Client
Project Overview
We delivered a centralized boiler and chiller automation solution for Samsung Electronics' Noida plant using Mitsubishi FX5U PLCs and Xarrow SCADA. The system enables real-time monitoring and historical logging of steam production, PNG consumption, water usage, pressure, temperature, and flow, providing operators with complete visibility into critical utility operations.
Faridabad's water distribution runs through 95 remote sites — 22 renny wells, main and secondary boosting stations, and intermediate stations — organised into seven distribution lines. The city needed every site's flow, pressure, tank level, and energy consumption visible in real time at the ICCC, with the data stored for historical analysis. Sites range from deep wells running four 30 kW submersible pumps to boosting stations with motors above 100 kW — none of them previously connected to anything.
Each site received a remote terminal panel built around a Mitsubishi FX5U PLC — digital and analogue inputs for Endress+Hauser flowmeters, pressure and level transmitters, plus energy data captured over Modbus from the site's meter. A local Mitsubishi touchscreen HMI shows operators everything on site; a GSM modem with an M2M SIM transmits the same data over TCP/IP to the ICCC. Every panel runs on an online Eaton UPS with external batteries, so monitoring survives the power failures it's partly there to detect.
At the ICCC, GENESIS64 SCADA hosted on a Dell PowerEdge server (40 cores, 132 GB RAM) aggregates all 95 sites for live and historical observation, with SQL Server 2022 handling storage.
Collecting the data was the beginning, not the point. The platform ingests roughly 4,000 rows every 10 minutes, around the clock — about 3.45 crore rows a month, headed past 330 crore over five years. On top of it, role-based dashboards serve each user what they need: engineering sees motor hours, energy, and maintenance data; billing sees distribution volumes; authorities see site-wise and month-wise comparisons that answer the operational question — is this locality receiving its usual supply, and if not, where in the seven lines did it change?
A city's entire water distribution, previously invisible, now monitored 24×7×365 from one control room — every pump start, every drop in line pressure, every site's energy draw logged and comparable across weeks and years. The system has run continuously since commissioning.
Tell us what runs manually today and what it costs you. A senior engineer — not a sales team — will look at your scope and give you a straight technical answer: what we'd build, how long it takes, and what it's likely to cost. If we're not the right fit, we'll tell you that too.