MCC vs IMCC

From the Field Level to the Management Level

It is astonishing to see how technology is offering nail-biting state-of-the art solutions to the electrical panel industry today. Latest in the series are the Intelligent MCCs aka IMCC.

Traditionally MCCs housed start-up and drive units. But today’s units go far beyond these basic functions. Modern Intelligent centers have now replaced conventional protection devices like overload relays by programmable controllers and metering equipment for complex control schemes and safety features.

The need for Intelligent solutions was felt often by end users (clients of OEMs), to prevent faults in automated processes and costly plant downtimes. Our clients’ requirements were to eliminate huge control wiring that spans throughout the plant for control of the MCC Panel. They found trouble shooting to be a tedious job.MCC vs IMCC

PHARMA AUTOMATION – TO SCALE UP PRODUCTION

Title: Pharma Automation – To Scale Up Production .
Date of Submission: 26th February, 2018.
Department: Pharma Automation Team.

Today the pharmaceutical industry faces several challenges – namely:

• To lower drug prices
• To improve drug quality
• To expedite time to market

And this is where Big Data and IoT will play a big role. Drug manufacturers need to come up quickly with ways to reduce time taken to reach from clinical trials to approvals to actual production. Innovative approaches to manufacturing will be the key to success. IoT in the pharmaceutical industry might consist of a network of sensors on the shop floor. Production supervision, remote diagnostics, drug flow management would be some of the cases driven by this new technology.

Companies might even go one step further of using social media apps to capture patient demographics, to find patients for clinical trials, for getting feedback from patients, and so on. In short they might come up with their own class of CRM systems.

Cotmac Electronics offers pharma automation solutions that are tailor made to suit each company’s processes and requirements. Our portfolio of solutions includes:

• User Archives For Batch Processing
• Simatic Logon, Electronic Signature
• Client/Server Model With Server Redundancy
• Configuration of HART Devices
• Configuration of ISP Modules

Sections automated are:

• Reactors
• Distillation Column
• LLE (Liquid Liquid Extractor)
• RFE/FFE (Resin/Fractional Film Evaporators)

Benefits to our customers include:

• Up-to-date system documentation
• Total integration of all processes in plant engineering and operations
• Increased work efficiency and reduced planning time
• Reduction of engineering costs because of simplified processes

FROM VAT TO AUTOMATE

Title: From Vat To Automate.
Date of Submission: 20th February, 2018.
Department: Brewery Automation Team.

 

The age-old method of crafting beer must now be found only in museums. Presuming they must have used copper cauldrons, wooden barrels or vats and such like – the brew must have varied day to day with the vagaries of the humans who brewed them, and the variation in the quality of ingredients.

With urbanization and advances in technology, in the field of brewery automation, high-tech plants have arrived – with the assurance of consistent high standards of quality. Today most areas such as brew house, fermentation cellar, filtration, filling plant and energy generation can be simultaneously managed. All controls can be managed through easy-to-read-and-operate graphic interfaces. Faults can be quickly located and rectified.

Digitalization provides effective support for brewers in the form of sensors to monitor temperature and boiler pressure measurement and actuators to control valves used across the entire brewing process. The quality of a brew is guaranteed by the precise control of the brewing process. Automation isn’t just about the quantity that can be produced, but also the high quality that can be achieved and maintained.

Cotmac Electronics plays a pivotal role as the Automation Solution Provider in any area of Brewery Automation.

We have handled a wide variety of challenging requirements that include:

• Upgrading manually operated plants to full or partial automation.
• Automation of malt handling, brew house, and brew house Clean in Place (CIP) sections.
• Batch planning and recipe management.
• Increasing brew length while maximizing brew per day.
• Minimizing manual interventions.

Implementations have covered:

• Totally Integrated Automation (TIA) (with PCS7 V 7.0, ET 200S stations and Danffos drives on Profibus DP).
• Control Systems Based on S7-400 / S7-1500 / PCS7.
• VFD on Profibus / Profinet Network
• Recipe Management Software and Batch Planning Software
• Customized block and faceplatetailored to the requirements of customer.
• Event logging & change controlfor batch analysis / Record.
• Upgradation in minimum shutdown time.
• 
  

 Simple Easy to read UIs

We offer users operator-friendly and easy-to-diagnose process operation reports, which contain detailed analyses of each brew. And benefits to customer are manifold, such as – improved productivity, consolidated reporting systems for analysis, optimum control of critical process parameters, better utilization of man-power and operations.

TYPE TESTED & PARTIALLY TYPE TESTED ASSEMBLIES

Title: Type Tested & Partially Type Tested Assemblies.
Author: Mr. Girish Todkary.
Designation: Senior Manager- Marketing.
Department: Cotmac Electronics,Pune.

 Type Tested Assemblies(TTAs)

A low voltage switchgear and control gear assembly/control panel conforming to an established type or system without any deviations likely to significantly influence the performance, from the typical assembly verified to be in accordance with this standard.

When type tested assemblies are being used it is necessary to check that they are constructed in accordance with the specified type test and that any deviations from the type tested construction do not have a significant influence in the performance as verified by the type test.

Deviations from the type test, which could affect the performance, are:

> Structural changes which will affect the mechanical strength of the assembly.

> Incorrect sizing of busbar or cross section area which will affect the temperature-rise limits.

> Busbar supports spacing, changes in the type or quantity of busbar supports, and the

busbar support structure, which will affect the short circuit withstand strength.

> Reduction in compartment size may result in overheating of components and wiring may

cause component breakdown or insulation failure and possible short circuit faults.

 PARTIALLY TYPE TESTED ASSEMBLIES(PTTAs)

A low voltage switchgear and control gear assembly, containing both type-tested and non type tested arrangements, provided that the latter are derived from type-tested arrangements which have complied with the relevant tests.

The type-tested arrangements should cover as a minimum the mechanical assembly, the main and distributor busbar systems complete with all busbar supports.

The standard allows for use of the other parts in the assembly that are not part of the type test for the assembly for example, components and compartment layouts provided they themselves have been derived from type tested arrangements.

Cotmac Electronics Pvt. Ltd. is India’s leading Siemens authorized system house & also Licensed Partner for manufacture & assembly of SIEPAN 8PU Low voltage switchgear panels (TTA panels).

Cotmac offers Siemens SIEPAN 8PU Type tested panels.

Some of the advantages & features of SIEPAN 8PU are listed below:

• Siemens innovation & technology
• Maximum reliability in protection of your plant and equipment
• Maximum safety for operating personnel
• Suited for the most arduous site conditions
• Compact and space saving

Highlights:

• Conformance to Type Tested assemblies (TTA)
• Conformance to Seismic withstand up to Zone V
• Conformance to Internal Arc Containment (IAC)
• Fully compartmentalized, bolted & modular design for PCC & MCC

All variants available with a choice of aluminium and copper for bus-bars.

Degree of ingress protection up to IP 54 for all ratings.

With wide service network spread throughout India & abroad, Cotmac is a preferred choice for a complete & one stop solution in automation & Type tested panels.

SIMATIC PCS 7 CONTROLLER – CUSTOMER’S NATURAL CHOICE

Process Industries have to meet with more and more complex and competing demands. SIMATIC PCS 7 with it’s functional variety, flexibility, and performance, has the potential for implementing innovative solutions that meet the special challenges of the process industry. SIMATIC PCS 7  benefits from its seamless integration in Siemens Totally Integrated Automation (TIA),

As well as transparent process control, SIMATIC PCS 7 also offers monitoring of product quality and key performance figures for the efficient operation of your process plants, and it ensures more flexible processes, higher plant availability, and investment security.

The operator interface offers a high level of user-friendliness and simple, intuitive interaction with the plant. Ergonomic symbols, task-oriented faceplates, uniform representation of status information, and optimized alarm functions allow safe process control.

Automation of Ultra-Pure Water Plants requires precise planning and careful construction of control panels. It’s a matter of pride that the first plant in INDIA of UPW (Ultra-Pure Water) has been commissioned by Cotmac, by Intelligent Integration of Simatic PCS7 Solution.

In this particular application UPW is being used for washing of Electronic components to avoid the shock in PCB’s. Raw water is used to go first for RO (Reverse Osmosis) Process. During this process dissolved solids and TDS present in water are eliminated. In the next stage water has to go for UF  (Ultrafiltration) Process, where suspended solid and solutes of high molecular weight are retained, while water and low molecular solutes pass through the membrane. Again the water passes through the EDI (Electro deionization) – a technology that utilizes electricity, ion exchange and membranes that dissolve impurities from water.

Cotmac’s Solution with Simatic PCS7 was the natural choice of customer. The system offered includes HOT Redundant System, Soft communication for VFD’s, Event Based Synchronization, Human Machine Interface with real time process, flexibility and reliability solution given to customer. Finally, the Automation System is integrated with PLS (Process Life Safety) System for Total Plant Automation.

Benefits of our Solution:

• Reduction of operating costs.
• Centralized Operation for all the processes through HMI.
• Ease of diagnostics.

Existing installations can easily be expanded or converted by using the SIMATIC PCS 7 Controller.

AUTOMATION OF DUST COLLECTION SYSTEM

 AUTOMATION OF DUST COLLECTION SYSTEM


Proper dust collection and air filtration is important in any work space.  Every steel plant can have it’s own industrial releases, that can be hazardous. In today’s scenario, air pollution and it’s treatment is a major issue in this industry. The large scale furnaces release huge amount of light weighted particles. The casting takes place by melting the iron/steel into liquid and pouring them into moulds which have cavities of desired shapes. The polishing and shaping of the casts forms dust in large amount.
Thus treatment of these unwanted dust particles has to be carried out as they cause big environmental problems.

OUR SOLUTION

COTMAC worked along with OEM to offer automated solution for Customer’s Ash handling systems. We installed centralized PLCs at three remote stations. IO count was more than 1500. All stations communicate through Fiber optic cable in kilometers range.

BENEFITS TO CUSTOMER

• Reduction in dust emission in environment.
• Troubleshooting was simple and faster due to SCADA.
• Reduction in manpower and operation cost due to centralized operation.
• Easy commissioning and diagnostic.
• Improved Powder conveying and storage efficiency due to better control.

Today Cotmac Electronics is ranked among the best of Automation Solution Providers across the globe.

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