Successful implementation doubles productivity

January 2006 System Integration & Control Systems Design

Elquip Solutions, a leading importer and distributor of high-end automation products and capital equipment in South Africa, recently installed a custom-built automation unit for Robor Pipe Solutions, a subsidiary of Barloworld Robor specialising in tube and pipe manufacture. "The automation equipment that Elquip Solutions supplied to Robor's TOSAline plant was designed, custom-built and then fine-tuned once it was installed," said Mike Cronin, managing director of Elquip Solutions.

TOSALine produces steel piping that is lined with a polyethylene layer, making it a key product for municipalities and industries with rural water, effluent and waste water management requirements.

"Our objective was to facilitate the requirement of a 50% increase in the plant's productivity within a month of the new automation equipment installation," says Cronin. "The TOSALine facility is the only plant in South Africa currently manufacturing ultra thin polyethylene lined piping. This meant that we had to work closely with Robor's engineering team to upgrade the existing automation solution, to fully realise and maximise efficiency on the production line."

Elquip Solutions supplied Robor Pipe with a Hitachi EH 150 PLC with analog modules; that was integrated with Eurotek Interface Relays and Hitachi SJ 200 variable speed drives, with full vector control. The equipment was housed in Zanardo panel enclosures. Elquip Solutions also designed and wrote the PLC programme. Elquip had a six week period to design and install the system; while working around ongoing production in the factory, in order to minimise downtime.

"The final physical installation took place during a two week shut-down and was completed well within the allocated time," points out Andre van Soelen, Robor Pipe Solutions' project manager and engineer on this installation.

"The production process is multistaged and quite complex. Accuracy is crucial as far as temperature control, timing, speed control and cooling is concerned. We were very impressed with the service from Elquip Solutions. They demonstrated their dedication to finding the best possible solutions for our requirements, they anticipated our needs and, most importantly, they met each of the deadlines that they had committed to."

Robor's technical director, Johan Scholtz, comments: "Elquip Solutions' expertise and tailored automation solution helped us to meet our goal of increasing production from the previous levels of 400 m per shift, to the current production of 600 m per shift. What is more, we know that the operators will become more familiar with the process and therefore, once we streamline the operations even further, we will significantly increase production in the future."

For more information contact Mike Cronin, MD, Elquip Solutions, 011 826 7117, [email protected]

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