Migration at Rasheed Performance Chemicals
Our Project
Migration of PCS7 from V7.1 to V9.1 in Turkey
● A hydrogen plant was transferred to a new site in Adana city, Turkey, where the client wanted to conduct thorough testing of all electrical installations, including transmitters, pumps, and other equipment. This process is essential in the realm of automation engineering to ensure efficiency and reliability.
● After completing all tests, we successfully migrated the PCS7 to a newer version, enhancing the overall construction automation for future mechanical projects.
Works done
● Our team conducted a thorough review of the transmitters' configuration and installation, making the necessary modifications to enhance the setup as part of our automation engineering efforts in construction automation.
● We performed a loop test for all the transmitters, along with an IO test between all the panels and the equipment on-site, ensuring the success of our mechanical projects.
Our Experience
● Once we powered on the power panel, many problems arose during our mechanical projects, but our automation engineering team efficiently resolved all these issues. ● Our automation team successfully migrated the software from PCS7 V7.1 to PCS7 V9.1, ensuring a seamless start-up of the new software without any complications.
Calibration of Dosing Belt Conveyors at Danieli
Our Project
Success Story from Automecon at Ezz Steel – Ain Sokhna
Client: Danieli
We have successfully completed a project focused on automation engineering for the calibration and configuration of dosing belt conveyors. These systems are monitored by Siemens Miltonic's BW500 integrators, providing a powerful solution for belt scale and weigh feeder applications within the realm of construction automation and mechanical projects.
Works done
● Initially, our professional mechanical team was on site to conduct mechanical checks and inspections of the installations for conveyors and load cells as part of our automation engineering efforts. ● The mechanical team implemented various modifications to the conveyors to ensure that the installations met the necessary requirements for construction automation. ● Additionally, the mechanical team tracked the conveyor by running it at maximum speed without load for a period to verify the mechanical installations and gather important conveyor data, such as length and conveyor speed in m/s, essential for our mechanical projects.
Our Experience
● The electrical and automation engineering team checked the electrical installations of load cells and speed sensors and made the required modifications.
● The automation team configured the integrators and performed load cell balanced, zero, and span tests as part of our construction automation efforts.
● A static load test was conducted by our automation team to ensure everything was in place before calibration.
● Following all tests, a dynamic calibration was executed by our team, achieving an error percentage value of less than 2% in our mechanical projects.
Refueled of Stickers and Painting at Total Energies
Project Description
One of our successful projects involved the supply and installation of pump cables at Marsa Alam Airport Depot, as well as the provision of earthing rods and their accessories. We also handled the refueling of stickers and the rebranding of vehicles, in addition to supplying and installing 9 Electrical Panels IP66 and laying cables for the ABB Project, showcasing our expertise in automation engineering and construction automation.
Works done: -
· For the installation of pump cables, we utilized Elsewedy Cable Multicore Cables with stranded copper conductors. During the installation phase, all three cables were laid from the MMC panel to the pumps' location. The cables were connected in the MCC Panel with electrical isolation between the MCC and the pumps’ JB, ensuring optimal performance in our mechanical projects.
· Regarding the painting project, our team successfully applied a coat of Jotamastic 87 on Total trucks before applying a square meter of the finish coat (Hardtop xp) to test compatibility with the existing layers. After allowing it to cure in sunlight for 7 days, we applied the stickers. We always strive for perfection.
Maintenance contract at Lamar factories
Project Description
● Due to our expertise in automation engineering and the quality service provided by the Lamar maintenance team, we have successfully entered into a contract with Lamar maintenance to cover various aspects of maintenance at the factories.
Works done: -
● Our team will conduct monthly visits to back up all the Siemens PLC programs and check the diagnostics of the PLCs, ensuring optimal performance for all mechanical projects.
● We are responsible for offering advice on any projects related to the devices included in our contract, supporting construction automation initiatives.
● In case of any unexpected issues, our technical office team provides online support, and if an emergency visit is required, a site team will be on location within 24 hours to resolve the problem.
● Our training team will conduct a training course for Lamar maintenance upon their request, as stipulated in our contract.
SCADA System at Natgas
Our Project
This project involves the development and implementation of a sophisticated SCADA system that leverages automation engineering to efficiently monitor and control the complex operations of natural gas distribution within Natgas stations, aligning with the principles of construction automation in mechanical projects.
The system encompasses the following key functionalities related to automation engineering, particularly in the context of construction automation for mechanical projects:
- Real-time Monitoring and Control:
● Inlet and Filtration Processes.
● Metering Operations.
● Heater Systems.
● Pressure Reduction Stations.
● Odorant Systems.
● Outlet Distribution Networks.
- Advanced Alarm Management:
● Real-time alarm detection and notification within automation engineering frameworks.
● Comprehensive alarm logging and historical data storage to support construction automation efforts.
- Robust Data Logging and Reporting:
● Continuous historical data acquisition for analysis and optimization in mechanical projects.
● Generation of detailed daily and monthly reports to facilitate informed decision-making and regulatory compliance.
Cement storage silos management at ACICO Cement factory
Our Project
Success Story from Automecon at ACICO Cement factory in Al Kuwait
● Supply, Upgrade and Commissioning a new Siemens PLC I/O panel to accommodate the instrumentation and control signals related to the new cement silos, along with necessary modifications in the existing PLCs and SCADA screens in 3 mills as part of our automation engineering efforts.
● Our scope was the following:
Part I: Instrumentation/Control Engineering & Supervision on Installation
- Design and selection of required cables for all instruments related to construction automation.
- Design of the cable routing, either through cable trays or closed conduits.
- Supervision on installation of instruments.
- Review wiring diagrams and supervise cable termination between instruments and the control panel.
- Loop check of all instrument cables.
- Assist in the implementation of as-built drawings for the mechanical projects.
Part II: Supply of Silos Control System
- Supply of I/O panel with ProfiNet Interface to accommodate the signals coming from and going to the 6 new silos instrumentation and control equipment.
- Supply of new CPU S7-400 with ProfiNet communication to be installed in the existing mill 1 PLC, establishing communication between the PLC and the new I/O panel.
- Supply of new CPU S7-300 with ProfiNet communication to be installed in the existing mill 2 PLC, establishing the same communication.
- Modify the PLC program in both mill 1 PLC and mill 2 PLC to add the necessary sequences to operate the new silos.
- Modify the Siemens WinCC SCADA in mill 1 and Mill 2 to accommodate new graphics displays and monitoring readings needed to operate the new silos. Install modifications on both WinCC workstations and establish redundancy between them.
- Supervision on the installation of the new I/O panel only.
- Loop testing, commissioning, and starting up of the system.
Projects at Capital Drilling
Project Description
Supplying fabrication parts and mechanical repair for equipment at Sukari Gold Mine in Marsa Alam is a key aspect of our services. Capital is a Complete Mining Services Provider, assisting them in running their business with less downtime for their heavy equipment through our expertise in automation engineering. Our services include supplying customers with spare parts, fabrication parts, and mechanical/electrical repair for their equipment, which is integral to construction automation in the mining sector.
Here are examples of our services:
· General Supply for all materials and tools
· Mechanical Parts (e.g., pumps & bearing)
· Electrical Parts (e.g., Circuit Breakers & Cables)
· Accessories (e.g., Plastic Covers)
Manufacturing:
· Kits for special trucks
· Coolers
· Rods
Our commitment to mechanical projects ensures that we provide high-quality solutions tailored to the specific needs of our clients.
Single Line Diagram for Electrical Panels at FRONERI
Our Project
● The client encountered issues with electrical installations at the specified sites, which include storage and distribution areas crucial for construction automation.
● Our task involved conducting several site visits to identify the problems and devise solutions, culminating in the creation of a single line diagram for each site.
Works done: -
● A team of electrical engineers and technicians undertook a thorough inspection of every panel and cable, gathering essential data to address the electrical issues.
● Following these visits, our team prepared detailed reports for each site that outlined the identified problems and proposed solutions. These reports included a comprehensive load study for each panel and cable across all sites, essential for effective automation engineering.
● The technical office team, with support from the site team, drafted the necessary single line diagrams.
● Additionally, the technical office team assessed the sites' loads based on the site team's findings and designed new panels and cables to resolve the client's issues, delivering these designs promptly to the clients to enhance their mechanical projects.
Control and monitor system for New Horizon Tank Terminal
New Horizon Tank Terminal (NHTT)
● We have been tasked with designing the monitor and control system for NHTT from the ground up as part of our automation engineering efforts.
● Commissioning and startup were integral to our project, alongside the radar tank gauging and truck loading systems, which are crucial elements in our construction automation strategy.
Works done: -
● For a monitor and control system
▪ Our automation team developed the PLC program for the terminal using Siemens Simatic Step 7, ensuring robust automation engineering practices.
▪ We crafted the SCADA system utilizing Siemens Simatic WinCC v7.5, which plays a vital role in monitoring mechanical projects effectively.
▪ Our commissioning team performed an IO Test for the PLC panel and conducted a loop test for all transmitters on site.
▪ All site transmitters (level, pressure, differential pressure, vacuum switches, and flow) from various vendors, including Emerson and Wika, were connected and configured by our skilled automation and electrical teams.
▪ The commissioning and startup for our system were completed successfully, marking a significant milestone in our automation engineering journey.
● For the Wireless Radar Tank Gauging system
▪ A segment of our automation team possesses extensive experience with the Emerson radar tank gauging system (RTG).
▪ We successfully installed and assembled the RTG devices (level, temperature, tank hubs, and Thum devices) across the twenty-five tanks at the terminals.
▪ Following mechanical and electrical installations, specialized engineers configured the devices with the required tools and software (Tankmaster) before successfully starting up the system.
▪ Effective communication was established between the SCADA software (WinCC) and the Radar Tank Gauging software (Tankmaster) using the Modbus protocol to aggregate tank data from the RTG system for comprehensive reporting and monitoring in WinCC.
● For the Truck Loading System
▪ The truck loading system integrates micro motion flow meters from Emerson and smart load presets from Advanced Systek, reflecting our commitment to efficient construction automation.
▪ Our automation team, experienced in this preset technology, successfully configured and operated the preset efficiently.
▪ A secure communication link was established between the micro motion flow meters and the PLC to gather flow and totalizer values for effective reporting and monitoring in WinCC.
▪ Hard-wired signals were connected between the presets and the PLC, facilitating the automated process by allowing the PLC to request a pump when operators set the quantity at the presets.
