Digital factoriesTop 10 LoRaWAN solutions for industrial IoT

Toxic Gas Monitoring SolutionCO, CO2, Temp, Humidity, PPM,

PM2.5

Temperature and Humidity

Monitoring SolutionHeat Loss, Measurement,

Threshold breach (Boilers, Ovens),

Surface monitoring at various

places viz Bus Bars, Transformers,

Induction Motors, Data Centres

Plant Energy Monitoring with

Machine DataModbus to LoRa Converters, Data

Extraction and Transmission from

machines

Machine Trip Status

Monitoring Solution – NONCMonitor Industrial O/P via NO-NC,

VFD Tripping, CNCs, Compressor

Tripping, Breaker Tripping

Pressure MonitoringDifferential Pressure

(atmospheric) Monitoring,

Weight Sensing

Gas and Water/Fluid Flow

Monitoring Solution Flow Monitoring, Gas Pressure

and Consumption Monitoring,

Fluid (Oil, Water, Chemical

fluids) level monitoring

Load Monitoring Solution-

Load Protector DeviceTransformer Monitoring, Main

Distribution panel, Sub

Distribution Panel, Motorised

Control Panel etc.

Smart Plant Lighting – Single

or Group Controlling Scheduling, Dimming,

Astronomical Calendar Sync,

Luminosity Control etc.

Movable and Immovable

Assets TrackingTrack asset location, monitor

temperature and anomalies

remotely

Manual Call Point / Service

Request ButtonEmergency Alarms, Repeat Orders,

Maintenance and Support

Requests, Pantries, Customer

Experience Centres

Worker Safety Watch – People

Tracking

Fall detection, Body temp,

Indoor Tracking, Idle time

Access Tracking

Manage & Monitor Your

Plant Area Access

Digital factories, powered by Tata Communications

Use case 1 : Plant energy monitoring with machine data (MODBUS to LoRa)

The Challenge

• Distributed energy meters across the plant

• No control over energy usage & maximum demand

• Energy planning depends upon electricity bill at the end of

each month

• Difficulty in energy accounting

• Low System Power Factor at load ends

• Inability to study the load characteristics/profiles

• No data to figure out Transmission & Distribution (T&D) loss

Solution

IoT based Energy Monitoring Solution with Modbus to LoRa

Converters

• Wireless Modbus RS 485 to LoRa Converters fixed onto

traditional energy meters

• Energy management application on IoT Platform

• Custom energy monitoring reports and dashboards

Benefits

• Benchmarking energy consumptions

• Specific level Energy Consumption Accuracy

• Reduction in Distribution Loss

• Reducing Peak Demand

• Eliminating equipment Idle Time Operation

• Predictive Maintenance

• Root Cause Analysis

• WAGES Monitoring (Monitors non-electrical parameters like

Water, Air, Gas, Electricity & Steam Generates specific energy

consumption data)

Module technical specification:

Power Supply 85 ~ 280 AC/DC 50Hz

Power consumption <3VA(230VAC/50Hz)

RS485 Input Modbus RTU Protocol

No. of energy meter

supportUpto 10

Module dimensions 108mm(W) x 73mm(H) x 61mm(D)

EnclosurePolycarbonate White/Grey color,

DN Rail mounting

Operating

temperature0-60oC

Energy meters

MODBUS to LoRa Converter

KLGCC Electricity Demand Profile

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Date & Time

Ele

ctr

icit

y D

em

an

d (

kW

)

East Course outgoing feeder West Course out going feeder Driving range outgoing feeder Club House MSB 1 Club House MSB 2 Total demand

Friday MondaySundaySaturday Tuesday Wednesday

Peak demand

Use case 2 : Smart plant lighting with single/group control

Benefits

• Save Money & Energy

• Ease of maintenance & reduce maintenance cost

• Remotely control of street light & monitoring

• Automatically adapt luminosity to needed conditions

• Centralized operations

The Challenge

• Optimize energy consumption, ensure savings , observe

trends

• Centralized control of street lights through application

• Easier management of individual LED warranty

• Street lights should be adaptable with dimming feature as

per requirement

• Street lights should have on and off feature based on the

environmental Sunlight intensity

Solution

• The street lights are factory fitted with LoRa module.

• The module communicates with Tata communications

IOT network.

• The module enables with sharing of power

measurement parameters e.g. Ampere, Voltage, Kilo

Watt Hour (KWH), Kilo Watt (KW), Power Factor.

• The module takes command web portal via IOT platform

to switch ON/OFF or Dim the concerned street light(s).

• The controlling commands can be scheduled for

group(s) of street light(S).

Individual light control

Group light

control

Analysis ParticularsSodium

vapourLED

LED with on/off

automation

LED with On/Off +

Dimming

Voltage 250V 230V 230V 230V

Current 1.6A 0.91A 0.91A 0.91A

Wattage 400W 210W 210W 210W

Working hours 12 12 9 6.75

Units consumed per 12 hrs 4.8 2.52 1.89 1.42

Unit rate ₹ 12.00 ₹ 12.00 ₹ 12.00 ₹ 12.00

Consumption cost per 12 hrs ₹ 57.60 ₹ 30.24 ₹ 22.68 ₹ 17.04

Annual consumption cost per lamp ₹ 21,024.00 ₹ 11,037.60 ₹ 8,278.20 ₹ 6,219.60

Annual consumption cost per 100

lamps

₹ 21,02,400.00

₹ 11,03,760.00 ₹ 8,27,820.00 ₹ 6,21,960.00

Savings wrt Sodium vapour ₹ 9,98,640.00 ₹ 12,74,580.00 ₹ 14,80,440.00

Appx. first time cost15 lacs(18 month payback period)

5.5 lacs(14 months payback period)

Recurring maintenance costs from

2nd yearNil 15-17% - 2 months payback period

Use case 2 : Smart plant lighting with single/group control

47.5% 60.0% 70.4%

Use case 3 : Worker safety and tracking

The Challenge:

• Lack of visibility in worker movement across the plant

• Traceability of employee during emergency evacuation

• Employee movement in hazardous/ restricted area

• Attendance of employees

• Safety of women employees during transportation

• Alert for unexpected accident

Solution:

• Tracking of employee/worker

• Detection of abnormal conditions

• Fall and Immobility detection

• Alert indication for access to unauthorized area

• Heart Rate Monitor

• Skin temperature Monitor

Tata Communications IoT Employee Health

and Safety watch

Use case 3 : Worker safety and tracking

Benefits:

• Improve worker safety

• Help in quick emergency response

• Provide alerts if worker in hazardous/radiation/restricted

area

• Reduction in operating cost by delivering timely

information

• Improve employee satisfaction index

OFF

NO

ENTRY

ON

SOS

45o

SUPERVISOR PROXIMITY BEACON

HAZARDOUS AREA

SKIN TEMPERATUREWEARABLE

ENTRY BEACON

HEART RATE

NO ENTRY

Use case 4 : Moveable and immovable asset tracking

The Challenge

• Higher turn around time for material shipments

• Lost assets - difficulties in locating

• Idle assets - reduced productivity

• Real Time tracking of asset movement

• Alerts for breaching geofence

• Pay per Use of Assets

• Asset Health Monitoring Challenges

Benefits

• Less time spent tracking assets

• Save money from inventory shrinkage when a lost asset

must be replaced

• Optimum utilization of resources or asset

• Low maintenance costs thanks to LoRa sensors low

power operation, ensuring batteries can last longer

• Employee safety

• Monitor Asset condition remotely

Solution

• GPS, Accelerometer, BLE, WiFi, AGPS, Temperature &

Humidity

• Longer battery life

• Geo-fence & POI

• Facility to integrate analogue or digital sensors

• Asset Tracking history

A,B,C are LoRa based asset tracking devices

(A)

(B)

(C)

Use case 5 : Toxic gas monitoring solution

The Challenge

• Wired Infrastructure for connecting sensors

• Higher installation and infrastructure maintenance costs

• Large plant area difficulties in cabling across the plant

• Requires immediate alerts on poisonous gases outbreak

Solution

• Wireless Environment Sensors

• Industrial Grade Gas Detectors – Detects various

Hazardous Gases

• Central Monitoring Station with Alarms

• Detects - CO, NO2, H2S, Propylene, Combustibles,

Sulphur Dioxide, Phosphine and Others

Benefits

• Monitors and Alerts Poisonous Gas outbreaks instantly

across the plants spread across few sqkms

• Central monitoring hub for health status of each sensor

and the alarm status is displayed

• Complete wireless system for easier installation and

maintenance

• Fewer single boosters or routers due LoRa technology

advantages

Cloud based dashboard application

Use case 6 : Temperature and humidity monitoring solution

The Challenge

• Manual Temperature and Humidity readings

• Distributed Temperature and Humidity sensors across

plants

• Delayed alerts on thresholds breaches and alerts

generation

• Costlier wired infrastructure across the plant

Solution

• Measurement range -40°C to + 85°C Accuracy ±0.5°C• Measurement range 0%RH to 100%RH Accuracy ±2%RH

• Battery Enabled

• Plug & Play device

• Low Powered

• Light weight & easy

• to mount

Benefits

• Monitors and Alerts Temperature and Humidity changes

instantly across the plants spread across few sqkms

• Central monitoring hub for health status of each sensor

and the alarm status is displayed

• Complete wireless system for easier installation and

maintenance

• Fewer single boosters or routers due LoRa technology

advantages

Live installation of

environment sensors

Tata

Communications’

environment

monitoring

device

Use case 7 : Gas and fluid flow monitoring solution

The Challenge

• Need for a completely automated reading, monitoring,

alerting metering devices with less infra and operating

costs

• Need for Automated Billing and consumption analysis

• Need for directed demand and supply planning

• Easy tampering and theft of meters

• Meters have been removed and updated in the system as

under repair, but water consumed

• Faulty meters, thus faulty readings or no readings

Solution

• Billing Management —Payment information, service

connects and disconnects, tariff units of measure,

load control signals, and fraud detection

• Data collection and Geo map integration

• Device and application controls, standard protocol

support

• Monitoring and diagnosis

• Data analytics based consumption & many other

parameters

Benefits

• Provides real-time billing information, reducing estimated

readings and re-billing costs

• Monitors Tampering, Theft and Alerts

• Increases cash flow by allowing quarterly or semi-monthly

accounts to be converted to monthly billing

• Reduces customer complaint calls and increases customer

satisfaction

• Helps in Demand Forecasting and Supply planningFluid flow monitor and cloud based dashboard application

Use case 8 : Machine trip status monitoring solution

The Challenge

• VFD, CNCs, Compressor, Breaker Tripping Monitoring

• Remote Industrial Alarm Monitoring

• Remote Transformer Trip Monitoring

Solution

• Status change report – Reporting based on port

change state.

• Periodic Report - Report current status of ports

every

• Self-test report – Self-diagnose ports if they are

functional

• Self-test seconds – Self-diagnostic time period in

minutes.

Benefits

• Proactive Monitoring of NONC Switches

• Quicker resolution of Tripping in Machines

• Higher continuity of operations

Use case 9 : Remote monitoring and control of machines

The Challenge

• Lack of control on machines – no view on idle time,

production time

• No voltage and current consumptions monitoring

• No automatic switch off or on based on threshold

• Send alerts on the power fluctuations

• Higher infrastructure costs of the wire based controls

Solution

• Simple solution for remote control applications where

faulty wire maintenance is not possible or practical

• Controlled through application remotely

• Devices available for Single Phase and 3 Phase

Applications

Benefits

• Remotely control machines through web or mobile

application

• Instant view of machine idle time and production

time data

• Instant alerts on power failures

• Minimal infrastructure setup costs due to wireless

plug and play feature

LoRa based smart switch

Use case 10 : Load monitoring and protection solution

The Challenge

• Machine failures with short circuits due to higher load

fluctuations

• No automatic on-off of machines due to load imbalances

• Lack of instant alerts during voltage, current, earthing

leakage and temperature threshold breaches

Solution

• LoRaWAN based Load Protector device

• Load/Machine/AC protection features – Under

Voltage/Over Voltage, Under Current/ Over Current,

Open Neutral, Earth Leakage and Temperature Monitoring

(Upper Limit/ Lower Limit)

• Load Cut off – Has inbuilt relay to cut off

load/machine/AC

• Fire retardant Device casing

Benefits

• Remote control of any Load/Machine/AC or other

equipment’s via application

• Protection against any mis-happenings due to power

fluctuations

• Accurate Energy/Power consumption monitoring and

accounting

• Built in Temperature Sensor with extended half meter

cable with thermostat

• Inbuilt Relay – Trips and protects/saves your device from

any failures

MODBUS converter

Transformer

sensor

aggregator

More use cases

Fluid level monitoring Pressure monitoring Access tracking

Manage & Monitor Fluid Levels

in your Machineries

Monitor the Pressures data of

Machines’ differential Pressure

(atmospheric) Monitoring. We

can also provide Weight

Pressure Sensing solutions.

Manage & Monitor Your Plant Area

Access

Tata Communications is building an IoT ecosystem on LoRaWANTM. Here is why

Flexible deployment and customization of LoRa®

network at remote manufacturing plants

LoRa® uses license free 865-867 MHz ISM bands

LoRa® has very wide coverage range about 5 km in

urban areas and 15 km in suburban areas

LoRa® consumes less power and hence longer battery life

Each LoRa® Gateway device is designed to handle 1000s of end

devices or nodes

Longer Battery Life for

wireless sensing devices –

More than 1-5 years

(based on data frequency

set) for a non-

rechargeable battery

Private customized LoRa

IoT Network setup

exclusively for IoT

applications across the

manufacturing plant.

Long Range – Sensing

devices can communicate

with LoRa base stations

installed 5-10 sq. kms

across the plant without

any signal boosters.

NO SIM Card – Embedded

LoRa RF Module

communicates with the

base station on license

free band (865 MHz -867

MHz) in India

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