Availability
Services
from ABB, Allen Bradley, Areva, Foxbro, Honeywell, Siemens, Yokogawa and Sensor
An open Enterprise Integration Approach for Driving
Manufacturers. 2 Device Integration
Manufacturing Performance PLANT FLOOR

* Source: Wonderware Website

4.1
 Case Study Automation and Manufacturing Solutions - Nestle India Ltd.
Stage A: Supply Chain Management System
Nestle

h
World’s Leading food company
h
Switzerland’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
1 US $590 Million Turnover, 2 60 Depots 3 100’s of Locations 4 Happy Customers
manufacture popular brands like Nescafe, Milo , Lactogen, Fruit’N Dahi, Kit Kat, etc. 15 Plants, 35 Brands
550 SKU’s

Business Challenges Stage B: Manufacturing & Automation

h
Milk powder manufacture requires handling of large quantity (150 MT) of
milk on a daily basis.
h
With 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.
h
Lactogen manufacturing needs different recipes based on quality of raw
material.
h
Manufacture of coffee and chocolates need proper handling of proteins
and other nutrients in appropriate proportions. 1 Login to the project Nestle Egron Plant 2 Egron Plant View 3 Nestle product - Lactogen

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

KLG Solution
h
KLG’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.
h
Optimal operation of Egron and Evaporation has resulted in savings of upto
10% milk usage done by reduction in spoilage and enhanced quality.
h
Capability to handle 75 recipes was attained and transition time for Login to the project -
1 2 Fruit’N Dahi Plant Overview 3 Nestle product - Fruit’N Dahi
change in recipe was reduced by 400% resulting in use of various milk Nestle Fruit’N Dahi Plant

varieties and optimal purchases.

h
Introduction 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.
Login to the project - Nestle Kitkat Kitkat process overview
2 Nestle product - Kitkat
1 2 3

4.2
 Case Study Automation and Manufacturing Solutions - Essar Steel
Essar Steel Limited - The second largest private sector steel
producer in India has an integrated steel complex at Hazira, Gujarat. Essar Steel
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 CONTINUOUS
specifications, the plant offers tremendous flexibility in charge mix, CASTING

lot size and product mix / range. Operations are highly automated to
improve operational efficiency and productivity. It has high level of ELECTRICAL ARC LABEL REFINING
FURNACE FURNACE VD - VACCUM
DEGASSING

automation for both process and business applications. It has a state- VOD - VACCUM OXYGEN
DECARBORISATION
HOT BRIQUETTE
of-art hot rolled coil (HRC) plant with a capacity of 2MMPTA. It is the IRON HOT STRIP MILL
COIL BOX

only mill in India capable of rolling up to 2000-mm wide coils. DESCALER DESCALER FINISHING MILL LAMINAR COOLING

Business Challenges. WALKING BEAM

FURNACE
REVIERSING
CROP SHEAR
DOWN COILER

h
ROUGHER
High Volume and a large variety of product types. WITH EDGER

h
PLATE
Changing market demand and prices required plant SERVICE CENTER
2 RH Furnace 3 Factory Floor Integration
SHEAR LINE

management to change product mix and schedule in near real

time to improve profitablity. 1 Steel Production Process
h Automation and technology at different levels was a major
challenge. Technology was sourced from various
suppliers globally resulting in data islanding.

Solution offered
h Solution as a step towards establishing an integrated real
time information system on the plant floor using Windows
platform.
h Solution 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.
Ÿ
Information was logged without any manual interventions
and errors. 4 Alloy Addition System 5 Nozzle Gas System

Ÿ
Timely corrective actions were ensured and much needed
co-ordination between various departments was achieved. 6 Vacuum System

Ÿ
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.

4.3
 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. Steel Production Process

Business Challenges
h Islands of legacy automation from diverse vendors.
h No integration between processes and plants.
h Plant floor not integrated with IT system.
h Poor visibility for managers of plant activities and plant
operation.
h Lack of tracking, control, scheduling and optimisation
systems. 1 Dynamic Scheduling of Slab Caster & Melt Shop. 2 Gantt Chart Showing Status of Heats
h No interface with business system.

KLG Solution
h Continuing collaboration over last seven years to devise a
Manufacturing Executing System (MES) linking Plant Floor
to SAP ERP system seamlessly over 12 mills.
h Production simulation and real-time scheduling of
continuous casters.
h Major improvements in plant operation and profitability.

2 Discharging System 4 Online Inspection System

Finished Inventory
1 Status of Wire Rod Mill Machinery 3 Mill Order Screen 5
Management

4.4
 Case Study Automation and Manufacturing Solutions - Reliance Infocomm

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

Reliance Infocom
(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.

2 Reliance Infocomm - National Network

Business Challenges Operation Center
Monitoring
l of the entire network on 24 x 7 basis and 100% Reliance Infocomm All India Network
1 Reliance Infocomm Network in the State of Maharashtra
Redundancy for telecom stations in 426 locations.
Fault & Performance Management.
l

Traffic Monitoring.
l

Operation Support System (NEMS,Clarity).

l

Remote configurable architecture.

l

KLG Solution
3 Reliance Infocomm MCN
Application
l for realtime monitoring of operating parameters of 4 Reliance Infocom - Process Parameters 5 Diagnostic Screen Communication Status
network.
Escalation of alarms & resolution of issues.
l

Performance measurement.
l

Control from one center for the entire network

l

Unlike
l 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. 6 Reliance Infocomm MCN Diesel
Generator 1, Energy Unit
The
l NOC could monitor the pan-India network on a 24 X 7 X 365 basis by Generator and Tank Fuel Level
7 Reliance Infocomm - Historical
overview 7 Reliance Infocomm - OSP SCADA Alarms trends
employing state-of-art digital systems to track, display and maintain
the complex network.

8 Reliance Infocomm - Historical Trends

4.5
 Client List Automation and Manufacturing Solutions
Human Machine Manufacturing Plant Information Plant-to-Business
Sectors Interface/scada Execution Systems Management Integration
Sectors Key Customers
Food & Beverage
Oil & Gas
l KLG’s customer base includes reputable
Colgate Palmolive
Indian companies across a wide spectrum of
Automotive
l Nestle India
industries.
Metal
l Pepsi Foods
Godfrey Phillips India Ltd.
Power
l Titabhi Sugar
Godfrey Phillips India Ltd. is primarily a tobacco Consumer Packaged Goods
l Process Industries product company. Well known for its Four Square,
Red & White, Cavander’s, Jaisalmer, etc. brands of Duracel
Breweries cigarettes. Godfrey Phillips is today the second Godfrey Phillips India Ltd.
largest player in the Indian cigarette industry with
Cement an annual turnover of over US$ 265 million. ITC Ltd.
Chemicals Godfrey’s Chakala Factory is a regular user of
solutions developed and offered by KLG. This time Automotive
Cigarette they wanted to have automation on the plant floor Amar Raja Batteries
where they had multiple Metler Toledo Weigh Scales
Fertilizer and LNI systems which are primarily used for DGP Hinoday
weighing of Cigarettes during manufacturing Maruti Udyog
Paint process. Based on the weight and other factors for
the cigarettes they define the Quality of the running MRF Tyres
Pulp & Paper batch.
Metal
Sugar KLG provided a solution and the following Essar Steel Ltd.
features and benefits were available after
Food & Beverage
l implementation: Hindalco Industries
l Automatic recording of weight data, Tata Steel
Power
l eliminated incorrect data entry, more time
for operators to focus on productivity. Oil & Gas
Engineering Procurement & Construction
l
l Online details about the Produced Weight, British Gas E & P
Production Standard Deviation, Light / Good
Textile
l
/Heavy Cigarette, Stop Times, efficiency and BPCL
Consumer Packaged Goods
l rejects resulted in better quality and lower Indian Oil Corporation Ltd.
production costs
l User could get the details of which Maker is Chemical
running which Brand, the latest weight, the Asian Paints
Min & Max. 30 Cig. Wt, Average Cig. Weight,
Average Density, Standard Deviation, etc. Castrol India
Galaxy Surfactants

Indofill Chemicals
Indian Oil Corporation Ltd.
Rallies India Ltd.
IOCL - The IOC group is the leading producer of Syngenta
various Petrochemicals & LPG in India. Wonderware
InTouch is being used for the Terminal Automation of EPC and Other Industries
the LPG filling station. Wonderware InTouch runs on ABB
a 486/75 PC linked to an Allen-Bradley S5 series PLC
via 1784-KT cards running at 9600 baud. The system Alstom
monitors the Pre-weighing Stage of an empty LPG
Areva
cylinder & the actual filling as well as the Post-
weighing stage indicating various valve outputs, Bhabha Atomic Research Center
conveyer positioning & the weight of the LPG at pre
& post filling stations. BHEL
HEG Ltd.

4.6
SBU Power Systems Solutions SG61 Technology

Automatic
KLG Business Model - India, Asia and developing countries Consumer Meter
Indexing- Reading
Highlight - India
Meter Reading
l30% to 50% loss of power in distribution sector total of 30,000 MW costing US$ 10 Billion GPS Survey / Spot Billing
in cash loss and another US$ 20 Billion in residual losses GIS Mapping
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 route Implementation Revenue
lKLG has worked with 5 million consumers of 8 utilities in India for past 5 yeas in the Automation of Collection
areas of Meter Reading, Billing, Energy Accounting, GIS and Revenue Management and (SCADA) IT Backbone
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 Energy
technologies and hardware Feeder Accounting
lKLG has developed its application on IBM software and is the only premier ISV for Renovation
utilities in India Loss
Diagnostic
Study

SG61
TM

TECHNOLOGY

business application software

Remote controller and communication hardware

using GPRS /CDMA

Theft prevention hardware

Automatic meter reading

Automation and communication backbone software

TCP/IP Broadband backbone for multimedia applications

6.1
 SBU Power Systems Solutions
POWER SECTOR IN INDIA
POWER GENERATION POWER DISTRIBUTION 11/0.415 kV

·Installed Capacity - GENERATION RELATED ISSUES NETWORK

120000 MW Peak ·Plant Load Factor ·Alternates to Thermal in Hydro 66/33/11kV
Shortage - 12.6% Improvement and Nuclear have not picked up
Base Energy ·Low Quality, high ash content as per expectation
Shortage - 7.5% coal as primary source of ·Peak and Energy Shortages still M
·Sources of Power fuel remain ; hence no possibility of S TE
132kV SY
Generation ·Alarmingly low participation spinning reserves N
Steam - 57%, Hydro - 26% TIO
of private sector in capacity ·Environmental pollution BU
RI RU
Nuclear - 2.4%, Wind-1.7% augmentation ST
DI R AL
Gas - 10%, Diesel - 1.0%

POWER TRANSMISSION SHO

PPIN
G
IC
T
ES
M
Transmission System
· TRANSMISSION RELATED ISSUES DO
IN
comprises 400kV network · Grid Discipline, with ·Interconnection of regional DU
ST
for Main & Bulk overdrawals resulting in grid grids for transfer of bulk power RI
AL OF
FIC
E

transmission. Total collapse from one part of the country to

Transmission network is · Enforcement of Availability another
AL
about 22000 km Based Tariff (ABT) CI
ER
Power Grid Corporation
· · Weak Reactive Power M
M
is responsible for Management resulting in CO
transmitting electricity poor voltage regulation High
at 400 kV and 220 kV Switching Transients DOMESTIC SECTOR
POWER DISTRIBUTION
Compounded annual growth rate reduced from 13% in 1984-85 to 5.0% in 2002-03 due to
·
DISTRIBUTION RELATED ISSUES shortage of power availability
·Power is distributed at ·APDRP and subsequently · Inefficient / poorly designed Energy charges may be partially subsidised for this category in some states
·
0.4 kV level after being Indian Electricity Act 2003 and managed network/equipment Non-technical losses including theft, tampering of meters, billing and collection errors are
·
stepped down from have made distribution · Metering - not 100% DISR
T IBUT
COMPANON
I
Y common
11 kV companies more · High Aggregate Technical and
accountable and opened Variance between Sanctioned load vs. Connected load is high; with middle class
·
·Total Distribution Commercial Loss- 30% to 50% consumption patterns changing rapidly, especially in Metros and Class A cities
capacity is about up privatisation · Distribution companies are
250000MVA; total number · Average annual compound financially stressed
of consumers is over 130 growth rate of electricity · Tariff structure based on
million consumption since 1950 has subsidising agricultural sector at
·Distribution sector is been 8.9 % COMMERCIAL SECTOR
the expense of Commercial
managed by state owned · Electricity consumption in and Industrial sector; resulting BANK
distribution companies different sectors Compounded annual growth rate reduced from 9% in 1984-85 to 5.4% in 2002-03 due to
·
in theft and /or shifting of shortage of power availability
/ boards / corporations Agriculture- 24.9% Commercial and Industrial sector
or private companies Industries - 33.9% to own captive generation Quality and Reliability of supply is of major concern to this sector
·
Domestic & Commercial-32% · Weak Revenue Management and Most commercial buildings opt for own in-house generation for continuous supply relying
·
Others - 9.2% Energy Accounting. Lack of Load on expensive diesel
Forecasting - Long Term and Energy charges to this sector are comparably high because of cross-subsidy resulting in
·
Short Term theft

USERS OF POWER
AGRICULTURAL SECTOR INDUSTRIAL SECTOR
Highly subsidised or free power to agriculture sector; with flat rate tariff in many states
· On the receiving end of the cross-subsidy policy, this sector has the highest tariff among all users
·
Main use of electricity is for pumping ground water for irrigation; total number of electricity
· with unit charges as high as Rs 5/- per unit
driven pumps is about 141 lakh with compounded annual growth rate of 13.3 % 8.6% compound growth rate per annum
·
Share in overall electricity consumption is about 30%
· Lack of reliable and good quality power supply to this sector has led to own captive
·
Agriculture supply is predominantly high loss due to longer HT/LT line and misuse of single
· generation by many industries, hence reducing revenue share of utilities
phasing period
Extensive scheduled and unscheduled load shedding
·
HVDS is being implemented in many states
·

6.2
SBU Power System Solutions Vidushi

Vidushi-Transmission & Distribution Information GIS based simulation and on screen analysis Electrical network tracing GIS based Reliability & Load Flow analysis
Management System for better decision making

Consumer
Indexing

Consumer & Vidushi Plug-ins

Asset data
Energy (Powered by
SAP ERP SAP ISU Meter Data Accounting
SAP NetWeaver R )
Mass Bill Generation at billing center Generation of Unique Consumer Identification
Meter Reading Number

Meter
SAP Netweaver XI Reading

Utility Distribution SAP NetWeaver Web Application Server

Management System

On-spot Meter Reading and Bill Generation Distribution Network Manager - Hierarchal
representation of network up to end consumer

Generation of Exception Report Automation of New Connection release process Capturing of meter details and online status Collection of detailed information of different
updation assets owned by Utility

6.4
SBU Power System Solutions Vidushi

1. Generation of MIS reports 2. Trend analysis for better decision making 3. Technical loss calculation and analysis

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
 SBU Power System Solutions SG61

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 1. Online energy data analysis and reconciliation 2. Substation SLD with Asset details 3. SLD of electrical network 4. Electrical network status at LT level

! 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 5. Real time energy trend of substations, feeders, 6. Substation wise energy auditing 7. Revenue management using financial audit 8. Real time energy trend at Feeder level
distribution transformers & consumers

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

9. Alarm status in control room 10. SG61 theft detection system 11. GPRS/CDMA meters for online data analysis 12. Integration of PLC (Power Line Communication
and MIS Meters) of Singapore Technologies

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

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
Power System Solutions Client List
UPPCL, Lucknow JVVNL, Jaipur EPC Projects
GIS Mapping, Consumer Indexing, Database preparation, Monthly Meter Reading along with load survey, logging PSEB, Patiala
Bill generation, Bill Distribution, Disconnection, of tamper events, wiring verification and their analysis RGGVY works covering 17 Districts of Punjab.
Reconnection, DT wise Energy Accounting for Lucknow, using CMRI and web based software for analysis and JdVVNL, Jodhur
Varanasi, Bareilly, Gorakhpur, Moradabad and Allahabad generation of MIS reports for various categories of 5,000 RGGVY works for Hanumangarh and Sriganganagar
city for 8.5 Lac consumers. no. of consumers in seven circles of Jaipur Discom for a Districts.
period of 3 years. AVVNL, Ajmer
Urban Focus Programme for Banswara and Chittorgarh
UPCL, Dehradun circles.
MSEDCL, Maharashtra
GIS Mapping, Consumer Indexing, Load flow studies, AVVNL, Ajmer
Energy Loss calculation, Meter Reading, Bill Generation, Digital Camera based photo meter reading for 13.5 Lac Feeder Renovation Programme for Banswara and
consumers. Chittorgarh circles.
Bill Distribution for Dehradun, Rudrapur circle covering
3,29,312 consumers. MVVNL, Bareilly JVVNL, Jaipur
Meter reading, spot billing, revenue realization, Feeder Renovation programme for Bayana division
disconnection, reconnection, DT wise Energy under Bharatpur circle.
BEST, Mumbai Accounting for 89,601 consumers. DHBVN, Haryana
WBSEDCL, Kolkata HVDS / LVDS works under “OP” circle Gurgaon
Business process Automation System including Spot Billing for 10,45,959 consumers covering 3 zones, DHBVN, Haryana
Distribution Information Management System 11 circles, 20 divisions, 50 supply stations and web Feeder Segregation Programme under “OP” circles
(Connection management, Billing, Asset Management, based software for MIS. Hisar and Gurgaon.
Network manager, Consumer Indexing, energy Audit, Torrent Power
Meter Management, Consumer Information System) Meter reading of 2,200 Distribution Transformers of
covering 10 Lac consumers, Automatic Meter Reading for Bhiwandi circle using CMRI and data analysis using
feeders, Distribution Transformers and consumers, Load software.
Forecasting, ABT Metering, IVRS based Call Centre and DHBVN, Haryana
Camera based Spot Billing for 2 Lac consumers etc. Digital Camera base photo meter reading for 50,000
consumers.
PSEB, Patiala
JDVVNL, Jodhpur
Meter reading and billing for AP 53,000 consumers.
Spot billing for 10 Lac consumers for a period of 3 years The Ahemdabad Electricity Co. Ltd.
and Supply, installation and commissioning of Web based Mapping of Transformers and Consumer Indexing for
software covering 100 sub-divisions connected on WAN. 2,20,000 consumers.
BSES Rajdhani Power Limited
Survey, Electrification, Meter reading / Bill
JVVNL, Jaipur distribution.
NDPL
Geographical Positioning survey, GIS, Consumer
Survey, Mapping, Sequencing, marking / painting of
Indexing, Asset Coding for 5 Lac Consumers, integrated
poles, Meter Reading Energy audit for loss tracking and
web based software covering 50 locations on WAN having
Revenue Management.
GIS, consumer Indexing, Asset Management, Energy
Reliance Energy
Accounting, CRM, Consumer Billing, Analysis, collection
Survey, design, engineering, BOQ generation with
and linkage of spot billing / camera based billing system
complete project report of LT clean up system.
and Interface with SCADA system.
6.7
Engineering Procurement and Construction

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.

7.1
 connectgaia.com
Energy Today – The Startling Reality
The earth is facing a severe crisis. On the one hand we lack adequate secure supplies of connectgaia.com works through one or more intelligent devices installed at user premises
affordable electricity and on the other we are faced with the environmental harms of based on an organisation's business requirement. There is no software to install or maintain nor
generating and consuming too much of it. 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
Added to this, power loss occurs at all levels of charts that pinpoint energy consumption trends quickly.
production, transmission, distribution and TECHNOLOGY FUEL RESERVES

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consumption. At a macro level as a result of connectgaia.com's unique Virtual Network allows you to group & label 'metering & controlling

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disconnected islands of energy and peak load INNOVATION &
points' in a logical manner to suit your requirement, regardless of how your buildings or plants

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ENERGY are wired. connectgaia users can also compare energy use across several facilities, from a

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scenarios and numerous other variables that

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result in peaks and troughs that are difficult to PRICING CAPACITY
single account. With this solution, users can switch on or off electrical/electronic equipments

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CLIMATIC CHANGES

cater to. And at the micro level, power wastage from remote locations through their secure web page, effecting 50% saving worldwide.
results from negligence, convenience or simply a POLLUTION ENVIRONMENT PRESERVING

lack of manpower resources, for e.g. machines

IMPACT ECOSYSTEMS
The intelligent device installed at user premises communicates with thousands of sensors –
and equipment idling, lights that remain burning Temperature, Pressure, Flow, CO2 level, Humidity, etc. Hence, the power advantages of this
in broad daylight. 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.
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 BUILDING 2 BUILDING 1

connectgaia.com is the enabler for the Intelligent Grid. At one level of the grid is the Power BUILDING
FACILITIES
Highway, which flows from Power Plants, Transmission Towers, through Substations and MANAGER

Transformers to the End User. When this is superimposed with the IT Highway with Intelligent INTERNET OFFICE C
Meters and Sensors, Remote connect/disconnect of Power and the World Wide Web, it gives birth OFFICE A
CLOUD

to an intelligent system.

How does the connectgaia.com solution work?

connectgaia.com is a low cost web based solution that allows power consumers to MEASURE, OFFICE B
VISUALIZE, ANALYZE, CONTROL AND SAVETM electricity in Real-time, Anywhere, Anytime –
across the Enterprise. The solution leverages advanced metering, sensor, proven IP CAFETARIA
GYM
communication technologies and a robust IT backbone to bring intelligence into electricity
consumption.

8.1
 connectgaia.com
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
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.
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.
8.2
 connectgaia.com
Accessing the connectgaia.com portal MEASURE:
connectgaia.com solution can be accessed over the internet anywhere and anytime. You Dashboard: lets you customise all the important reports, which you would like to view at
simply need to create a username and password once the solution is installed at your premises. regular intervals, on ONE SCREEN.
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 VISUALIZE:
the user. connectgaia.com core application handles device provisioning, package
Reports & Graphs:
subscription and other back office functionality.
connectgaia.com solution offers
following reports, which will help
you visualize the energy
requirements of your organisation
and plan accordingly.

Instant Parameters
Load Profile Energy Consumption

Portal features
connectgaia.com enterprise portal is built on the latest IBM SOA platform and offers the
following features:
MEASURE, VISUALIZE, ANALYZE, CONTROL & SAVETM

8.3
 connectgaia.com
Energy Distribution
Trend Monitors
ANALYZE:
! 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.
CONTROL:
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.
SAVE:
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.
connectgaia.com – a holistic solution
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
Empowers you, enriches your life
! 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
connectgaia.com enables users to:
! 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.
8.4
 connectgaia.com

Intelligent Lighting Unit

Street-lighting Management - BEST, Mumbai
Features Benefits
Programme overview:
Centralized operation Convenience of operation and flexibility of Pilot project for automated operation of 10 SLPs of Dadar, Mumbai
monitoring
Calendar/Time Based Allow to operate the network as per the Programme objectives:
Operation Management: Automatic operation/ remote management of street lights through
Scheduling astronomical conditions
time based or calendar based scheduling.
Remote Operation Provides ease accessibility, usability, Asset Management: Online Health Monitoring of equipments enabling quick fault detection.
management & control Power Supply Monitoring: SLP wise monitoring of energy consumption, voltage fluctuations,
frequency profile, load profile pattern, power factor etc.
In-built power and No separate cabling to implement
data transmission connectgaia.com solution Programme design and implementation strategy:
Enhanced service Out of the many solutions proposed to BEST, connectgaia.com was the chosen one for its
Automatic mal-function
capabilities in the following domain:
notification online
Saves energy consumption hour – hours ! Operation Management ! Asset Management
Power conditioning &
- Calendar Based Scheduling - Online health monitoring
voltage regulation during low traffic time zones - Astronomical Scheduling - Enables Quick Fault
Flexibility of operation Anywhere, anytime, precise control - Need Based Scheduling – Detection
ON/OFF operation ! Power Supply Monitoring
Historical logs Provides trend analysis, load forecasting, - Remote Management - SLP wise electrical
etc. parameters
Quick fault Improved system uptime & customer - Voltage fluctuations
identification and satisfaction
restoration Conclusion: Before the installation of
Asset management Better capacity utilization, reduced connectgaia.com intelligent street lighting
system, the average operation hour of street
maintenance costs lighting system was approximately 11.23
connectgaia.com ePOD hours and annual energy consumption of each
SLP 35000 kWh but with the installation of
A green switch providing real time monitoring & control of electrical connectgaia.com, BEST could manage their
equipments street lighting and public area lighting
! Single phase metering (16, 20 and 25 Amp.) network better leading to considerable
! Compatibility with European, US, South East Asian and Indian Sockets annual energy savings of 56852 kWh/ annum.
! Remote On/Off This has provided BEST with an intelligent
! Wireless communication - WiFi/Zigbee system enabling optimization of its
! Acts a child to connectgaia.com mother unit manpower and assets leading to savings.
! Scheduling and Alarms

8.5
 KLG Systel - National Presence

Shimla
Dehradun Varanasi

(Head Office)
Gurgaon New Delhi
Allahabad
Lucknow
Jaipur

Bhopal

Vadodara

Kolkata

Jamshedpur
Mumbai
Pune

Plot No. 70A, Sector - 34

Gurgaon - 122004 ( India )
Hyderabad
Tel: +91-(0) 124-412 9900
Fax: +91-(0) 124-412 9999
Email: investor@klgsystel.com
Website: www.klgsystel.com
Bangalore

Trichy Chennai