Plant Automation (Level 1, 2 and above)

Advanced state-of-art process framework systems guarantee safe and easy to understand plant operations.

Electrotherm offers an exhaustive range of cost-effective automation applications for all production units in the metal making and melting industry under one roof. This includes optimized and effective process control, stable process optimization systems, and solutions for quality-assured production. Our products and solutions can considerably improve the performance and quality of the production and enable it with high-qualitative desired outputs.

PLC Based Dynamic Load Manager (PDLM)

  • PDLM is used to maintain the constant actual power demand of the plant from the supply line. If actual KVA tends to exceed the sanctioned KVA, the PDLM reduces the power of the induction furnace. By using PDLM, maximum sanctioned KVA can be utilized, which optimizes the overall load factor of the plant.
  • When more than one furnaces are in operation on a single grid, PDLM can work still more effectively by sharing the total available power.
  • Power to the furnace can be shared through priority selection switches wherein one furnace can be provided full power while the other runs at reduced power.
  • The overall productivity of the plant will increase because of the optimum use of available power. No human intervention is required for monitoring and controlling furnace load.
  • CT & PT failure protection is provided in the system which reduces power to a minimum with an alarm indication.

PMA 100 (PLC Based Melt Automation with HMI Provision)

These modules have been introduced to enable foundries to derive maximum benefit from the latest state-of-art melt automation techniques. The system features include:

  • HMI Display: The latest version of PLC with 9-inch color HMI. The HMI displays all safety interlocks. Any unhealthy interlock will be easily identified by a corresponding change in the interlock display color.
  • Digital display of parameters like voltage, current, power, frequency, earth leakage current, and water conductivity.
  • Alarm generation of each event like power ON/OFF, trip, interlock failure for fault diagnosis.
  • Alarm history for finding the cause of the recurring problems.
  • The fault diagnostic features enable a comprehensive check of deviation in critical system parameters including water temperatures, water pressure, electric limits, etc.
  • Historical graphical trending of key information like Power vs. Time, Voltage vs. Time, etc.
  • Auto sintering facility: A pre-determined sintering cycle can be fed into PMA 100 to facilitate automatic sintering for more accurate sintering. This results in a better lining life.
SPA 100 – SCADA Based Plant Automation
  • Implements centralized SCADA (Supervisory Control and Data Acquisition) system for the whole plant.
  • Display of all the important parameters of each furnace, pump house, DG Set, etc. Key furnace parameters include the ones related to the electrical system, metal temperature, water pressure/flow, etc.
  • Monitoring on SCADA of all electrical parameters of plant HT & LT feeders.
  • Trending, alarm generation, Storage of historical parameters.
  • Automatic control of maximum KVA demand by the intelligent program on an instantaneous basis by controlling the furnace power. This increases furnace load factor (an important requirement of electricity board) and results in the overall reduction of power consumption.
  • Power optimization of the furnace by automatic cut/off of furnace capacitors depending on the load conditions.

  • Recording and storage of data related to furnace weight and metal temperature (optional). Load cells in customer’s scope
  • Heat-wise power consumption, daily, weekly, and monthly power consumption reports can be generated. All the generated reports can be printed.
  • Remote web access through the internet from any location in the world (optional).
  • Fiber optic network used for faster and noise-free communication.

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