MELSS Automation Ltd (MAL) - The prime focus of the organization during its formative years and its subsequent years had been Electronic Weighing Systems, Mobile Weighing Systems, and Material Handling Automation & Batching Control Systems for Process Industries. Besides, Sales & Service of Standard Instruments of reputed international manufacturers was also a part of business. The Projects dealt, called for expertise in the field of Mechanical, Electrical & Electronics and Software. In due course, the same had developed into core strength. All these projects were of small & medium proportions. There was a long felt urge to venture into Public Sector Infra Structural Projects to harness the acquired expertise which would help in the growth of the Organisation and eventually contribute to the progress of the Nation. In today’s Indian scenario where lot of thrust is given for infrastructure development, C&I plays a vital role, be it, Power, Water Treatment & Management, Cement etc.
Since 25 years, MAL was catering to the industrial process automation in various spheres. The venture started off in a humble manner in the year 2002 with development of Control Software for some Projects. The company ventured with a separate division “Control & Instrumentation” (C&I). Since then, the company has been a supporting partner in executing projects to NLC, NTPC, Sahara, VIDC, Chennai Metro etc. directly and also through various prime contractors. In this process, MAL has the strength of direct associate with the Super Thermal Power Projects and many prestigious Water Distribution & Management Systems, which is both for Drinking Water Sector and Agricultural Sector.
For any Project, Measurement, Control, Monitoring & Reporting are the four vital aspects which form the backbone to keep the system in place besides running the project efficiently. MAL supports this initiative through effective implementation of its C&I Module. In a nutshell this is called the Central Nervous System for any process industry.
The C&I projects handled by MAL can be broadly classified under the following heads
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Lift Irrigation Schemes
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Water Distribution / Transmission Systems
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Drinking Water Distribution Systems
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Water Treatment Plants (WTP)
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Sewage Treatment Plants (STP)
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Effluent Treatment Plants (ETP)
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Plant Automation
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Modernisation of the Metro Water Distribution and Sewage System through C&I and Telemetry
MAL Scope / Components of the C&I Projects generally encompass
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Programmable Logic Controller of internationally reputed make like GE-Fanuc, Rockwell etc
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Telemetry employing GSM, Broadband, Radio Communication, Radio Frequency.
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SCADA System (Supervisory Control And Data Acquisition) developed with reputed software from GE-FANUC
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Instrumentation like Flow meters, Level & Pressure Transmitters, Pressure Switches etc.
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Control Desks
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PLC Panels
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MCC Panels
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MIMIC (a schematic representation of the process with indications)
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Vibration Monitoring System
Deliverables from MAL for a C&I Project will include
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Detailed Engineering
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Procurement of Equipments
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Design of SCADA software for Regional Control Centre (RCC),
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Testing of System
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Delivery of System Components (hardware & software) with Manuals
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Erection & Commissioning
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Operation & Maintenance
Details of various projects done /in process/envisaged
C&I for WATER DISTRIBUTION/TRANSMISSION SYSTEMS
These Water Distribution & Transmission Systems cover various locations and require telemetry to link the various distant locations (30 kms). Data Communication efficiency becomes a very important aspect of such a System and the communication network setup needs to be robust.
System Description
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The Drinking water scheme at various locations is controlled from the Regional Control Centre (RCC) using the SCADA HMI Software
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The Remote telemetry stations are configured with either GSM or PSTN modems to communicate with RCC SCADA System.
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PLC system in each Regional telemetry station is used to OPEN / CLOSE the Valve and also to measure the amount of Flow of water, Monitor the Level of the Reservoirs wherever applicable as well as monitor the healthiness of the Incoming Supply.
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The Process indication of Flow and Level at each of the Regional Telemetry outstation are displayed in the respective Process Indication displays
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The communication inside the RCC is configured in redundant mode.
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The RCC Centre is equipped with Operator Work Stations, Engineering Stations and communication devices for sending and receiving Data to the Regional Telemetry Outstations
MAL has successfully implemented one such project
Similar Project was commissioned for a Steel Industry employing Relays in place of PLC.
C&I System for LIFT IRRIGATION SCHEMES
Lift Irrigation Schemes involve effective supply of irrigation water to thousands of farm fields through Pumping Stations, Headers and Main Distribution Chambers. Various Instruments are provided at all these locations and based on signals received from the instruments, the pumps will be controlled by a PLC based system to maintain required water distribution. MAL is providing the entire Instrumentation & Control Package for this.
System Components include
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Telemetry Transmitter & Receiver (to cover all the analog & digital signals of intake pumping system, MDC’s and SDC’s status of all control switchgear) to cover 30 kms distance
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Redundant PLC based control system
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Local Control Panel with micro-processor based alarm Annunciator, Digital Panel Meters, Power Supply, I/Os, Utility Sockets etc.
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All instruments as per P & IDs and as required by the System
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Vibration Monitoring System for all pumps and Motors
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Field instruments like Pressure Indicators / Gauges, Pressure Switches at pump discharge, Ultrasonic Type Level Transmitters for sumps of pump houses, Pressure Transmitters for pump discharge headers, level transmitter in Main Distribution Chamber, Thermometers with contact, Thermowells, Temperature Switch, RTD, Flow Transmitters, Flow Glasses, Flow Switches, VFDs
The entire monitoring of the system is captured on SCADA screens at various locations to provide real time information
Above Scheme is for one of the Lift Irrigation Projects
C&I for WATER TREATMENT PLANTS
Main elements of a Water Treatment System are Inlet Process, Alum Dosing Process, Middle Level Process and Filtering Process & Storage Tank & Outlet.
Here the number of monitoring points within a single location is more due to presence of many processes involved in treatment of water. Capturing these inputs effectively becomes the requirement and controlling the various components based on these inputs becomes critical. MAL has provided a robust system for such application
MAL has successfully commissioned one such system for a major contractor
C&I for EFFLUENT TREATMENT PLANTS
MAL has also been involved actively in projects related to Environment Control by providing C&I solutions to Effluent Treatment Plants. MAL Scope of supply for such projects generally include
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PLC Panel to control motors, dosing pumps, 2 way butterfly valves, flow meter conductivity meter, pH controller, pH meter, level indicators
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MCC (Motor Control Centre) Panel
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MIMIC Panel of 8 sq meter area for the sections like Pre Treatment, Ultrafilter, Organic Scavenger, Nano Filter & Reverse Osmosis
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PC with necessary Accessories
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SCADA Software for plant data acquisition and controls
Above scheme has been implemented for a World Bank aided Common Effluent Treatment Plant (CETP) for the Tamilnadu Government.
