Predictive maintenance policy adopted by many industries necessitates an absolute reliability across power plants, utility, transport systems, and emergency services. Maintenance is a critical activity that takes place in production. Machine failures during production can lead to adverse effects on the production schedule, delivery delays, or employee overtime to compensate for the loss.

Digital Blanket® allows thresholds to be set for all the key parameters and warning or alarms are generated when threshold is breached. This provides unified alerts and ticket management for proactive management of energy consumption and equipment across multiple factory sites and ensures that any issues are responded to in structured and time-bound manner. This also helps in smoother functioning of the equipment and improved life

Real-time tracking can avoid potentially critical situations (e.g., voltage surge) due to timely action and can increase equipment life. This means reduction in on-site service costs, reduced down-time and equipment change.

The trends, seasonality over the period (daily, weekly, monthly etc.) can provide good insights to the business and help optimize energy costs. Thresholds can be set for various parameters and whenever there is a breach, an immediate alert can be sent to concerned people/teams. This can be further integrated into a helpdesk tool for SLA tracking.

Alternate Text
Alternate Text

Digital Blanket® Smart Plant Productivity gains

  • The factory staff productivity is enhanced due to anytime, anywhere data access. This usually helps the client optimise resource strength across sites.
  • Provision of on-demand reports reduces need to manual collation and maintaining documents from multiple sites.
  • Exception based management removes the need to have an operator available in front of the system all the time.
  • Operator can get alerted only when their intervention is needed.
  • Digital Blanket® monitors the functionality of HVAC, Mechanical, Electrical, Plumbing as well as key parameters and settings in DDC / SCADA configurations to alert on anomalies in real time. These alarms include Delta T mismatch, CO2 level, Temperature Levels, Blower Status, Pressure Levels, Chilled Water Valve Status, duct leakages, chiller pump status etc.
Alternate Text

Predictive Maintenance : Leading to Energy & ESG Management

Energy monitoring is mostly a manual activity, which is prone to errors. Energy bills are available, but they only act as a ‘rear view mirror’. Digital Blanket® provides a very structured approach to Energy Management.

Energy Measurement & Trending

Energy Metering, Source and Load, Trend energy consumption by hour, day, week, month across system, zone, floor, building etc.

Energy Data Qualification

Qualify all collected energy data for data quality and reject outliers due to faulty systems. Prepare data for energy analysis.

Energy Analysis

Analyse energy consumption patterns by site, machine or project. Identify peak loads and factors, power quality issues, compare actual usage vs set targets.

Energy Benchmarking & Baselining

Baseline energy usage for each site / process / shift etc. Benchmark energy usage with industry benchmarks for the specific city / segment / weather. Compare buildings / sites / floors through Energy Performance Indices – per unit area or per occupant or per system.

Energy Forecasting

Use statistical models to predict energy consumption and hence prepare for proactive actions.

Energy Costing

Allocate energy cost by business group, department, area, building, grid, green energy, diesel generator and by load – HVAC, Lighting, UPS, Machinery etc. Gain understanding of energy costs and what can be optimized.

ESG Sustainability Reporting

Energy consumption reported against equivalent CO2 emissions or trees saved. Report against set targets.

Energy Optimization

Review energy usage and identify opportunities for reducing wastage including better scheduling, better fault detection, load optimization etc.