Projects

Turnkey Solution for Chemical Manufacturing Plant

1. Project Details:

Industry: Chemical
Location: Dahej, Gujarat
Project Duration: 6 months
Team: Client – 2 engineers; MWA: 2 engineers

Need of the project:

MCC Room
  • Expansion due to higher production demand
  • Automation system for continuous critical process plant without loss of data.

2. The Problem:

  • Due to critical process plant any shutdown in the system would lead to huge losses and rejection of batch product
  • Improvement in bottom line with proper decision making
  • Reduction in power cost

3. The Solution:

  • Compact Logix HOT Redundant PLC system over DEVICENET communication to avoid system failure and loss of data.
  • FactoryTalk SCADA based system for Visualization of plant.
  • FactoryTalk VantagePoint to provide information that enables analysis and helps manage manufacturing consistency, energy use and other factors that can improve the bottom line
PCC Room

Features Offered:

  • SMS alerts for critical data
  • Customized batch reports
  • Database connectivity & data exchange between Manufacturing plant in one state & head office in other state of India.

Scope of Work:

  • Designing, Erection & Commissioning of Automation System
  • Laying & termination of instrumentation cables – Power, control, signal and earthling cables.
  • Supply and installation of instruments: Valves, Transmitters, Cable tray, Conduits, glands etc..
  • Supply and installation of JB’s, FLP Boxes, Cable tray, Conduits, glands etc..

BOM:

RIO Panel
  • PLC Control Panel – 1 Set
  • RIO Control Panel – 1 Set
  • Weight Indicator – 10 Nos
  • Load Cells – 30 Nos
  • Flow Transmitter – 4 Nos
  • Level Transmitter – 3 Nos
  • Level Transmitter DP type – 10 Nos
  • Pressure Transmitter – 6 Nos
  • Temperature Transmitter – 8 Nos
  • Temperature Element PT100 – 12 Nos
  • Control Valve – 4 Nos
  • On-Off Valve – 90 Nos
  • Three Way Valve – 5 Nos
  • Flow Switch – 2 Nos
  • Pressure Switch – 6 Nos
  • Level Switch – 3 Nos
    Main PLC panel
  • Limit Switch – 3 Nos
  • Magnetic Type Level Gauge – 8 Nos
  • Temperature Gauge – 20 Nos
  • Pressure Gauge – 12 Nos
  • Temp. Scanner 16 Inputs – 3 Nos
  • Junction Boxes – 8 Nos
  • FLP Boxes – 10 Nos
  • Commercial Grade Computers – 3 Nos

4. The Results:

  • Production demands are met leading to higher revenue
  • 6-8% power saving resulting in around a profit of Rs. 5-6 Lakhs
  • Better decision making has helped locate and correct sources of inefficiencies quickly leading to better bottom line
System Configuration

 

SCADA