Projects
Steel Plant Automation Upgrading Project
SCADA Integration for Pharma Facility
Configured SCADA and PLC systems for a GMP-compliant pharmaceutical manufacturing plant
PLC Panel Installation – Food & Beverage Plant
Increased production efficiency by 30% and reduced energy wastage.
Oil & Gas Control System Upgrade
Improved system reliability, safety compliance, and operational continuity.
Mining Operations Automation
Reduced manual intervention, improved worker safety, and increased throughput.
Digital SCADA Upgrade
Increased batch quality, reduced manual reporting, and achieved 20% faster production cycles.
DCS Modernization
Improved process safety, minimized downtime, and enhanced energy efficiency across critical units.
Smart Energy Monitoring
Reduced energy costs by 18% and improved sustainability compliance.
PLC Panel Expansion
Boosted throughput, reduced system failures, and enhanced worker safety.
Overview
To modernize operations and enhance efficiency, a comprehensive automation system was deployed at a major steel plant. The project integrated SCADA, DCS, PLCs, and industrial communication protocols across critical production units.
Key Technologies
- SCADA: Enabled real-time monitoring, alarm management, and historical data logging.
- DCS: Managed continuous processes like chemical treatment and energy systems.
- PLCs: Controlled discrete operations such as conveyors and robotic arms.
- Alarm Management: Set up alarm thresholds, priorities, and notification mechanisms.
- Protocols: Used Modbus TCP/IP, PROFINET, OPC UA, and EtherNet/IP for seamless device communication.
System Architecture
- A layered architecture was implemented
- Field Level: Sensors and actuators
- Control Level: PLCs and DCS
- Supervisory Level: SCADA systems
- Enterprise Level: MES and ERP integration
Project Highlights
- Efficiency Boost: 15–20% increase in throughput
- Downtime Reduction: 30% fewer unplanned outages
- Enhanced Safety: Improved alarm systems and interlocks
- Data Visibility: Real-time dashboards and analytics
Challenges Overcome
- Legacy system integration
- Network redundancy and latency
- Operator training and change management
Future Outlook
- Predictive maintenance with AI/ML
- Cloud integration via OPC UA
- Cybersecurity enhancements
Automation Upgrade at Timber Cutting Plant
Overview
A timber cutting facility faced significant operational inefficiencies due to outdated, non-automated
machinery and a lack of system communication and monitoring. The project aimed to modernize the
plant with integrated automation technologies to improve productivity, safety, and data visibility.
Challenges Faced
- Non-Automated Machinery: Manual operations led to inconsistent output, increased labor costs, and frequent downtime.
- Non-Communicating Equipment: Machines operated in isolation, preventing coordinated control and centralized monitoring
- No Monitoring System: Lack of real-time data made it difficult to track performance, detect faults, or optimize processes
Solutions Implemented
- PLC Integration: Programmable Logic Controllers were installed to automate cutting, sorting, and packaging processes
- SCADA System: A centralized SCADA platform was deployed for real-time monitoring, control, and alarm management.
- Industrial Protocols: Communication protocols like Modbus and OPC UA enabled seamless data exchange between machines and control systems
Results & Benefits
- Productivity Increase: Output improved by over 25% due to automation and reduced manual intervention
- Operational Visibility: Real-time dashboards and alerts enhanced decision-making and fault response
- Reduced Downtime: Coordinated control and predictive maintenance led to fewer breakdowns.
- Scalability: The new system supports future expansion and integration with ERP/MES platforms
Results & Benefits
The plant plans to implement AI-driven analytics for predictive maintenance and further optimize energy usage and resource planning
