Case Studies

Challenge

A major thermal power plant required a fully CPCB Schedule IV-compliant OCEMS covering SO₂, NOₓ, CO, PM, and stack flow across two units — with direct data transmission to CPCB and SPCB servers.

Solution

Labtech supplied and commissioned a complete extractive OCEMS with heated sample probes, Peltier coolers, NDIR/UV analysers, PM monitors, and an industrial DAS with GSM/LAN dual-path connectivity to regulatory servers.

Outcome

100% uptime during CPCB audit; Schedule IV compliance achieved within 60 days of commissioning. Real-time data transmission to CPCB server with zero data gaps over 12 months.

Challenge

A combined cycle power plant needed a complete steam and water analysis system covering pH, conductivity, dissolved oxygen, silica, and sodium across multiple sample points — integrated with the plant DCS.

Solution

Labtech designed and commissioned a multi-stream Wet SWAS panel with sample extraction probes, conditioning unit, five online analysers, a local HMI, and Modbus TCP integration to the plant DCS.

Outcome

Cycle chemistry excursions detected within minutes instead of hours. Turbine blade deposits reduced by 40% over the first operating year. Full DCS integration with real-time alarms.

Challenge

A municipal water utility needed real-time visibility of flow, pressure, and water quality across 35 remote pumping stations — with no reliable wired connectivity at most sites.

Solution

Labtech deployed IoT edge gateways with 4G/LTE connectivity at each station, integrating electromagnetic flow meters, pressure transmitters, and water quality sensors into a centralised cloud dashboard.

Outcome

Non-revenue water losses reduced by 22% within six months. Pump failures predicted 48 hours in advance through vibration trend analysis. Centralised monitoring of all 35 stations from a single dashboard.

Challenge

A pharmaceutical manufacturer required a fully automated purified water generation and distribution system with 21 CFR Part 11-compliant data logging, audit trails, and alarm management.

Solution

Labtech engineered a Siemens S7-1500 PLC-based control system with SCADA, automated CIP/SIP sequences, conductivity and TOC monitoring, and an SQL-backed audit trail for regulatory compliance.

Outcome

FDA audit passed on first inspection. System uptime of 99.6% over 18 months. Manual operator interventions reduced by 85% through automated sequences.

Challenge

A large chemical plant's effluent treatment plant required continuous online monitoring of pH, COD, BOD, TSS, and conductivity to meet SPCB consent conditions and avoid regulatory penalties.

Solution

Labtech installed a multi-parameter online analyser panel with automatic calibration, GPRS data transmission to the SPCB server, and a local display with configurable alarm thresholds.

Outcome

SPCB consent conditions met continuously for 24 months. Automated alerts prevented two potential consent violations. Data transmission reliability of 99.2% over the monitoring period.

Challenge

A petroleum refinery required high-accuracy custody transfer flow measurement for crude oil, refined products, and utility water lines — with OIML-certified meters and tamper-evident data logging.

Solution

Labtech supplied and commissioned Coriolis and electromagnetic flow meters across 18 measurement points, with a centralised flow computer, HART integration to the DCS, and OIML-certified calibration certificates.

Outcome

Measurement uncertainty reduced to ±0.1% for custody transfer lines. Reconciliation losses cut by 1.8% of throughput. All 18 meters commissioned within a planned 14-day shutdown window.