Remote data acquisition, energy monitoring, batch control, tank farm inventory and furnace automation for chemicals, cement, sugar, rice and rubber plants.
Chemical, cement, sugar, rice and rubber plants rarely need a control system built from scratch. They need one section automated well, a reliable way to measure what the plant consumes and produces, and data that management can trust. That is the work we do in process industries: precise field measurement acquired from dispersed devices, brought into SCADA, used for control where it pays, and reported where it matters.
We bring the same engineering discipline used on LPG terminals and metering skids: an I/O list and control philosophy first, panels built to drawings and tested, software tested against the I/O list, and a named engineer after commissioning.
Flow, level, pressure, temperature and quality from field devices and skids brought into one SCADA over Modbus, HART, Profibus or OPC. Mass flow meters at oil terminals and a net oil computer for ONGC are examples.
Meters on every incomer, transformer and major drive, with consumption per shift, per section and per tonne produced, demand alarms and power quality trends. Delivered for Vishnu Cements.
Recipe download, dosing, mixing, heating and discharge sequences with batch reports for sugar, rubber and chemical processes. Andhra Sugars and Parker-Markwell run our batch controllers.
Radar gauges and level transmitters with strapping tables, so stock, net volume and transfers are measured, not estimated. Radar gauge integration at Tata Chemicals, Kolkata.
Temperature profiles, burner management, zone control and ramp and soak recipes, with every cycle logged.
Boilers, compressors, cooling towers, DG sets and water systems sequenced and monitored alongside the process, so operators see the whole plant on one screen.
New control systems for mills and plants, from I/O list to control room, and migration of relay logic or unsupported PLCs to current platforms. ABB PLC rice mill automation for Vasundhara Rice Products.
Shift and daily production, consumption and downtime reports, management dashboards, and secure one-way interfaces to SAP and other ERP systems.
Annual maintenance contracts, spares, remote support and planned upgrades for the control systems we install and for systems other vendors left behind.
Tank farm gauging, reactor and batch sequences, remote data acquisition and loading automation.
Energy monitoring, kiln and mill supervision, weighfeeder and packing plant integration.
Juice flow and batch control, boiler and evaporator supervision, molasses and spirit tank inventory.
Mill sequencing, drier control, silo level and weighing on PLC and SCADA.
Batch weighing and mixing, curing and press cycle control with recipe management.
Most enquiries begin with one problem: an energy bill nobody can break down by section, a batch that depends on one experienced operator, a tank farm reconciled by hand, or a PLC that is out of support. We scope that problem, propose the instruments and control needed to fix it, and build so the next section can be added to the same SCADA later. Send us the process flow diagram and a description of the problem; we reply with an approach and a budget.
Live tank levels posted to SAP every morning without manual entry, running at about 22 IOCL and BPCL plants.
PLC panels, marshalling and SCADA workstations built to our drawings, wired, tested and documented before dispatch.
Annual maintenance for running iFIX and GE PLC systems, and migration of legacy control systems without a long shutdown.
Measurement and control across the process industries.
Emerson mass flow meters at IOCL and HPCL terminals, net oil computer for ONGC, radar gauges for Tata Chemicals, energy monitoring for Vishnu Cements, ABB PLC rice mill automation for Vasundhara Rice Products, rubber batch automation for Parker-Markwell, batch controller for Andhra Sugars.
Yes. We select, supply, calibrate and integrate flow meters, radar gauges, analyzers and energy meters alongside the PLC and SCADA, and we represent Nirmal Industrial Controls in Telangana and Andhra Pradesh.
Yes. Most process industry jobs are brownfield: a batch section, a tank farm, a furnace or an energy monitoring layer added to a plant that keeps producing. We build and test offline, then cut over in an agreed window.
GE iFIX and Cimplicity with GE PLCs by default, and Honeywell HC900 or ABB PLCs where the client's standard asks for them. Field devices from Emerson, Nirmal and other makes integrate over Modbus, HART, Profibus and OPC.
Yes. Shift, daily and monthly reports, web dashboards for managers, and secure one-way interfaces to SAP or another ERP, as we run for about 22 LPG plants.
Tell us what you are planning, even if the details are still rough. We reply with a technical approach and an offer.