Automation Solution for Steel Plant

1. Project Details:

Industry: Metals

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

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