NLMK INDIA Coating Pvt Ltd
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Utility PLC System for NLMK India’s Cold Rolling and Processing Facility at Aurangabad Industrial City, Maharashtr

  • Client : NLMK INDIA Coating Pvt Ltd.
  • Industry: Steel Manufacturing & Processing

The system was designed to ensure seamless automation, high operational reliability, and advanced process control for critical plant operations. The project scope also included supervision for erection and PG testing, ensuring compliance with stringent industrial standards.

Items Supplied

Components of the PLC System
  • Reinforced Cement Concrete (RCC) strengthening of columns, beams, and roofing.
  • HMI & SCADA Integration for real-time process monitoring and control.
  • Analog & Digital I/O Modules for plant-wide automation..
  • Industrial-Grade Ethernet Switches & Fiber Optic Network Components for high-speed data communication.
  • Engineering Workstations & Programming Software for seamless configuration and diagnostics.
  • Mandatory Spares as per BOM, ensuring long-term system sustainability.

Our Projects

Challenges and Solutions

Coordination and Integration
  • Challenge: Seamless integration with existing SCADA, Data Acquisition (iba System), and Capital Equipment Control Systems.
  • Solution: A multi-layered communication architecture using Modbus RS485, Industrial Ethernet, and Optical Fiber Ring Network ensured flawless data exchange between Utility PLC, Substation Automation, and Process Control Systems.
Logistical Complexity
  • Challenge:Timely delivery of critical automation components, considering global semiconductor shortages
  • Solution: A pre-planned procurement strategy ensured on-time supply of Honeywell PLC hardware and networking components, mitigating supply chain disruptions.
Technical Execution
  • Challenge: Deploying a fail-safe automation system with near-zero downtime in a critical production environment.
  • Solution: The Hot Standby Redundant PLC Architecture with automatic failover switching provided a 99.99% system availability, ensuring continuous plant operations.
Safety and Compliance
  • Challenge: Meeting stringent industrial safety and automation standards.
  • Solution: Ensured full compliance with IEC, ISA, IEEE, and NEMA standards while implementing advanced cybersecurity measures, including industrial-grade firewalls.
Environmental Considerations
  • Challenge: Minimizing energy consumption and ensuring a sustainable automation setup.
  • Solution: Optimized PLC programming and control algorithms to reduce power usage while maintaining peak system performance.

Project Significance

This project marks a major milestone in industrial automation, reinforcing Technisys Engineering Pvt. Ltd.’s expertise in high-performance automation solutions. The successful deployment of the Utility PLC System has significantly enhanced plant reliability, efficiency, and process control at NLMK India.

Successful Completion

  • System Commissioned and Running Successfully.
  • Achieved Performance Guarantee Parameters.
  • Optimized Production Efficiency with Real-Time Monitoring.
  • Optimized Production Efficiency with Real-Time Monitoring.
  • Client Satisfaction Achieved.