A Complete Solution with Fallback Control System
INTEGRATING MULTIPLE CONTROL SYSTEMS
The Challenge
Integrating the furnace's DCS with other machine control systems posed a significant challenge. Our objective was to develop a comprehensive solution, considering the intricacies and high stakes of the manufacturing process, enabling efficient automation to oversee a vast array of 1500+ IOs. A key aspect of this endeavour involved seamlessly incorporating diverse systems into the PCS 7 framework.
Additionally, we implemented discrete electrical control systems, such as the Reversal Panel, and an Air Control Panel to serve as reliable fallback options. The project scope encompassed approximately 20 nos. LV Switchboards, including PCC, iMCC, PDB, LDBs, Bus ducts, and more, each playing a crucial role in the overall setup.
The Solution
Velox Automation successfully secured this order amidst intense competition. A prominent player in the Glass industry has chosen to establish their brownfield project for Solar Glass in South Gujarat. Their requirement entailed implementing a state-of-the-art DCS for the furnace and seamlessly integrating it with various machine control systems.
Our dedicated engineer diligently commissioned the system, adhering to the client's schedule and meeting the complete satisfaction of their engineering team. To ensure a seamless plant startup, comprehensive training and hyper-care support were provided, guaranteeing a smooth transition into operation.
- Central Control System powered by a hot redundant Siemens PCS 7 setup, ensuring enhanced reliability and redundancy.
- The Machine Control System integrated through Industrial Ethernet, MODBUS TCP, and Profibus, enabling efficient data exchange and synchronized control of machines.
- Integrated Energy Management System.
- Incorporated Web Enablement, web-based technologies and functionalities into existing systems and applications.
- Integrated Pneumatic Control Panel.
- Velox delivered intricate and extensive projects with timely execution at scale.
- 3rd Party Consultants ensured compliance and validation of our solutions.
- Offered a comprehensive solution for Automation, LV Switchboard, and Busduct needs, ensuring seamless integration and efficient management.
Why Velox Solutions Makes Sense
- Velox seamlessly Integrated multiple control systems.
- Centralised Monitoring & Control was integrated for easy access of data and getting notified in minimum time.
- Real-Time Energy Monitoring system provides live insights into energy consumption, allowing organizations to monitor and analyze energy usage in real-time.
- Velox built on an open architecture, promoting interoperability and avoiding any form of monopoly.
- Access from anywhere in the world
- Fallback control systems prevent production loss by seamlessly taking over in case of disruptions or failures, ensuring uninterrupted operations.
- There is a decrease in specific energy required to melt glass.
- Less Release of harmful particles in atmosphere during the melting process
- Less emission of greenhouse gasses.