Commissioning of - SIMATIC B.Data Based Energy Management System

We are proud to have Successfully commissioned North India's first Energy Management System ( EMS ) based on SIEMENS B.DATA Energy Management System.

We had the privilege of working for SIEMENS for Implementation of North India's first SIMATIC B.DATA Based Energy Management system for DIAL. 

The EMS system captures the Energy data from 8 existing substations using SIEMENS WinCC. New PAC 3200 meters were hooked to Existing S7-400 / 400H Systems  for capturing of the Energy Data.

B.Data is a very powerful and latest Energy Management software from siemens, which meets all the legal requirements for 50001. Here is a Glimpse of the System

Generation of Energy Report – Plant Performance (KPI)

Following is the Daily KPI (Key Performance Indicator) Report generated by B.DATA Energy Management System. It shows the daily energy consumption for all the Incoming and Outgoing feeders.

Energy Consumption Report

DashBoard For Previous Day and Current day Energy Consumption

The Dashboard shows in Graphical format at a Glance the Energy Consumption display of current and previous day.

Energy DashBoard

DashBoard For Previous Day and Current day Power Status

The Dashboard shows in Graphical format at a Glance the Power Consumption Display of current and previous day.

Power Dashboard

Implementation of B.Data provides the following potential Benefits

B.Data fulfills the following legal obligations

CO2 Reporting.

Supporting ISO 50001.

Waste and waste water regulations

Long term archiving requirements

Monitoring of other Emissions.

Energy Data Management image

Increase the competitiveness

Increase the company attractiveness (recruiting)

Investment in green technology

Sustainability Index

CO2 and/or water foot print

Reducing costs for energy

Awareness raising

Energy controlling

Optimizing production processes thanks to cost transparency

Optimized energy procurement

Fast decision finding

Investment protection

Reduced effort in all project phases.

Rupendra Negi and Mukesh Kumar were part of the team which implemented the challanging project. Special Thanks to SIEMENS for all the support.

Commissioning of SCADA at Buddh International Circuit

Commissioning of SCADA at Buddh International Circuit

MNC Automation Pvt .Ltd. has been instrumental in System Design, software development and commissioning of Substation SCADA system  at Buddh International Circuit
( Formula-I RaceTrack ) on Yamuna Expressway ( Greater NOIDA ).

Here are a few glimpses of the Buddh International Circuit and the SCADA Screens.

F1 Cars Waiting for Flag-off

SCADA Home Page

We have implemented the SCADA for the 220kV GIS , 33kV GIS, 11kV GIS system besides some important 415V systems,  including the 11kV Ring Main network connected over Fiber-Optic Communication Rings.

System Overview

The Ring Main

The Complete data is displayed on SCADA Stations in the Main Substation building.

Detailed Electrical Data

MNC Team was also present at F1 Circuit throughout the Racing period in 2012 to ensure smooth performance of the system

Automatic Grid Synchronisation System at HNG Bahadurgarh

Successful Commissioning of Automatic Grid Synchronisation System cum Substation Automation System at HNG Bahadurgarh

MNC Automation's Team has successfully commissioned Automatic Grid Synchronisation system cum Substation automation system at HNG Bahadurgarh.  

The system is based on SIMATIC S7-300 PLC with WinCC Based SCADA system. Besides a Touch panel has been provided for local control.

Overview on large 40" Display Screen

The system controlles the Synchronisation to Grid of 4 Nos. GE Make Gas Generators, 3 Nos. Sulzer Generators and 2 Nos. Wartsila Generators ( Total 9 Generators ).  

All the Substations have been connected on a Fiber Optic Network and plant overview is available on two Large 40" display screens in Main Control Room as well as Shift Office.  The Control as well as lice Data for the complete 132kV / 11kV system is available on one screen.

Synchronisation and Load Lontrol Screen.

For 3 Nos. Sulzer Generators as well as 1 No. Wartsila Generator, the system also controlles the Active and Reactive power when these are synchronised to the Grid.

Plant Overview

This was a challenging assignment especially considering that 3 different type and makes of Generators had to be synchronised to the Grid. As usual MNC accepted the challenge and designed and commissioned the system meeting the client's requirement.

With the commissioning of this system, customer can prevent tripping of their plant on planned Grid failures as well as Grid restoration thus reducing down-times and increasing production efficiency.

Successful Completion of FAT of CMRL- RTU

Integrated Factory Acceptance Test was Conducted for RTU Panel for the first RTU Panel for Koyambedu RSS + Depot ASS1. 

The RTU panel is based on SIPLUS RIC and SICAM TM-1703 with IEC-60870-5-104 Protocol.

Explaining the Testing Procedure

A Close-up view of the RTU Panel

SCADA FAT in Progress

Integrated FAT in Progress

 The FAT was attended by representatives of CMRL, SIEMENS, Wintech and MNC. 

CMRL ( Chennai Metro ) - RTU Testing

RTU Panels for CMRL are based on SIPLUS-RIC Platform

CMRL - RTU Panel Test in Progress

RTU Panel Testing on Actual RTU Panel for Koyambedu RSS + Depot ASS1 

CMRL - RTU - Software Testing 

CMRL - RTU - Software Testing 

 The Software Validation Test Setup consists of the following Test Kits :

a) SIPLUS RIC Redundant RTU System with IEC-60870-5-104 Protocol

b) SICAM TM-1703 based IEC61850 to IEC-60870-5-104 Gateway 

CMRL - RTU - Software Test Kits for SIPLUS-RIC and SICAM TM1703

Commissioning of Substation SCADA systems at GGSR Refinery Bhatinda

We have recently commissioned several Substation Automation Systems (SAS ) at HPCL-Mittal Guru Gobind Singh Refinery, Bhatinda, Punjab.

We had the privilege of being entrusted by SIEMENS with Commissioning of Substation Automation Systems at  four substations  in GGSR Refinery, Bhatinda (Punjab). Salient features of the SAS systems are as follows :

• Data Concentrators : SIEMENS - SICAM AK1703 ACP 
• SCADA : SIEMENS SICAM-230
• IEC 61850 based communication with Protection relays
• Modbus RTU communication with DCS & ECS systems

Typical SAS Architecture

Following Substation SCADA systems were commissioned by MNC Team at GGSR site :

1. CDU-VDU ( Substation SS-15)
2. Raw Water Treatment Plant - RWTP (Substation SS-28)
3. MS BLOCK ( Substation SS-19)
4. COOLING TOWER ( Substation SS-23) 

Typical MIMIC Screen

Typical Feeder Display

Munish, Ramananda & Tashi were part of the MNC Team at GGSR, Bhatinda Site.

Commissioning of 2 Nos. 4 HI Cold Rolling Mills at JSL Ltd

 We at MNC are proud to have recently commissioned 2 Nos. 4HI Cold Rolling Mills for rolling of Blade Steel at JSL  Hisar. This was a challanging assignment involving state of the art controls.

Fig-1 : Cover Page of JSL House Magazine

Both the Mills have Been supplied by Sherman International, USA. All the PLC, Drives, MCCs and Control Desks / Panels were supplied by Unique Automation Controls. 

The Mills are provided with State of the Art control system including :

a)  S7-400 PLCs + WinCC SCADA for Mill Control and interlocking wih following features :

     - Speed , Torque and Tension Control
     - Diameter , Length and Wrap Calculation
     - Automatic Slow Down (ASD)
     - Automatic Gauge Control ( AGC )
     - Pass Scheduling
     - WinCC SCADA for each Mill with Common SCADA in Control Rool
     - Engineering station cum IBA High Speed Trending system.

b) SINAMICS DCM (6RA80) for Control of Mill and Coiler Drives + Common POR
    SINAMICS G120 for paper winders Control.
    All the Drives communicate over High Speed Profibus with Control System.

c) S7-300 for Common Roll Coolant Filtration System

d) Intelligent MCCs with Built in ET200S I/Os to eliminate control Cabling

e) Control Desks with built in ET200S I/Os to eliminate control Cabling

f) All the Automation systems and SCADA Stations ( Including Engineering Station )
   communicate on high speed Ethernet network.

Fig-2: Article in JSL House Magazine regarding Commissionioning of Mills

Rakesh, Mukul and Vivek were part of the MNC team which executed this prestigious project at JSL Ltd, Hisar ( Haryana ).

MNC Team in the Control Room

Mill-3 Running at Top Speed of 400MPM

View of the Control Room