Welcome To SPAES Meet at GOA - · PDF file3.9) Success: Inauguration By Dr. A.P. J. Abdul Kalam “Siemens Process Automation End-user Summit India

“Siemens Process Automation End-user Summit India”2011 , Goa. Dated 11/08/2011

Welcome To SPAES Meet at GOA

Hi-Mak Process Controls, Baroda

Presentation From :


Welcome To SPAES Meet at GOA

Presentation on PCS7 Project For: India’s First Carbon Fiber Plant

By

Keyur Vyas ; B.E. M.Tech (IIT B’bay)

Hi-Mak Process Controls, Baroda


Presentation Path

1) About Us : 3 Min.

2) Our Domain Knowledge : 2 Min

3) PCS7 of India’s First Carbon Fiber Plant : 8 Min

4) Customer Speaks : 2 Min


1.0 About Us

We are Learning Organization, We Believe :

Learning is Life.

Learning Builds Future.

Learning is Growth.

We are in Service to Industry with Siemens

Automation Solutions & Products since 1993.

We are “Solution Partner” Since 2009.


1.0 About Us

Infrastructure:Office: 5500 Sq. ft

Works : Manufacturing Area for Panels:

1) 2000 sq. ft for Routine Projects

2) 7000 sq. ft for Large Projects


1.0 About Us (Office)Marketin

gMarketin

g

Account & LogisticsAccount & Logistics

H/W EngineeringH/W Engineering

S/W EngineeringS/W Engineering


1.0 About Us (Office)Experience sharingExperience sharing TestingTesting

Technical TrainingTechnical Training Personal TrainingPersonal Training


1.0 About Us : (Works)


1.0 About Us : (Works)

PCS 7 PanelPCS 7 Panel PCS 7 Panel

PCS 7 Panel

PackagingPackagingSinamics S 120 PanelSinamics S 120 Panel


Our Certifications• System House Since 1994.• Solution Partner Since 2009. • ISO 9001: 2008. – Quality assured• CRISIL Rating – 2 A

( 2A Means : High Performance Capability)

1.0 About Us


Food & BreweriesFood & Breweries Petro-Chemical & ChemicalsPetro-Chemical & Chemicals

2.0 Our Domain Knowledge

Power , Oil and GasPower , Oil and Gas


Metal, Machine & FoundryMetal, Machine & Foundry OthersOthers

2.0 Our Domain Knowledge


3.1) What is Carbon Fiber?• Carbon fiber is a material consisting of extremely thin fibers about

0.005–0.010 mm in diameter and composed mostly of carbon atoms. It is Known for high tensile Strength and Low weight. Carbon fibers are usually combined with other Resin materials to form a composite.

3.0 PCS7 of India’s First Carbon Fiber Plant


3.2) Back Ground • Kemrock being Composite company it was right for them to add Carbon

Fiber in their product palate. • Based on Carbon Fiber technology developed by CSIR and NAL, Kemrock

has decided to Put capital to setup an commercial production.



Kemrock Industries and Exports LimitedAerial View ( A HUB of Composites)



3.3) Customer Expectation:• High Reliability , Dependable and Safe Operation. • Total Automation , Drives and Electrical Solution for A

Commercial plant for mass production of Carbon Fiber 400 TPA.• Different Technological solutions on One Automation Platform. • Easy and Fast Manageability of changes during Trial and

Testing. • Joint working of Control Philosophy.



3.4) Challenges• Competitors: Emerson, Honeywell, Yokogawa ABB, AB etc.• Process was Underdevelopment for commercial use.• Very Preliminary data sharing possible at Bid stage. • Different Types of Process Integrated to one System

– Polymer Section requires Basic Functionality of DCS.– Spinning Section requires functionality of DCS and Textile and Spinning.– Carbonization requires function of DCS, Fabric like handling and Safety.

• Easy and Fast Manageability of changes during Trial and Testing. • Totally Integrated Automation was asked by Customer with :

DCS + Intelligent Drives with stretch , tension control + Standard Drives. Industrial Electrical Heating solutions. ( Including Low Voltage Heating) Electrical Panels MCC and PCC.



3.5) Our Approach to the Challenges• We Approached with Totally Integrated Solution with PCS7 ,

Sinamics S 120 and MM4 Drives , PCS 7 Capability to do High speed data processing for Intelligent functions of Synchronization and tension control with Stretch handling along with Standard functionality of Closed loops and sequencing.

• We relied on our dedicated team with Experiential Knowledge of various Industrial domains which Hi-Mak acquired in learning Path to Provided Optimum Solution.



3.6) Solution Offered

Total IO 2750Sinamics S120 74MM4 Drive 140Heating solution 24



3.7 ) Winning the Order ( WIN-WIN-WIN ) • Its acknowledgement of strength of Solution Offered. • It was acknowledgement of benefit to customer with Solution

Partner and Siemens Integrated strength.



– PCS 7 with two AS 417H , Redundant Server and client OS , ES with 74 Sinamics S 120 and 140 MM4 drives with Heating solutions were installed.

– An operational level of control philosophy with proper safety and availability precautions was derived first in project by solution partner team.

– An engineering solution based on experience of different industry segment like chemical, Textile fiber and Converting solutions was applied by Solution Partner.

– A complete engineering solution with Superior adaptability for modifications helped Customer to adapt modification for improvements.

– Thanks to Siemens TIA concept.

3.8) Implementation and Execution



3.9) Success: Inauguration By Dr. A.P. J. Abdul Kalam3.0 PCS7 of India’s First Carbon Fiber Plant


3.0 PCS7 of India’s First Carbon Fiber Plant 3.9) Success: Inauguration By Dr. A.P. J. Abdul Kalam


• Let me make Honest statement : Automation System was working as expected But , Stabilizing High end Technology for continuous production was not a Easy Task for total project team.

• Many Problems were yet to solve for smooth operation ranging in all areas of engineering let it be electrical , mechanical or process related or Operational

• Kemrock and Hi-Mak Team continued to thrash out one by one by detailed study with exceptional patience.

• Finally Everything was sorted and Okay after Long Nightmares.


3.10) Problem Faced after Production Trial Run !!


3.10) Benefit of Compound Strength Like Carbon fiber composite !!


Product & Application Knowledge

Supp

ly, S

ervic

es a

nd

Solut

ionBackup Support,

Training and

Warranty

A WIN-WIN-WIN

Composite


Few Words from Customer Perspectives:

Mr. Mihir Patel ; Kemrock ; VP Carbon Fiber Plant

4.0 Customer Speaks


Thank You

Documents

Welcome To SPAES Meet at GOA - · PDF file3.9) Success: Inauguration By Dr. A.P. J. Abdul Kalam “Siemens Process Automation End-user Summit India