Expertises

Furnace Burner Management System

Water Plant Improvement Project

Project Summary:- Supply, Design, Engineering, Testing, commissioning of Burners, combustion fan, related burner valves and equipment's, PT and DPT transmitters and Allen Bradley Logix platform PLC & Training of System.

Objective:-

  • Disinvest the existing set of Burners, Burner Management System, Controls and replace with New Burners along with its Control System.
  • To achieve the Melt Rate of 10T/hr.
  • Reducing the inventory cost by utilising the same equipment's as installed in other Furnaces.
  • To avoid frequent failures and disruption in production.
  • To reduce the Maintenance Cost.
  • Transfer of critical Burner Data to MES/ SCADA for further Analysis and Reporting.

Wireless Communication System

Wireless Communication System

Project Summary:- Supply, Design, Engineering, Testing, Commissioning of New Rockwell CLX PLC System, Required Modification in the Local SCADA and Integrating with Emerson Make Wireless Gateways.

Objective:-

  • To Calculate and Obtain Total Plant AIR Flow Consumption.
  • To Calculate and Obtain Individual area wise AIR Flow Consumption.
  • Reporting Structure in SCADA.
  • DATA Transfer to PMS For Further Use and Analysis.
  • To Minimize and eliminate any Air Leakages.

Implementation Of New Rod Feeder Machine In HCD-1 & HDC-2

Wireless Communication System

Project Summary:- Supply, Design, Engineering, Testing, Commissioning of New Rod Feeder Machines in HDC-1 & HDC-2 Casting Station Ch-02 with New Dedicated Rockwell CLX PLC System along with Power Flex 750 Series VFD's. Including all related field cablings works, Trunking, Testing and Commissioning

Objective:-

  • Precise Control of Rod Feeding operation during Casting with the tolerance Band of +/-0.5%.
  • Simultaneously feeding of different kind of alloys as per the end user requirements.
  • Auto adjustment of Feeding Set Points as per the Variation in the CASTING Speeds.
  • Provision of Manual Set Point Entry for Individual alloy Feeding.
  • Quality Improvement for the Finish Ingots
  • Reduce Manual Intervention and Human Errors

Billet/Ingot Sample Identification and Marking Systems

Billet/Ingot Sample Identification and Marking Systems

Project Summary:- Supply, Design, Engineering, Testing, Commissioning of New Marking Machine and Integration with New Rockwell Logix L3x and PanelView Plus 7 HMI for Graphic Display & Alarams. Laying of New Power Cables, CAT6 Cables and Pneumatic Air Pipe Tapping.

Objective:-

  • To Eliminate the Manual Process and Human Errors.
  • Data Interface between MES SCADA & Marking Machine PLC to obtained the required cast / furnace batch no's.
  • Auto Track Record System as per the individual sample Nos and benefit of time stamping.

Reverse Rotation Protection System for Main Pumps @ DEWA

Reverse Rotation Protection System for Main Pumps @ DEWA
Reverse Rotation Protection System for Main Pumps @ DEWA
Reverse Rotation Protection System for Main Pumps @ DEWA
Reverse Rotation Protection System for Main Pumps @ DEWA

Dry Air Package System

Dry Air Package Systems

Project Summary:- Design, Supply, Engineering, Testing, Commissioning & Training of New dedicated Control Logix PLC Control System, Provision of SCADA Connectivity, ATS Panel for the New Supplier Dryer Package Unit In Cast House 1 & 2.

Objective:-

  • Replacing obsolete Booster compressor and desiccant dryers system.
  • Develop more reliable and friendly related system.
  • To provide dedicated PLC Control System with HMI for Local Operation.
  • Transfer of critical Information data to MES System for further analysis and Reporting.

Water Plant Improvement Project

Water Plant Improvement Project

Project Summary:- Design, Supply, Engineering, Testing, Commissioning & Training of Field instrumentation (Magnetic flowmeter, Vortex flowmeter for Blended and unblended line, Ultrasonic Level TX for Hotwell & Coldwell, Position switch for manual valve and DP switch to Duplex filters) and integrated to existing ControlLogix PLC system.

Objective:-

  • Improve the performance of cast house CH water plant
  • To Compute amount of water for each complex for Blended and unblended Line.
  • Monitoring and Recording of Pressure Points at critical Locations during Casting Operations.
  • Monitoring of Critical Emergency Hand valves for Each Casting Supply Lines.
  • Transfer of DATA to MES System for Further Analysis and Calculations.
  • To Minimize the Water Wastage

Deep Tunnel Storm Water System Terminal Pumping Station And Sea Outfall

Deep Tunnel Storm Water System Terminal Pumping Station And Sea Outfall
Deep Tunnel Storm Water System Terminal Pumping Station And Sea Outfall

Project Summary:- Design, Supply, Test and Commissioning of Control System Make SIEMENS SIPLUS S7-1500 ET200 Series PLC system, Rockwell SMC50 Soft starters enclosed on Form 4 Type 6 Elsteel Make MCC Panel to New Hydraulic Pack for Penstocks and HOV Valves and Cylinder system.

Objective:-

Stormwater and groundwater enter the TPS overflow chamber from a DN10 m tunnel. The Stormwater flow deliver to the Arabian Gulf via duckbill diffusers through Terminal pump station. The Penstock and HOV vales are work on Hydraulic system which inflatable dam and stop logs will be used to prevent backflow of tidal seawater into the overflow channel during maintenance activities.

Pumped flows and flows in the overflow channel are measured and recorded in ICA/SCADA to provide total TPS discharge flows.

Furnce Door Operation Monitoring Systems

Furnce Door Operation Monitoring Systems

Project Summary:- Supply, Design, Engineering, Testing, Commissioning of New LED Display Board (SIEBERT) and Integration with existing Rockwell Logix PLC in Cast house Complex.

Objective:-

  • Caution and Clear Visibility to Furnace Operators.
  • Total Time Calculation from Initial Furnace Process Till Final Casting.
  • Opening time will be available for further Reporting Structure and Product Analysis Purpose.

Up-gradation Of New Vibor Feeder Machine @ Dock

Up-gradation Of New Vibor Feeder Machine @ Dock

Project Summary:- Supply, Design, Engineering, Testing, commissioning of Control System with Rockwell CLX PLC and PF 753 VFD for the New Vibro Feeder Machine.

Objective:-

  • Replacement of existing obsolete vibratory feeders with latest state of art of control technology.
  • Replacement the DOL Starter with new VFD control System.
  • Precise transfer of coke from each silo with proper Auto Blending operations.
  • To Maintain and limit the coke transfer from each silo to its maximum capacity.
  • Data exchange with SCADA System for easy monitoring and control of VFD Control Vibratory system.
  • Implementation DLR Topology for seamless operations.