Automation System for RO Plant at AMNS Hazira
Centralized Siemens S7-1500 PLC Automation with Wonderware SCADA
The Challenge:
Vasu Chemicals LLP won an order for an industrial reverse osmosis (RO) plant at the AMNS Hazira utility facility and partnered with Velox Automation to implement the complete automation and electrical scope. The project required the implementation of a centralized control and monitoring system while integrating the existing MCC panel, a new MCC panel, 40 third-party VFDs, remote I/O stations for ETP and lime dosing systems on Profinet, and the Wonderware SCADA platform. Integrating multiple plant sections, including the RO plant, ETP, and filter press systems, into a tight project schedule created additional complexity. The project was further challenged by a material lead time of approximately 14 weeks due to a global semiconductor shortage following the COVID-19 pandemic.
The Solution:
Velox Automation provided a reliable and scalable automation solution using the Siemens S7-1500 PLC platform with ET200SP remote I/O architecture and Wonderware SCADA for centralized control and monitoring. This solution successfully connected old and new MCC panels, 40 third-party VFDs using Profinet, remote I/O stations, and over 200 energy meters via RS-485 communication across RO, ETP, and filter press systems. To address global supply chain constraints, Velox leveraged its vendor network across India, adopted a phased implementation strategy aligned with procurement schedules, and completed the project within the committed timeframe without compromising quality or performance.
Why Velox Solutions Makes Sense
For the Client:
Despite global supply chain disruptions, the project was successfully completed within the planned schedule. The integrated automation system provided centralized monitoring and control across RO, ETP, and auxiliary utility systems while ensuring seamless integration with the existing AMNS infrastructure. Modern architecture improved operational reliability, scalability, system visibility, and ease of maintenance for critical utility operations.
For the Environment:
The central automation system enables efficient monitoring of utility operations and energy consumption through the integration of over 200 energy meters. Improved process visibility and optimized equipment performance help reduce energy waste, support efficient water treatment processes, and contribute to more sustainable plant operations.