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Automation Solution for Steel Plant

1. Project Details:

Industry: Metals

Location: Joda, Odisha
Project Duration: 3 months
Team: Client – 1 engineers; MWA: 2 engineers

RIO Control Desk

Need of the project:

  • The entire plant was completely operated manually. Due to increase production demands in the market there was a huge dependency on man power leading enormous delays, rejection and production loss.
  • Optimizing of energy consumption to save cost of power

2. The Problem:

  • Due to manual operation system accuracy was dependent on manpower leading to product rejection, loss in production
  • Reduction in cost of power
  • Collecting data at high speed and high volume for analysis of process variables & trends
  • Reduce downtime, quality issues and inefficiencies affecting the bottom line.

3. The Solution:

  • Compact Logix Redundant PLC system to avoid system failure, data loss, improved system accuracy and increased production
  • FactoryTalk SCADA based system for plant Visualization & monitoring of key power parameters
  • FactoryTalk Historian to handle high-speed time-series data. Improve decision making related to process, time, and material management by comparing variances to targeted parameters.
  • FactoryTalk VantagePoint to provide information in a context that enables analysis at-a glance. Operators as well as executives can share this data and make real time or predictive decisions based on correlations and trends revealed by the VantagePoint to reduce power & down time.

Features Offered:

  • SMS alerts for critical data
  • Customized Batch Reports
  • Database connectivity & data exchange between plant and head office
  • Easy analysis of high speed and volume data
  • Real-time KPI data for all stakeholders
  • Pre-configured reports and dashboards
  • Web-based access to all critical data
  • Monitoring of all essential plant KPI’s
  • Monitoring motor current from 150 devices
  • Monitoring power parameters from 120 devices

Scope of Work:

  • Designing, erection & commissioning of Automation system
  • Dismantling all the existing manual control panels & replacing it with new control panels
  • Installation of Server Computer
  • MIS integration (Historian and Vantage point). Designing of dashboards, trends & reports
  • Data connectivity and data exchange between plant & head office

BOM:

  • PLC Control Panel – 1 Set
  • RIO Control Panel – 2 Sets
  • Weight Indicator – 4 Nos
  • Load Cells – 6 Nos
  • Current Meters – 40 Nos
  • Temp. Scanner 16 Inputs – 3 Nos.
  • Commercial grade Computer – 2 Nos
  • Industrial grade Computer – 1 No

4. The Results:

  • Due to Automation, system accuracy has improved with no dependency on man power leading to increased production, reduction in downtime and better product acceptance in the market.
  • 10-12% power saving resulting in around a profit of Rs. 8-10 Lakhs
  • Better decision making due to availability of necessary KPI’s 24×7

 

Main PLC & RIO Control Desk
SCADA System
System Design/Configuration