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]
Further reading:
PCS Global
System Integration & Control Systems Design
Project and industry:
PCS Global led a digital infrastructure initiative in a southern African data centre setting, aiming to merge several essential operational systems into one cohesive platform.
...
Read more...
Seamless migration from ET 200M to ET 200SP HA for future-ready automation
System Integration & Control Systems Design
Project and industry:
Moore Process Controls undertook a modernisation initiative spanning the mining, petrochemical, and oil & gas sectors. This project involved upgrading legacy Siemens ET200M I/O
...
Read more...
Proconics Modernises Refinery Tank Automation with Compliance-Focused, Brownfield Upgrades
System Integration & Control Systems Design
Project & Industry
Proconics was engaged to modernise automation and SCADA systems across a refinery tank farm. The project involved complex brownfield integration, aligning new automation with existing
...
Read more...
Project & Industry
System Integration & Control Systems Design
Project: Upgrading essential automation and SCADA systems at a coal mine.
Outcome: A modern, stable automation and SCADA environment with reduced technical debt and easier support, ready for expansion.
...
Read more...
Major digital transformation project for Isuzu Motors
System Integration & Control Systems Design
Isuzu Motors South Africa, in partnership with NoMuda and S4 Integration, has kicked off a major two-year digital transformation project to modernise its production environment.
Read more...
Modernising Vertical Filter Press Machines with Future-Focused Control Systems
System Integration & Control Systems Design
Project and Industry
Pressure Filter Specialists approached us to modernise vertical filter press machines for the Minerals and Metals industry. The goal was to improve reliability, reduce downtime,
...
Read more...
Project & industry
System Integration & Control Systems Design
Project and Industry
This project involved delivering a complete electrical, instrumentation, and automation solution for a new OEM drum-twister machine, replacing an ageing unit in a major cabling production
...
Read more...
It’s a risky business not to challenge standard language
System Integration & Control Systems Design
On the surface, contracts all look alike. Once you’ve seen one, you’ve seen them all, or so it seems. Maybe so, but hidden within the standard language can be language that shifts the other party’s risk to you.
Read more...
Containerised Electrical & Control System Powers Paste Plant in Botswana
System Integration & Control Systems Design
Delivering a complete, containerized solution for a mine’s paste plant in Botswana, this project stands as a model of modern EC&I execution — integrating electrical, control, and automation systems into
...
Read more...
Control system upgrade: Smelting
SAM Systems Automation & Management
System Integration & Control Systems Design
Systems Automation & Management recently completed a major control system upgrade in the smelting industry. The project was delivered on budget and achieved a positive ROI for the client.
Read more...
printer friendly version