IOT- Insight into Industry Trends

- The Path to Top Quartile Performance

Jagdish Pranami – DGM & HOD Electrical Instrumentation,

SRF Limited, Dahej
 Introduction Speaker

Name : Jagdish Pranami

Designation : Dy. General Manager (Electrical & Instrumentation)

SRF Limited – Gujarat

Industrial Experience : Projects , Operation & Maintenance of

Heavy chemical , Fine chemical , Fluoro-chemical, Specialty
chemical , Power

Key responsibilities:
Innovative projects
Designing concepts
Project Management
Maintenance
 Early Adopter's Experience: SRF Limited
Company Profile

• A legacy of more than 100 years – lineage of Sir Shri Ram & Dr. Bharat Ram
• Established in 1973, SRF is a leading Indian multi-product industrial group
• Corporate office at Gurgaon, near New Delhi
• Company Turnover of INR 6000 Cr
• 11 manufacturing locations
1. 9 in India
2. One each in Thailand and South Africa
• Selected TQM in 1991 as the methodology to drive quality
• Technical Textiles Business successfully challenged the Deming Prize in 2004
• Bhiwadi unit of Chemical Business successfully challenged the Deming Prize
in 2012. 4
 What is IoT and IIoT?
The internet of things, or IoT, is a system of interrelated computing devices, mechanical and digital
machines, objects, animals or people that are provided with unique identifiers (UIDs) and the ability to
transfer data over a network without requiring human-to-human or human-to-computer interaction.

A thing in the internet of things can be

any natural or man-made object that can
be assigned an IP address and is able
to transfer data over a network such as,

v A person with a heart monitor implant

v A farm animal with a biochip transponder

v An automobile that has built-in sensors to

alert the driver when tire pressure is low

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 What is IoT and IIoT?

• The internet of things is also a natural extension of

SCADA (supervisory control and data acquisition), a
category of software application program for process
control, the gathering of data in real time from remote
locations to control equipment and conditions.
• The hardware gathers and feeds data into a computer
that has SCADA software installed, where it is then
processed and presented it in a timely manner.

Last Generation First Generation

SCADA IIoT

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IoT Applications

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 IIoT - History

• Kevin Ashton, co-founder of the Auto-ID Center at

MIT, first mentioned the internet of things in a
presentation he made to Procter & Gamble (P&G)
in 1999.

• Wanting to bring radio frequency ID (RFID) to the

attention of P&G's senior management, Ashton
called his presentation "Internet of Things" to
incorporate the cool new trend of 1999: the
internet.

• MIT professor Neil Gershenfeld's book, When

Things Start to Think, also appearing in 1999,
didn't use the exact term but provided a clear
vision of where IoT was headed.

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Industry 4.0 - Evolution

1st Revolution 2nd Revolution 3rd Revolution 4th Revolution

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SCADA – An Overview

Machines Manager Reliability Manager HSSE

(Health, Security, Safety, Environmental)

SCADA Operator Console

Cloud
Network LAN Process Engineer
Server

Controller

Wireless Gateway

Analog Input Wireless Input

Digital Input / Output
Analog Output
Connected Services are based on See, Decide, Act
Data Monitoring

Decide
Expert Analysis

Data Collection Analytics and Action

See Act

On-Premise Sensing and Repair Recommendations,

Data Collection Collaboration, or Services

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Application for Safety Data Display from Remote Area (1.5 Km)

CO & ETHYLENE GAS 4-20mA Analog Signal to Entire wireless

STORAGE Wireless Transmission infrastructure/Network

DCS Graphics
ANTENNA FOR SIGNAL TRANSFER WIRELESS GATEWAY

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 Wireless Implementation in Tank Farm
Challenge:
• Tight schedule for green field specialty
chemical project
• Space constraints with variety of product
manufacturing in the same location
• Diversified Manufacturing processes
• Elevated process units with multiple recipe
production
Applications:
• Process measurements Utilities and Tank
Installation in Utilities & remote monitoring area
Farm area
• Remote Data measurement in the
Hazardous Chemical storage area
Solution:
• Wireless networks were deployed for Pressure,
Level , Temp and Remote measurements in
process plant WirelessHART mesh network architecture
 Benefits of IIoT
Overall Benefits
• Monitor their overall business
2018: Implemented Wireless
processes Pressure Gauges that
• Improve the customer experience Improved Worker safety
• Save time and money
• Enhance employee productivity

n
tio
• Integrate and adapt business models 2017: Implemented Wireless Analog

lica
• Make better business decisions Multiplexer that Enhanced Productivity

ep
of employees
• Generate more revenue

&R
n
tio
2016: Implemented Wireless Pressure and
Results - SRF 14

• Worker tracking improved op Temperature Transmitters on remote equipment

Ad
that Improved Process Reliability
• Improved safety
• Productivity improvement 30 %
2015: Implemented Wireless HART
• Cost saving 11 %
Technology that resulted in Cost saving &
• Quicker startup saving @ 70% Quicker startup of plant
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Chiller Condition Monitoring – IIoT Implementation

SCADA Operator Console

Cloud

PLC

Real Time Condition

Monitoring
Chiller Real Time Data
Analytics
 Challenges & Opportunities in Mobility, IT infrastructure & network
security in chemical process industries

Maintenance challenge
• Pump failures lead to severe downtime
• Maintenance team gets to know only after the occurrence of the failure
• Condition Monitoring lets maintenance team get notified of situation prior to failure by continuously
monitoring the process parameters
• All kind of mechanical equipment can be monitored and uptime of assets can be increased

IoT Gateway
Pump Parameters
Maintenance Engineer 16
 Challenges & Opportunities in Mobility, IT infrastructure & network
security in chemical process industries

Infrastructure challenge
• Outdated/Obsolete systems (DCS/PLC) have to be upgraded as and when necessary in order to
prevent the loss of data
• If the existing system is not compatible for digital transformation, migrating to a new system might
be the best option to stay in race
• Network must be capable of transferring such a humongous data and secure enough to thwart
cyber assaults

MOD Migration

Outdated System Compatible System

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 Challenges & Opportunities in Mobility, IT infrastructure & network
security in chemical process industries

Mobility
• Maintenance team uses FLP android based smartphones
• An integrated HMI fetching data from SCADA, PLC, DCS and other systems can be handy for the
operator

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IIoT Liability

Control
Systems
Network
Connectivity
Possible Threats:
• System Malfunction
Weak
Security
• Cyber Assault
• Access to Control System
• Information Theft

Plant Control System can be exposed to Cyber Attacks

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 System Malfunction

Possible Threat
• A deeper level of automation based on IIoT systems
are done, for instance, automatic ordering of
inventories based on IIoT data on cloud, then
malfunction of instruments / glitches in
networking/programming may lead to financial loss

Prevention 20

• A manual check has to be made mandatory in case

of taking actions upon IIoT data

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 Cyber Assault

Possible Threat
• The other applications in the device in which the
IIoT application is accessed might be prone to cyber
attacks

Prevention
• Built-in protection
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• Encryption
• Risk Analysis
• Authorization

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 Access to Control System
Possible Threat
• Intruder can gain the access to process control
network
• Intruder can alter the opening of critical valves that
may lead to disaster

Prevention
• Since the flow of data is
unidirectional, i.e. only process
data are fetched from control 22

system through OPC channel

and the communication with
cloud is through remote system,
this threat can be eliminated for
our case
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 Information Threat

Possible Threat
• Since the data points are from the critical
processes, a breach can expose the history of
parameters of the critical processes to the
competitors
• A diligent work around of this data combined with
our purchase data(which products are bought,
which equipment are purchased), other non critical
data can give a great all-round idea of the patented
processes

Prevention
• Built-in protection
• Encryption
• Risk Analysis
• Authorization
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THANK YOU