Q1. Could you start by giving us a brief overview of your professional background, particularly focusing on your expertise in the industry?

I am a technocrat in the Instrumentation field. My degree is also in Instrumentation & Electronics Engineering. So, anything related to Instrumentation excites me a lot. However, I have long experience in various industries and worked as a consultant, as a Client, and as a contractor in various projects in different locations

I started my career in the Fertiliser Industry with a company named Fertilizer Corporation of India in the year 1977– this is a Government of India Company. After an exhaustive training for two years, I was posted in the Planning and Development division of that company. Subsequently, that division was formed into a separate company - now known as Planning and Development India Ltd. This company is providing consultancy services for fertiliser companies and related industries also. Mainly providing Design, Engineering, Procurement, Inspection, Construction and Commissioning of these Industries. I continued to work in this company till July ‘1985.

Subsequently, I joined M/S Blue Star Ltd – a Company representing M/S Yokogawa Electric Ltd, Japan, in India. Here I worked from July’1985 to August’1987 as Asst. Manager in the Instrumentation project division. Subsequently, this division was developed as a separate Company and is presently named Yokogawa India Ltd.

After Blue Star Ltd, I joined a giant fertiliser manufacturing company named Indian Farmers Fertiliser Cooperative Ltd. This is one of the biggest cooperative companies working for the manufacturing of fertiliser as well as for development of farmers as a community. Here I worked for the construction of new plants being involved from the design stage to commissioning stage for Aonla-1 as well as for Aonla-2 projects. Each stream comprises Ammonia, Urea, Bagging, Power plant and Offsite plants. After the completion of project, I was involved in regular Maintenance of the Instrumentation Department of the same Units. Subsequently, I was again involved in the Phulpur -2 project of IFFCO, Phulpur Unit. A similar fertilizer plant at a different location. After the completion of the Phulpur-2 plant, I was made Head of Instrumentation for the Phulpur Unit of IFFCO. Subsequently, I was promoted to be the In-charge of Maintenance comprising Mechanical, Electrical, Instrumentation and Civil Departments. I continued to

After that, I joined Hanwaha Engg. & Construction Company, Saudi Arabia, at their Yanbu Site in December 2012 as Lead Instrumentation Engineer. The project of 2X375 M.W. Power plant and other auxiliary plants. I continued there till April’2013.

After that, I joined Dangote Fertiliser Project at Lagos, Nigeria in March’2014. The Project consists of 2X2200 MTP Ammonia plants, 2X3750 MTP Urea Plants, 2X 3750 MTP Granulation plants and other related Bagging and Offsite plants. I was working as the Head of the Instrumentation department. The job involves a review of Engineering drawings, Inspection at vendor’s works. Supervision of construction activity, FAT, SAT for various systems. Imparting training to new entrants etc.

After that, I joined Development Consultants Private Ltd. as Resident Engineer in November’2022, Control and Instrumentation for M/s D.C.P.L. at Wanakbori Thermal Power Station, Gujarat, for their 8th Expansion of 800M.W. Unit and worked for about 7 months.

• A “Performance Driven Professional” with an experience of 42 years in Project Management, Operations & Maintenance, Installation & Commissioning and Team Management in Fertiliser Plant, Power Plant, Petrochemical Plants with specialisation in the Instrumentation domain
• A keen strategist with expertise in administering Instrumentation project operations with a key focus on top-line & bottom-line profitability by ensuring optimal utilisation of resources
• Proficiency in managing the maintenance of various equipment for reducing downtime and enhancing the operational effectiveness of equipment
• Adept at handling erection & commissioning activities involving resource planning, in-process inspection, team building and coordination with internal / external departments
• An effective communicator with excellent skills in building relationships
• Made visits to various countries like the U.K., Italy, France, Singapore, Thailand, China, U. S. A, Holland, Denmark, Sweden, Saudi Arabia, Mauritius, Nigeria, etc. for official jobs & for attending International Seminars
• Attended training at Elcon-Italy, L&N – U.K. Yokogawa- Singapore, Honeywell - Singapore ASCII- Hyderabad (SEC-108), China etc
• Served as a regular Faculty in the FAI Programme for Instrumentation
• Acted as a Guest Faculty for MNNIT, Allahabad, for Special Control Systems like DCS, ESDS, etc. and at BIT, Sindri, for PG Diploma course in Instrumentation
• Worked in Saudi Arabia for about six months
• Worked in Nigeria for four years

 

Q2. What government initiatives and policies are accelerating digital instrumentation upgrades in fertilizer, petrochemical, and power plants in India, and what tangible operational or financial outcomes have these initiatives produced?

There is no policy or scheme by the Government of India to accelerate Digital Instrumentation in India. However, indirect benefit may be taken from other policies or schemes like Digital India Umbrella, India AI mission, Cloud Infrastructure (Meghraj), Industrial IOT, etc.

For the fertiliser industry, there is no single entity to handle this issue. The most prominent body is the Technical Advisory Committee of the Fertiliser Association of India, which has a long history of addressing and advising the Ministry of Fertiliser, Government of India, on Instrumentation and other technical matters for the industries. Similarly, the Fertiliser Industry Co-ordination Committee (FICC) is an attached office of the Department of Fertilisers. The Govt of India has a Technical Division, and they have the roles involving improvement in Instrumentation, especially concerning quality control, energy efficiency and project implementation.

However, in IFFCO Phulpur Unit, we converted Ammonia Plant, Urea Plant, Power Plant and Boiler Instrumentation from pneumatic to directly smart instrumentation, including DCS, ESDS in 1900/2000. The outcome was highly encouraging – the specific energy consumption of the Ammonia Plant came down by 2Gcal/Mt of ammonia. For the old plant, it used to be 11 GCal/MT, and it came down to 9 GCal/MT with this conversion only, the process and all other equipment remaining unchanged. Similarly, a significant improvement was observed in the specific consumption of coal in Power plants and Boilers also. In view of this, FICC recommended the conversion of pneumatic instrumentation to smart instrumentation, including DCS & ESDS, to all other fertiliser industries. As of date, all fertiliser industries are using smart instrumentation.

In India, the "Technical Development Committee", which primarily focuses on instrumentation for the petrochemical industry, was the one for Indigenous Materials (Petroleum, Petrochemicals & Fertiliser Industries), with regional zones. This committee, operated by entities like Engineers India Ltd. and Indian Oil Corporation Ltd., worked to qualify and promote domestically produced materials and instrumentation components.

Today, the work of developing and maintaining standards for instrumentation in petroleum and petrochemicals is handled as per the standards laid by national and international organisations.

International Organisation for Standardisation (ISO): The technical committee ISO/TC 67 covers materials, equipment, and offshore structures for the petroleum, petrochemical, and natural gas industries. It is responsible for developing and revising international standards like ISO 14224, which covers reliability data for equipment.

Indian committees collaborate with international counterparts to harmonise standards with global best practices.

American Petroleum Institute (API): This organisation publishes comprehensive recommended practices (RP) and standards widely used in the industry for instrumentation.

API RP 554: Addresses the functions and specifications for implementing process control systems.

API RP 555: Provides guidance on the selection, installation, and maintenance of process analysers.

International Electrotechnical Commission (IEC): Provides a chart of standards for instrumentation and control that are used globally and in India.

The Government of India is driving the digital transformation of the power sector through several initiatives and policies aimed at accelerating the adoption of digital instrumentation in power plants. The strategy focuses on establishing a robust digital infrastructure to improve operational efficiency, reduce losses, integrate renewable energy, and enhance service delivery.

 

Foundational digital infrastructure

India Energy Stack (IES): A flagship initiative by the Ministry of Power, the IES is a Digital Public Infrastructure (DPI) designed to create a unified, secure, and interoperable digital foundation for the entire energy sector. The IES is set to provide a standardised, secure, and open platform for managing, monitoring, and innovating across the electricity value chain, similar to how Aadhar and UPI transformed identity verification and payments.

Key features: Unique identifiers for consumers, assets, and transactions; real-time data sharing; open APIs for seamless system integration; and tools for consumer empowerment.

Pilot projects: A 12-month Proof of Concept (PoC) is underway to demonstrate IES using real-world use cases with selected utilities, including a Utility Intelligence Platform (UIP) for real-time insights and smarter energy management.

 

Grid modernisation and intelligent metering

National Smart Grid Mission (NSGM): Established in 2015, the NSGM is focused on deploying smart grid technologies to improve the reliability of the electricity network. It facilitates the adoption of Advanced Metering Infrastructure (AMI), which is critical for digital instrumentation.

Advanced Metering Infrastructure (AMI): This system involves deploying smart meters, a two-way communication network, and a Meter Data Management System (MDMS) to collect, store, and analyse metering data in real-time.

Smart Meter National Programme (SMNP): Spearheaded by Energy Efficiency Services Limited (EESL), the SMNP aims to replace 25 crore conventional meters with smart meters nationwide. These meters record electricity usage in real-time and send data to utilities, helping to reduce commercial losses and improve billing efficiency.

Implementation model: EESL operates on a Build-Own-Operate-Transfer (BOOT) model, which requires zero upfront investment from states, and costs are recovered through the savings gained from reduced Aggregate Technical and Commercial (AT&C) losses.

Revamped Distribution Sector Scheme (RDSS): This results-linked scheme links funding to reforms in AT&C loss reduction and reliable power supply. The RDSS supports IT enablement, including smart metering solutions, to improve the financial sustainability and operational efficiency of distribution utilities.

 

Operational and performance enhancement initiatives

Grid Controller of India Limited (Grid-India): Formerly known as POSOCO, Grid-India is the national grid operator responsible for the integrated operation of the Indian power system. Its functions include managing renewable energy integration, implementing market-based reforms like the Real-Time Market, and enhancing grid integrity.

Real-Time Data Acquisition System (RT-DAS): Executed under schemes like the Integrated Power Development Scheme (IPDS), RT-DAS projects enable real-time monitoring and data management. This facilitates remote monitoring of substations and extra-high voltage (EHV) facilities for an automated and digitally controlled grid.

Cybersecurity guidelines: The Central Electricity Authority (CEA) and the Computer Security Incident Response Team in the Power Sector (CSIRT-Power) have established guidelines for cybersecurity to secure the digital infrastructure. CPRI has set up test facilities to ensure compliance.

Mission on Advanced and High-Impact Research (MAHIR): This national mission, launched jointly by the Ministries of Power and New and Renewable Energy, aims to indigenously develop emerging technologies for the power sector. It supports pilot projects and facilitates foreign alliances to build competencies in areas like grid management and digitalisation for renewable energy integration.

Green Energy Open Access Portal: Grid-India operates this portal to facilitate the integration and operation of renewable energy sources, aligning with the country's targets for increased non-fossil fuel capacity.

AI and Machine Learning: The government is leveraging AI and ML for grid optimisation, demand forecasting, and predictive maintenance of power plant assets. This reduces the risk of outages and enhances operational efficiency.

Distributed Energy Resources (DERs): Policies promote the use of DER technologies, such as rooftop solar and microgrids, which are digitally managed to provide localised energy solutions, especially in rural and remote areas.

 

Q3. How is the growing prominence of renewable energy sources in India impacting instrumentation needs and investment priorities in conventional power plants and industrial facilities? What are the challenges in integrating these changes?

India has bridged the energy gap with green power. The country has doubled its investment in green energy in recent years as it hooks the last remaining habitations to the power grid. Green sources are now more than 40% of power capacity in India. This has definitely added an opportunity in the market of Instrumentation, mainly in the field of measurement and control of energy storage systems, including batteries, pumped hydro storage and thermal energy storage, etc. But it has brought a lot of challenges also for the instrumentation or automation systems. Instrumentation systems have to utilise it as a stepping stone to improve further. That creates the instrumentation needs and investment priorities in conventional power plants and industrial facilities.

The main challenges of renewable energy include intermittency, which is the variability of sources like solar and wind due to weather; grid integration, which requires modern infrastructure to handle fluctuating supply; high upfront costs for installation; and energy storage limitations. Other challenges involve land and resource constraints, public perception, regulatory hurdles, and dependence on global supply chains for key components. Technical and infrastructure challenges

Variability and intermittency: The output of renewable sources like wind and solar power is unpredictable and depends on weather conditions, making it difficult to match supply with demand.

Grid modernisation: Existing grids were built for traditional, dispatchable power plants and require significant upgrades to handle the decentralised and variable nature of renewables.

Infrastructure and transmission: Many renewable resources are located far from population centres, requiring the construction of new, high-capacity transmission lines, which can be costly and face permitting delays.

Energy storage: Developing and deploying cost-effective energy storage solutions is crucial to buffer the intermittent nature of renewables and store excess energy for when it's needed.

Grid stability and power quality: The lack of inertia from some renewables can complicate the balancing of supply and demand, while fluctuations from new sources can cause voltage and harmonic distortion issues, and Economic and regulatory challenges

Cost: Building new infrastructure, investing in storage, and upgrading existing systems require significant financial investment.

All these challenges create the opportunity for the development of a smart grid, a better storage system, and a smart control system to make it viable. Ministry of New and Renewable Energy (MNRI ) and Solar Energy Corporation of India Ltd (SECI) are also working relentlessly to achieve the country’s ambitious renewable energy target of 500GW from non-fossil fuels by 2030.

 

Q4. In the Indian fertiliser and petrochemical sectors, how is smart instrumentation supporting sustainability targets around energy efficiency, waste handling, or water/resource management? Can you share measurable outcomes from recent projects?

Smart instrumentation uses sensors, the Internet of Things (IoT), and data analytics to optimise resource use, reduce waste, and manage water more sustainably. By providing real-time, actionable insights, it enables companies to achieve measurable improvements across key sustainability targets.

Smart instrumentation helps industries reduce energy consumption and lower carbon emissions through real-time monitoring, predictive analytics, and process automation.

In practical operation, we have observed that with pneumatic instrumentation, the steam header with a normal pressure of 100Kg/cm2 fluctuates by +2Kg/cm2 to -2Kg/cm2. Whereas with the smart controller, this fluctuation reduces to +0.5 Kg/cm² to – 0.5 Kg/cm². This steady steam header reduces the consumption of steam by 1.5 T/H to 2.0 T/H. This reduction of steam consumption comes to approximately $0.5 0.5million to $0.8 million per year for a turbine of capacity 30 MWH.

Similarly, as I indicated, in the case of the Ammonia plant of capacity 900T/D, a saving of 2GCal/Mt will be about $13 million to $16 million per year.

Real-time monitoring: Sensors and smart meters monitor energy consumption of equipment and processes continuously, identifying inefficiencies or abnormal usage patterns.

AI-powered optimisation: Artificial intelligence (AI) and machine learning (ML) algorithms analyse data to predict optimal operational settings. For example, in manufacturing, AI can automatically adjust a machine's power draw to meet demand while avoiding energy waste.

Predictive maintenance: Smart sensors can detect early signs of equipment failure, such as unusual vibrations or temperature fluctuations, enabling pre-emptive maintenance. This extends the equipment's lifespan and prevents the energy waste that results from malfunctions.

Similar steps are already in practice, and APC (Advanced Process Controller) is used for this purpose. Otherwise, predetermined parameters can be monitored for a specific period, and the efficiency of the equipment or a part of the process can be evaluated with those recorded parameters.

Smart buildings: The use of smart technologies like smart metering, HVAC automation, and intelligent lighting in public buildings has been shown to reduce energy consumption by up to 40%.

Similarly, in a process plant, a thermal audit can be carried out for insulated pipelines to check whether the insulation is alright or not. This practice has been on for a long time.

Process plants: Advanced instrumentation in a process plant, combined with automated controls and data analysis, led to significant reductions in operational energy costs and improved overall efficiency.

Waste handling

By deploying smart bins and AI-powered systems, companies and municipalities can optimise waste collection, reduce landfill waste, and improve recycling processes.

 

How it works

Optimised collection routes: IoT-enabled smart bins use ultrasonic sensors to detect fill levels and transmit real-time data to a central platform. This allows waste management companies to optimise collection routes, skipping empty or nearly empty bins and reducing fuel consumption and emissions.

Enhanced sorting and recycling: AI-powered systems and machine learning algorithms can automate the sorting of waste materials, improving accuracy and reducing contamination of recyclable streams. This supports circular economy initiatives by maximising material recovery.

Waste-to-energy: Sensors can monitor waste-to-energy processes like anaerobic digestion to ensure efficient operations. For example, monitoring temperature and gas levels helps maximise energy generation from organic waste. Measurable outcomes

Waste management: A waste management company implemented IoT solutions to provide real-time analytics. This streamlined operations and led to lower operational costs from more efficient collection and resource recovery.

E-waste recycling: An IoT and AI-based e-waste system trained a camera to recognise e-waste for automated recycling. In the system's operational prototype, average bin overflows were reduced from 0.67 to 0.11 after implementation.

Textile recycling: A textile bin operator used sensors to monitor fill levels and optimise logistics, reducing collection costs by 20% and the time required per tonne of textile by 30%.

 

Water and resource management

In water-intensive sectors, smart instrumentation helps conserve water, reduce pollution, and manage resources more effectively.

How it works

Leak detection: Acoustic sensors and pressure monitoring can detect leaks and inefficiencies in water distribution systems in real-time. This prevents significant water loss and minimises environmental damage.

Smart irrigation: AI-powered systems in agriculture use sensors to monitor weather and soil conditions. This allows for precise, automated irrigation that prevents over-watering and conserves water resources.

Water quality monitoring: Sensors can continuously monitor water quality parameters like pH, dissolved oxygen, and turbidity. This ensures that water is safe and helps prevent contamination events.

Industrial production: By using water sensors and incorporating wastewater recycling, one industrial facility in Thailand reduced its water usage in production by 15% per year.

Water utility: A smart meter implementation at an institute campus in India saved approximately 14% of water by enabling corrective actions based on real-time data.

Smart manufacturing - Unlocking energy efficiency with IoT-based ...

22 Apr 2025 — Benefits of IoT-Based Energy Monitoring in Manufacturing: * Reduction in Energy Consumption. IoT devices continuously monitor the consumption and block when not required.

 

Q5. Looking ahead, what emerging instrumentation technologies are poised to disrupt Indian plant operations, and where do you foresee the largest investment opportunities or competitive advantages?

At present, most of the up-to-date process industries like refineries, petrochemicals, fertilisers, power plants, and chemical plants are already using smart instrumentation, APC, MMS(machine monitoring system), performance controller, etc. Looking at the present status, it appears that environmental sustainability will be shaping the future of process instrumentation, with industries prioritising energy-efficient solutions.

The future of Process Instrumentation is being driven by smart sensors, IIoT, AI-powered analytical and advanced automation. Industries that embrace the innovations will benefit from increased efficiency, reduced costs and enhanced sustainability.

Process instrumentation is evolving rapidly, driven by technological advancements, industry demands and regulatory changes. The integration of smart sensors, IoT-enabled devices and AI-powered analytics is revolutionising how industries monitor, measure and optimise their processes.

IIoT stands for the Industrial Internet of Things, which refers to the use of connected sensors, devices, and software in industrial settings to collect and analyse data for process automation and optimisation. It is a key component of Industry 4.0 and allows for real-time data collection, remote monitoring, and data-driven decision-making in manufacturing, logistics, and other industrial sectors.

IIoT: connects industrial machinery, sensors, and IT systems to create a network for data exchange.

It enables machine-to-machine (M2M) communication and the analysis of real-time data to improve efficiency and productivity.

Applications of IIoT include predictive maintenance, process optimisation, and real-time monitoring of operations across various industries like oil and gas and automotive manufacturing.

It integrates Operational Technology (OT) with Information Technology (IT) to improve decision-making and create intelligent control across dispersed industrial assets.

Wireless technology is another key enabler, reducing the reliance on cumbersome wired connections. Industrial Wireless Sensor Networks (IWSNs) enable seamless data transmission across large plants, improving monitoring efficiency and reducing maintenance costs.

Cloud-based monitoring platforms allow industries to collect and analyse vast amounts of data from multiple locations, improving efficiency and enabling real-time decision-making.

As process instrumentation becomes increasingly digital and interconnected, cybersecurity is a growing concern. Industries are implementing robust security measures to protect their critical infrastructure from cyber threats.

Looking at the present scenarios, it appears that we are slowly marching towards wireless transmission systems, at least for renewable energy sectors, and the development in all sectors may push us towards virtual instrumentation systems for industrial control systems.

In view of the above, I foresee the largest investment opportunity or competitive advantages in the following sectors ---

• Sensors sensing multiple parameters for the process.
• Wireless transmitters.
• Virtual Instrumentation
• Cybersecurity of Industrial Control infrastructure.

 

Q6. Can you provide examples of successful automation or instrumentation modernization projects in India’s fertilizer, petrochemical, or power sectors that demonstrate best practices or significant ROI?

As I indicated earlier that the conversion of pneumatic to DCS & ESDS was so encouraging for IFFCO Phulpur Unit that FAI directly started advising for the same to all Fertiliser industries that are using pneumatic instrumentation systems. FAI advised the Ministry of Fertiliser to advise all the industries to follow the same for the benefit of the nation. After IFFCO, Phulpur, other units of IFFCO, like Kalol Unit and Kandla Unit, followed the same route. The other industries to follow are Mangalore Chemicals & Fertilisers Ltd in 2003-2004 and Shriram Fertiliser & Chemicals in 2006, and then Duncan Industries, Kanpur. Kribhco has also done for their Fertiliser plants at Surat. Fertiliser is a controlled commodity and comes under ECA, and usually the margin of profit is very meagre. So they need the support of the Government even for this conversion. As of today, all the fertiliser industries are using state-of-the-art smart instrumentation systems for their plants.

However, petrochemicals are a profit-oriented business, and they did this conversion promptly, and they are always using the best technology available in the market. Petrochemical industries have used APC and Process optimisers before the same being used by Fertiliser industries.

But the scenario of Power Plants is different. There are many power plants that are still using old patterned instrumentation systems, typically small-capacity plants. Power plants have various categories – Private, Public, or Government-owned. Again, they are classified according to their capacity. Similarly, they are categorised in terms of the type of fuel also. All the plants with big capacities have changed to smart instrumentation systems. However, not all captive power plants have yet been changed to smart instrumentation systems. Similarly, most of the plants associated with sugar mills are yet to change to smart instrumentation. However, I do not have the current updated data, as the number of plants is huge. But it is sure that all new plants of low capacity are also coming with a PLC-based control system with smart transmitters.

However, the non-availability of pneumatic instruments and their spares is compelling the user to go for single-loop Electronic controllers or PLC-based systems. PLC-based systems are cheaper compared to single-loop controllers – this fact compels the user to go for smart instrumentation systems.

 

Q7. If you were an investor looking at companies within the space, what critical question would you pose to their senior management?

Instrumentation is a field where continuous change is going on, so if any company in this field can not adapt to these changes, then it will be obsolete very soon. Continuous change and improvement are a constant need in business in this field. Adaptation of new technology and development is another criterion to be followed in the field of instrumentation. If we see the history of business in the Indian and International markets, we can observe this impact – some good companies are no more in the business, and some newcomers are sailing strongly in the market.

As an investor in the instrumentation field, your questions to senior management should go beyond standard financial metrics to assess the company's specific market position, technological innovation, and operational resilience. The field is highly technical and competitive, with complex supply chains and demanding regulatory requirements.

What is your long-term strategic vision for the company over the next 5 to 10 years?

How do you plan to stay competitive amid evolving technology and market changes?

What is your sustainable competitive advantage, or "moat," against competitors?

This is especially critical in a sector with high R&D costs and potential for disruption. Is your moat built on intellectual property, brand reputation, superior service, or cost leadership?

What are the biggest threats to the company, and what do your strongest competitors do better than you?

A management team that is honest about its weaknesses is often more trustworthy.

What are the key risks facing the business, and how are you mitigating them? You want to hear an open and proactive discussion of risks, not a dismissive one.