High performance and accuracy for Chemical process and Textile factory
Composite Manufacturing Line
Challenge:
The customer was setting up a plant in India for the first time. They were looking for a partner who has expertise in both Automation and electrical systems. They were looking for a Distributed Control System for their new plant which involved chemical as well as textile processes.
There was also a requirement for the integration of third-party PLCs, HMIs, Energy Management Systems, VFDs & SMS alert systems. Velox was chosen after tough scrutiny by the global technical team of the customer.
Solution:
Siemens PCS7 control system was offered in a hot redundant configuration. Hot Redundant servers with 4 clients ( Siemens IPC) for operator stations were considered.
Remote IO stations on a redundant Profibus network with redundant interface modules formed the I/O bus network. A redundant ring network over ethernet was created for the communication between DCS and all other PLC systems. All VFD feeders were connected over Profinet. The Energy Management System was connected over Modbus TCP protocol. There were multiple on-field Operator stations and HMI for smooth operation and control.
Why Velox Makes Sense
For the Client:
This was one of the most reliable solutions having redundancy at AS, Power Supply, OS server, IO network, plant bus, and terminal bus. This meant zero downtime of the system. Centralized Automation leads to good coordination between different steps of production leading to almost zero wastage. An SMS alert system was implemented which enabled the customer to know about any abnormality and to take corrective action in the shortest possible time. The motor control centers were also controlled centrally. The energy management and process management working from a single system provided good synergy for calculating the production and conversion cost ratio.
For the Environment:
The final product is used for batteries, which helps to reduce overall pollution and carbon emissions. Since this was a local production, it brought down the cost substantially.