• ERW (Electrical Resistance Welding) pipes are manufactured by cold forming of steel coil into a round cylindrical shape. In the initial times it was done with the low frequency A.C. current to heat the edges. Now, since 1970 the low frequency process changed to high frequency A.C. current to produce a higher quality weld.
• 24 inch dia, 16mm thick ERW pipes are formed by using continuous coil to coil joining. The machine has got 14 sets of VFD’s of various capacities. The control philosophy automatically regulates the speed of individual roles even after size changing so as to maintain constant torque and incremental MPM. This has reduced considerable time in manual tuning of VFD’s after every size change.
• Major Applications:
  • Water Pipelines
  • Agriculture & irrigation (Water mains, industrial water pipe lines, plant piping, deep tube-wells & casing pipes, sewerage piping)
  • Gas pipe lines
  • LPG and other non-toxic gas lines

• The Mechanical Pipe Expander machine is principally a Hydraulic Mandrel type expansion head operated by a reciprocating cylinder a controlled pressure of 400Bar for various diameters of pipe under expansion.
• The entire mechanical equipment was supplied by M/s. MANESSMAN-DEMAG, Germany, pioneer in the field of steel pipe manufacturing.
• The max. Capacity of pipe under expansion is 12 meter long, 60 inch dia. & 50mm thick.
• This was the third machine of its kind & capacity in the world.
• Our roll in the project was panel manufacturing, drawings, software development, site erection & commissioning.

• The inside & outside pipe coating line was installed basically to provide anticorrosive paint coating on steel pipe.
• Again here also process technology was supplied by the M/S EUPEC, Germany.
• We had supplied the entire Automation system for blaster & coating line includes AC drives Panels, PLC panels, MMI operations, Software development & commissioning.

• Tack welding, a necessary preliminary step in many welding projects, must be performed correctly to achieve optimal results from the final weld and to minimize part defects. Quality is as important in tack welding as it is in the final weld.
• An advantage of this procedure is that if the alignment for final welding is found to be incorrect, the parts can be disassembled easily, realigned, and tack welded again
• Tack welding is real welding, even if the welds are deposited in separate short beads. It holds the assembled components in place and establishes their mutual location, ensures their alignment, Complements the function of a fixture, or permits its removal, if necessary, Controls and contrasts movement and distortion during welding, Sets and maintains the joint gap.
• It also Temporarily ensures the assembly's mechanical strength against its own weight if hoisted, moved, manipulated, or overturned

• In this process the ice in the shape of Flakes will be formed using the ammonia gas and cooling tower fan. Through the cooling tower pump the water is supplied to the machines for the production of Ice and once the ice is formed the FIM cutter motor cuts the ice as per required thickness depending upon the customer. Every 30 min we can achieve around 500kg of ice.
• The above process operation has been done by Cabinet Systems in PLC & HMI SCREEN both in auto/manual operations as per system requirements.
• In Manual Mode The Operator Can Manually Start The Motor Individualy By Start/Stop Push Button That Is Provided In The Panel And the Hmi Screen.
• In Auto Mode Cooling Tower Fan Start And After Some Delay Cooling Tower Pump Start (This Cooling Tower Fan & Pump Is Used In Order To Cool The Water That Is Coming From The Outlet).Once The Cooling Tower Pump Starts Fim Cutter Starts After Some(Fim Cutter Is Needed In Order To Cut The Ice As Per Customer Requiments Depending Upon The Thickness Of The Ice).And After Some Delay Fimwc Pump Starts.After All This Motor Gets Started Compressor Ready Indication Will Be Indicated On The Panel And After Some Delay Compressor Motor Starts.

• In This Process there are two cycles, one is freezing cycle and the other is Thawing cycle.
• Freezing cycle: In the freezing cycle ice will be formed by using ammonia gas. Using cooling tower fan, cooling tower pump the water is supplied to the tubes for the production of ice .
• Thawing cycle: In this cycle Because of Thawing Gas tube ice drops on the Tube ice maker Cutter then that cutter cuts that tube ice into pieces.
• The above process operation has been done by Cabinet Systems using PLC in auto/manual operations as per system requirements.

• In this process there is two cycle charging and discharging. Charging cycle: the ice formed will be stored in the ice container(capacity of ice storage will be depend on customer requirements).the ice will be levelled by using the rectangular link conveyor this operation will all the control are given both in auto/manual mode
• In Manual Mode The Operator Can Manually Start The Motor Individualy By Start/Stop Push Button That Is Provided In The Panel And HMI
• In Auto Mode Compressor Motor On Feedback Should Be There And After That Ice Gate Winch Should Be Down, Once The Ice Gate Winch Down Feedback Comes The Rlc Cradle Will Move Reverse Depending Upon The Time Set In The Hmi Screen After The Reverse Command Stops The Rlc Cradle Move In Forward Direction As Per Time Set In The Hmi Screen, Again When The Reverse Command Stop Lift Will Move In Up Direction As Per Time Set In The Hmi Screen.
• The Cycle Will Repeat Once Again Until And Unless Compressor Motor Stops.
• Discharge cycle: In this process all the ice are delivered using elevating and discharge screw conveyor. Here Ice Gate Winch Should Go Up Direction, After Getting The Up Feedback Discharge Screw Conveyor Starts And Rlc Move In Forward Direction And Lift Will Be Moving In Down Direction.

Water treatment covers the mechanism & process used to treat water that has been contaminated by some industrial or commercial activities prior to its reuse. The control systems used here are designed for automatic operations of pumping, treatment & disposal systems. Automatic & manual operation of the Plant is possible through PLC.

CLIENTS:
M/s. Thermax Limited, Pune
M/s Metito, Indonesia

• Tubes in lots of 2 to 4 inch dia and 6 to 7 meter length approx. pass through different zones of furnace with the help of conveyor. Here the furnace has N2 gas and its temperature is above 700 deg as per set parameter. This brightens the tube surface and improves the strength and quality of tube metal.
• M/s cabinet has done the automation to control the temperature of furnace and speed of the conveyor as per set process parameter with the help of PLC & SCADA. Collective data of process and Report per production batch is also generated and maintained.

• This type of furnace is used Clear the surface of billets by making it Red Hot. Typically there are 4 furnaces (2 Heating Zone, 2 Soaking zone). Billets are pushed inside furnaces through Pushers. Now once billets are inside the furnace, Cabinet Systems through its automation does the further process.
• The temperature inside the furnace is controlled by the 2 thermocouples (Control temperature & Safety temperature) which in addition is controlled by PID controllers. For firing the burners in the furnace a mixture of air (combustion blower) and gas is used.
• UV feedback from Pilot burners used in Soaking Zones are taken for Main burner start. These processes are then followed by the PID processes for controlling the temperature of air and gas ratio.

BF gases flared in the Flare stack of various chemical processes cannot be vented directly into the atmosphere, hence they are deliberately burnt. The burning of gas should be complete so that it reduces pollution & helps to maintain cleaner atmosphere. For flare system to function properly, the flow under emergency conditions must be evaluated.