Retro fitment of 400+ Roller Table Drives at AMNS CSP Plant
Zero Downtime Modernization with Siemens SINAMICS S120
The Challenge:
AMNS Hazira was operating with 15-year-old legacy master drives, resulting in frequent failures, outdated spares issues, and production disruptions. The client required a phased upgrade to Siemens SINAMICS S120 drives with zero production downtime and minimal shutdown time. Additional challenges include high ambient temperatures, dynamic platform installation, communication integration with existing systems, and severe space constraints.
The Solution:
Velox Automation implemented Siemens S120 variable frequency drives with a common DC link architecture to improve reliability and performance. PROFIBUS to fiber optic communication was integrated with existing systems, while Active Line Modules (ALM) and Active Infeed Modules (AIM) helped reduce harmonics and enable energy regeneration. Over 200 VFD panels were retrofitted using door-mounted air conditioners and Rittal enclosures that had anti-vibration mounting arrangements. A shared engineering station was created to work with both the old and new drive systems, ensuring that it connected easily to the PLC and fit well into the existing space.
Why Velox Solutions Makes Sense
For the Client:
The retrofit was executed with zero production disruption during phased implementation. The upgraded system reduced breakdowns, improved power quality, increased energy efficiency, and reduced reliance on maintenance. The new unified automation platform also improved system visibility, reliability, and future scalability.
For the Environment:
The implementation of regenerative drive technology and harmonic reduction improved overall energy efficiency and electrical stability. Reusing existing infrastructure through retrofit modernization also helped reduce material waste and supported sustainable plant operations.