Chemical plants throughout the world are facing turbulent times throughout their value chain. From research and development to production and distribution, the industry is facing pressure both internally and externally. These include stringent government regulations, compliance, mergers & acquisitions, rising energy and raw-material costs and production inefficiencies.
SENSYS with its open, scalable and simplified architecture lays strong foundation to help companies achieve operational excellence. We offer customized solutions in various domains including HMI/SCADA, Plant Information Management System, Overall Equipment Effectiveness, Energy Management, Manufacturing Execution System and Business Application Integration thus empowering the companies to achieve their manufacturing goals by maximizing the true potential of real-time information.


Operator Level/Centralized HMI

SENSYS provides state of the art, customized, high resolution representation of plant floor operations and processes in a Chemical plant. We ensure complete visibility and traceability within the system and enable the management to perform monitoring and control on real-time basis. Chemicals production involves several methodologies and processes such as steam/air reforming, thermal reforming, reduction, reforming, steeping, xanthation, dissolving, synthesis, gasification, compression, filtering, water treatment etc. We have expertise in providing customized dashboards to cater all the processes efficiently and effectively thus ensuring product quality and plant efficiency.

Plant Information Management System

SENSYS offers state of the art Plant Information Management System with advanced historian capabilities that allows data collection, data storage, data archiving and instant data retrieval upon user request. Chemical plants comprise multiple processes which lead to a large number of parameters and KPIs to be calculated and controlled. IntelliMAX enables clients to centralize data from various data sources and provides a central platform to access historical data. User can perform advanced trending and charting analysis on critical parameters such as process temperatures and pressures, steam generation, steam consumption, catalyst performance, heat transfer coefficients, methane slippage, steam to carbon ratio, H2/N2 ratios, cold and warm ammonia product flows, polytropic head and efficiencies, speed, compression ratios etc. Reports can be generated on KPIs such as production (tons)/day, electricity consumption (kwh/t), steam/heat consumption (Gcal/t), water consumption (m3/t), wastewater (m3/t), CO2 emission (m3)/day, natural gas consumption (m3/day,) etc. This data can be used to perform in-depth analysis on both processes and operations to get better insights and improve productivity and efficiency. Plant Information Management System shall provide a full collaboration module that shall include automatic emails and SMSes of critical alarms and events. Collaboration module shall have the flexibility to entertain multiple users, groups, and departments.

Energy Management

Chemical industry is one of the most energy intensive industries owing to the nature of processes involved. Our Energy Management System collects data from all the energy meters in the plant and provides specific energy dashboards that enable operators to analyze the current situation and take necessary measures to optimize energy usage. Our energy management solution provides visibility to entire system by providing real-time monitoring and insights of energy parameters such as KWH/Ton, MJ/Ton etc. for both supply and demand. It has the capability to provide in-depth analysis via advanced trending, charting and reporting on energy consumption by source be it Water, Gas, Steam or Electricity. By having an accurate data about energy consumption, user can better estimate patterns and perform in-depth analysis to optimize the supply and demand for energy. We offer load balancing and optimization taking into account the demand in real-time. This results in secure and reliable energy availability, improved energy efficiency and increased productivity. Careful consultation, plan and execution can result in saving 10% energy costs over two years of operation.

Condition Based Maintenance

Condition based maintenance is a maintenance strategy used to improve the effectiveness of maintenance programs and reduce the life cycle costs of assets. It plays a key role in the capital extensive chemical Industry where the goal is to maximize the performance of different assets such as pumps, compressors, etc. IntelliMAX caters to Condition based maintenance utilizing the real-time data associated with the asset such as Running hours, Temperature, Pressure, Vibration, Speed, Flow-Rate, Voltage, Current, Stress, etc. and analyzing these to determine the state of assets. These parameters are regularly monitored on real-time basis and the values of the mentioned parameters are compared against their set points to see deviations. Trends can be plotted to analyze the behavior and the maintenance be carried out as per condition.

Overall Equipment Effectiveness

SENSYS’s IntelliMAX EMI solution provides a comprehensive way to monitor and improve the performance of production processes in chemical industry through its OEE module. IntelliMAX EMI tracks key metrics contributing to OEE i.e. availability, performance and quality and provides users contextual analysis at equipment, assembly, facility and plant level. IntelliMAX EMI’s OEE dashboard enables users to analyze Planned vs. Actual OEE, visibility of key reasons causing downtime, knowledge of reasons attributing to performance loss and causes contributing to poor quality. It provides management with key information at plant level such as shutdowns per day, Quality Loss, Speed Loss, etc. This results in better utilization of the assets and production lines which improves productivity and profitability.

Integration with ERP

IntelliMAX EMI has the capability to integrate the plant floor data with other manufacturing and business applications such as SAP, Maximo, LIMS, etc. This facilitates information sharing across various business functions thus improving coordination and ensuring faster decision making. In case of chemical plants, it is vital to integrate all real time information such as production (tons), energy consumption (kwh/ton), quality compliance, raw-material consumption etc. with ERP systems. In addition, condition based maintenance of assets such as pumps, compressors, boilers etc. is vital for improving life cycle cost of plants. IntelliMAX EMI (being SAP and Maximo certified) completely addresses the needs of Plant Floor – ERP integration.