Process Automation Intelligence Solutions

Industrial Process Intelligence

Engineering Excellence in Automation

Strong Foundation

With deep roots in process engineering and automation, Prescient Automation helps industries transform their operations through intelligent and innovative solutions.

End-to-End Support

From design to implementation, Prescient Automation delivers customized solutions that streamline workflows, maximize efficiency, and build a foundation for sustainable future growth.

Scalable Systems

Working across a wide range of industries, Prescient modernizes facilities through scalable electrical and automation systems that enhance productivity and support sustainable growth.

Our Engineering Approach

A Partnership Built on Technical Depth

Industrial IoT Implementation

Case Studies

IIoT Monitoring Systems

Real-world implementations of integrated monitoring, analytics & predictive maintenance solutions.

Industrial boiler with multi-screen monitoring dashboard

Live System View

Boiler & SCADA
Control Station

System Online

8.65bar

175°Steam Temp

88.7%Efficiency

— From Data to Decisions —

Sensors

Field
Instruments

PLC

Schneider
M262

HMI

Local
Monitoring

MQTT Broker

Pub / Sub
Protocol

Node-RED

Data
Processing

Database

MySQL
Storage

Dashboard

Grafana
Analytics

Steam Pressure

Real-time

8.65bar

Steam Temperature

Real-time

175.3°C

Water Level

Real-time

68.2%

Boiler Efficiency

Real-time

88.7%

Boiler Sensor Parameters

Steam Pressurebar

Steam Temperature°C

Water Level%

Feed Water Flowm³/h

Fuel Flowltr/h

Flue Gas Temperature°C

Efficiency%

StatusON / OFF

Connection Protocols

PLC↔HMI

Modbus TCP/IP

PLC↔Node-RED

Modbus TCP/IP

Node-RED↔MQTT

MQTT Protocol

Database→Storage

MySQL

Visualization

Grafana

Data Format

JSON

Live System View

Water Filtration & RO
Control Station

System Online

4.2bar RO

12TDS ppm

96.4%Recovery

— From Data to Decisions —

Water Filtration Process Flow (Membrane + RO System)

Raw Water
Source

→

Multimedia
Filter

→

Activated
Carbon

→

Micron
Filter

→

UF / MF
Membrane

→

RO
System

→

Clean Water
Tank

Field Sensors

Pressure / Flow
TDS / Level

Siemens PLC

S7-1500
Controller

SIMATIC HMI

Local
Visualization

IIoT Gateway

Node-RED
OPC-UA

MQTT Broker

Pub / Sub
Protocol

MySQL DB

Historical
Storage

Grafana

Analytics
Dashboard

RO Feed Pressure

Real-time

4.2bar

Permeate TDS

Real-time

12ppm

Clean Tank Level

Real-time

74.5%

RO Recovery Rate

Real-time

96.4%

Key Monitored Parameters

Feed & RO Pressurebar

Raw Water Flowm³/h

Permeate & Reject Flowm³/h

TDS – Feed & Permeateppm

ConductivityμS/cm

pH LevelpH

Raw & Clean Tank Levelm

Membrane Differential ΔPbar

Pump Status & Valve StatusON/OFF

Communication Architecture

Field Devices↔PLC

Analog / Digital I/O

PLC↔HMI

PROFINET

PLC↔Node-RED

OPC-UA / Modbus TCP

Node-RED↔Broker

MQTT Pub/Sub

Alerts

SMS / Email / WhatsApp

Data Format

JSON

Live System View

Desalination (RO) Plant
Smart Monitoring & Automation

System Online

14bar HP

8TDS ppm

97.2%Recovery

— From Data to Decisions —

Desalination Process Flow — Pretreatment + RO System

Seawater
Intake

→

Screening
Filter

→

Multimedia
Filter

→

Bag
Filter

→

Antiscalant
Dosing

→

High Pressure
Pump

→

RO Membrane
System

→

CIP
System

→

Clean Water
Tank

Field Instruments

4–20 mA / Digital I/O

Pressure Transmitters
Flow Meters
TDS / Conductivity
pH / ORP Sensors
Level Transmitters
Temp Sensors

PLC Controller

Rockwell L30ER

High Performance
Reliable & Scalable
Integrated Security
EtherNet/IP Comm.

HMI Panel

Rockwell PV Plus 7

Local Monitoring
Alarms & Trends
Reports
User Management

IIoT Gateway

Industrial PC / Node-RED

Data Acquisition
Protocol Conversion
Edge Processing
Secure Connectivity

Cloud / Analytics

MySQL + Grafana

MQTT Pub/Sub
Flow Logic
Alarm Logic
Real-time Dashboards
SMS / Email / WhatsApp

Field Sensors

Pressure / Flow
TDS / pH / Level

Rockwell PLC

L30ER
Controller

PV Plus 7 HMI

Local
Visualization

IIoT Gateway

Industrial PC
Node-RED

MQTT Broker

Pub / Sub
Protocol

MySQL DB

Historical
Storage

Grafana

Analytics
Dashboard

HP Pump Pressure

Real-time

14.0bar

Permeate TDS

Real-time

8ppm

Clean Tank Level

Real-time

81.3%

RO Recovery Rate

Real-time

97.2%

Key Monitored Parameters

Intake / Feed / HP / Outlet Pressurebar

Raw Water / Permeate / Reject Flowm³/h

TDS — Feed & Permeateppm

Conductivity — Feed & PermeateμS/cm

pH LevelpH

ORP (Oxidation Reduction Potential)mV

Raw Water & Clean Tank Levelm

Feed Water & Permeate Temperature°C

Membrane Differential Pressure ΔPbar

Specific Energy ConsumptionkWh/m³

Pump Status / Valve StatusON/OFF

Communication Architecture

Field Devices↔PLC

4–20 mA / Digital I/O

PLC↔HMI

EtherNet/IP

PLC↔IIoT Gateway

EtherNet/IP

IIoT GW↔Broker

MQTT Pub/Sub

Node-RED→MySQL

MySQL Database

Visualization

Grafana Dashboard

Alerts

SMS / Email / WhatsApp

Data Format

JSON

Condensate Polishing Package in Fertilizer Plant with IIoT monitoring

Live System View

Condensate Polishing Package
Fertilizer Plant — Smart Monitoring

System Online

0.08μS/cm

7.2pH

99.6%Efficiency

— From Data to Decisions —

Condensate Polishing Process Flow — Pretreatment → Polishing → Post-Treatment → Boiler Feed

Condensate
Inlet

→

Strainer
Filter (SC-101)

→

Pre-
Filtration

→

Steam Condensate
Mixed Bed (×3)

→

Primary Mixed
Bed Polishers (×3)

→

Polishing Mixed
Bed Polishers (×3)

→

Post Treatment
Monitoring

→

Regeneration
System

→

To Boiler /
Feed Water

Field Instruments

4–20 mA / Digital I/O

Flow Transmitters
Pressure Transmitters
Diff. Pressure Trans.
Level Transmitters
Conductivity Analyzer
pH Analyzer
ORP Analyzer
Silica Analyzer

PLC / Control System

Siemens S7-1500

Field I/O Panel
PROFINET / Ethernet
High Performance
Reliable & Scalable
Control Valves (MOV/AV)
Dosing Pumps Control

HMI Panel

TP1500 Comfort

Local Monitoring
Alarms & Annunciation
Trends & Reports
User Management
MCC / VFD Panel
Network Switch

IIoT Gateway

MQTT Broker

Data Acquisition
Protocol Conversion
Edge Processing
Secure Connectivity
Ind. Ethernet Network
PROFINET / Modbus TCP

Cloud / Analytics

AWS / Azure / Grafana

Real-time Dashboards
Historical Reports
Water Quality Analytics
Predictive Maintenance
Resin Life Estimation
Energy & Water Reports
Email / SMS / WhatsApp

Field Sensors

Flow / Pressure
Conductivity / pH

Field I/O Panel

Signal
Conditioning

Siemens PLC

S7-1500
Controller

TP1500 HMI

Local
Visualization

IIoT Gateway

MQTT Broker
Node-RED

MySQL DB

Historical
Storage

Grafana

Analytics
Dashboard

Effluent Conductivity

Real-time

0.08μS/cm

Effluent pH

Real-time

7.2pH

Condensate Flow

Real-time

245m³/h

System Efficiency

Real-time

99.6%

Key Monitored Parameters

Inlet / Differential / Outlet Pressurebar / psi

Condensate Flow / Backwash Flowm³/h

Regeneration Flowm³/h

Conductivity (Feed & Effluent)μS/cm

pH LevelpH

ORP (Oxidation Reduction Potential)mV

Silica Concentrationppb

Tank Levels (Acid / Caustic / NaOH)m / %

Filter Differential Pressure ΔPbar

Condensate & Regeneration Temp.°C

Pump & Valve Status (MOV / AV)ON/OFF

Filter DP Status / Resin Life—

Power Consumption / Energy EfficiencykWh

Communication Architecture

Field Devices↔Field I/O

4–20 mA / Digital I/O

Field I/O↔PLC S7-1500

PROFINET / Ethernet

PLC↔HMI TP1500

PROFINET

Industrial Ethernet Network

PROFINET / EtherNet IP / Modbus TCP

IIoT GW↔Broker

MQTT Pub/Sub

Cloud

AWS / Azure / On-Prem

Visualization

Grafana Dashboard

Remote Access

Web Dashboard / Mobile App

Alerts

Email / SMS / WhatsApp

Data Format

JSON

System Capabilities

Key Advantages

Real-time monitoring of complete boiler operation

Centralized visualization through dashboard

Historical data logging for analysis

Reduced manual operator dependency

Faster fault identification & troubleshooting

Improved fuel & energy efficiency

Open architecture for future scalability

Multi-user remote monitoring capability

Process Automation Intelligence Solutions

Engineering Excellence in Automation

In-Depth Knowledge Across Core Industries

A Partnership Built on Technical Depth

IIoT Monitoring Systems

Key Advantages

Future-proof your operations with our automation solutions.

Services

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