Following the resounding success and warm reception of our previous article, which meticulously detailed our achievements in the Oil and Gas sector, Ultech Engineering is thrilled to present another compelling showcase of Ultech Engineering Project History. This time, we venture beyond the realms of oil and gas and dive into a broader spectrum of industries. Our new article unveils a rich tapestry of projects that span across general industries, demonstrating our commitment to automation excellence and innovation.

Project History in General Industries

At Ultech Engineering, we have consistently demonstrated our prowess in automating processes across a wide range of industries. While our previous article shone a spotlight on the remarkable feats accomplished in the Oil and Gas sector, this article delves into the heart of general industries, from palm oil, to cement, and revealing the depth and breadth of our expertise.

Over the years, we have primarily focused on installing, upgrading, and seamlessly integrating Programmable Logic Controllers (PLCs), Human-Machine Interfaces (HMIs), and Supervisory Control and Data Acquisition (SCADA) systems. We also get ample support from our principal brand partners; Siemens, Mitsubishi Electric, Rockwell Automation, DEIF, and Weidmuller. These core technologies form the backbone of automation, enabling us to engineer solutions that elevate efficiency, safety, and productivity across diverse industrial settings.

Industrial Automation Solutions in Greenfield and Brownfield Projects

Our journey in the world of automation encompasses both greenfield and brownfield projects, reflecting our adaptability and versatility. Whether we are building a telemetry system from the ground up or undertaking the complex task of upgrading inverters and soft starters within an existing plant, Ultech Engineering's commitment to excellence remains unwavering.

• Greenfield Projects: We take immense pride in our ability to conceptualize, design, and implement automation solutions for entirely new industrial setups. Our greenfield projects exemplify our capacity to create streamlined, future-ready automation systems that meet the evolving needs of modern industries.
• Brownfield Projects: In the realm of brownfield projects, we excel in breathing new life into existing facilities. Our expertise lies in upgrading aging automation systems, ensuring they remain at the forefront of technological advancements. By seamlessly integrating cutting-edge technology with legacy infrastructure, we extend the lifecycle of critical assets and maximize their operational efficiency.

1. Gantry Crane Migration Project Brief

In July 2018, Ultech Engineering undertook a significant project involving the migration of the Programmable Logic Controller (PLC) for a 100-ton Gantry Crane. This initiative was driven by the need to replace the obsolete PLC with a modern and efficient system to ensure the seamless and safe operation of the crane. The project showcased Ultech Engineering's expertise in automation, precision engineering, and commitment to keeping critical industrial equipment up-to-date.

Scope of the Project

The primary focus of the project was the migration of the outdated PLC system used in the control and automation of the 100-ton Gantry Crane. The goal was to replace the obsolete technology with a robust and contemporary solution that would enhance the crane's overall performance, reliability, and safety.

Key Components

• Obsolete PLC: The existing PLC system, deemed obsolete, was a critical factor in the decision to migrate. Outdated technology not only posed operational risks but also limited the crane's ability to meet modern safety and efficiency standards.
• New PLC System: Ultech Engineering supplied and implemented the Mitsubishi Electric Q-PLC as the replacement for the obsolete PLC. This advanced PLC system brought state-of-the-art control capabilities to the Gantry Crane, ensuring optimal performance and compatibility with modern industrial standards.

Benefits of the Migration:

1. Enhanced Control and Precision: The migration to the Mitsubishi Electric Q-PLC brought advanced control features, enabling precise and efficient operation of the 100-ton Gantry Crane. The new system allowed for improved manoeuvrability, positioning accuracy, and overall control.
2. Improved Safety Standards: The outdated PLC system presented safety concerns, especially as industrial safety standards evolved. The migration addressed these concerns, ensuring that the Gantry Crane adhered to the latest safety protocols, reducing the risk of accidents and improving overall workplace safety.
3. Reliability and Reduced Downtime: The modern PLC system brought enhanced reliability to the Gantry Crane, reducing the likelihood of system failures and unplanned downtime. This resulted in improved operational efficiency and minimized disruptions to critical lifting operations.
4. Integration Capabilities: The Mitsubishi Electric Q-PLC seamlessly integrated with other control and monitoring systems, facilitating a more comprehensive and interconnected industrial automation environment. This integration enhanced the overall efficiency of the Gantry Crane within the larger industrial ecosystem.

The successful migration of the Gantry Crane's obsolete PLC to the Mitsubishi Electric Q-PLC stands as a testament to Ultech Engineering's commitment to delivering solutions that optimize industrial processes. By modernizing the control system, Ultech Engineering not only ensured the continued and safe operation of the 100-ton Gantry Crane but also contributed to its long-term reliability and efficiency. This project exemplifies our dedication to precision engineering and the application of cutting-edge technology to elevate industrial automation standards.

2. Palm Oil FFB Transfer Carriage Project Brief

In August 2019, Ultech Engineering embarked on a groundbreaking project involving the implementation of a new Transfer Carriage Control System for the efficient handling of Palm Oil Fresh Fruit Bunches (FFB). This initiative was aimed at revolutionizing the manual and labor-intensive process of moving and loading FFBs, showcasing Ultech Engineering's commitment to automation excellence and efficiency.

Scope of the Project

The primary focus of the project was the supply and implementation of a cutting-edge Transfer Carriage Control System. This system was designed to automate the movement and loading processes of the Transfer Carriage, significantly reducing the reliance on manual labor and streamlining the overall workflow in the palm oil processing facility. Key Components: Mitsubishi Electric iQ-F PLC: Ultech Engineering supplied and integrated the Mitsubishi Electric iQ-F Programmable Logic Controller (PLC) as the brain of the Transfer Carriage Control System. The iQ-F PLC brought advanced control capabilities to the system, ensuring precise and efficient automation of the carriage movements. GS21 HMI (Human-Machine Interface): The GS21 HMI served as the user interface, providing operators with intuitive control and monitoring capabilities. This component facilitated seamless communication between the operators and the PLC, allowing for real-time adjustments and monitoring of the Transfer Carriage operations.

Objectives

1. Automation of Movement and Loading: The primary objective was to automate the movement and loading of the Transfer Carriage, reducing the manual effort required for these tasks. The implementation of the new control system aimed to streamline the entire process, making it more efficient and less labor-intensive.
2. Manpower Reduction: The project aimed to significantly reduce the number of personnel required to operate the Transfer Carriage. By automating key tasks, the reliance on manual labor was minimized, leading to a manpower reduction from 4 personnel to just 2.

Benefits of the Control System

1. Increased Efficiency: The Mitsubishi Electric iQ-F PLC and GS21 HMI combination enabled precise control over the Transfer Carriage, resulting in increased operational efficiency. The system facilitated faster and more accurate movements, optimizing the overall workflow in the palm oil processing facility.
2. Labor Savings: The automation of the Transfer Carriage operations led to a substantial reduction in the manual labor required for these tasks. This not only minimized operational costs but also contributed to a safer and more ergonomic working environment.
3. Improved Control and Monitoring: The GS21 HMI provided operators with a user-friendly interface for monitoring and controlling the Transfer Carriage. Real-time data and diagnostics ensured that any issues could be quickly identified and addressed, minimizing downtime and improving overall reliability.
4. Enhanced Safety: By automating the movement and loading processes, the project inherently enhanced safety by reducing the potential risks associated with manual handling of heavy loads.

The successful implementation of the Palm Oil Fresh Fruit Bunch Transfer Carriage Control System in August 2019 exemplifies Ultech Engineering's commitment to innovation and efficiency in industrial automation. By introducing cutting-edge technology and automation solutions, Ultech Engineering not only improved operational processes but also created a safer and more resource-efficient working environment in the palm oil processing facility. This project is a testament to our dedication to delivering solutions that address specific industry challenges and contribute to long-term sustainability and productivity.

3. Plant SCADA Migration Project Brief

In February 2020, Ultech Engineering undertook a complex and pivotal project involving the migration of a Cement plant's Supervisory Control and Data Acquisition (SCADA) system. The aim was to transition from an aging Wonderware InTouch SCADA to the robust Siemens WinCC SCADA. This migration project not only addressed the challenges posed by the obsolescence of the existing system but also ushered in modern features, improved reliability, and enhanced control capabilities for the cement plant.

Scope of the Project

The primary focus of the project was the migration of the existing SCADA system, which had been in operation for over a decade, to Siemens WinCC SCADA. This comprehensive migration involved over 5000 Input/Output (IO) points spread across four Siemens S7-300 Programmable Logic Controllers (PLCs). Additionally, the project included the supply and installation of a new SCADA server rack with redundant servers and Uninterruptible Power Supply (UPS) for high availability.

Key Components

Siemens WinCC SCADA: The core of the project involved the migration to Siemens WinCC SCADA, a state-of-the-art supervisory and control system. This SCADA platform is known for its advanced features, user-friendly interface, and robust capabilities.

Siemens S7-300 PLCs: The existing PLCs were Siemens S7-300 models, and Ultech Engineering ensured a seamless migration of over 5000 IO points from these PLCs to the new Siemens WinCC SCADA.

SCADA Server Rack: To ensure high availability and reliability, Ultech Engineering supplied a new SCADA server rack equipped with redundant servers. This setup was complemented by a UPS power supply to safeguard against power interruptions.

Objectives

1. System Obsolescence Mitigation: The primary objective was to address the obsolescence of the existing Wonderware InTouch SCADA, ensuring that the cement plant's control and monitoring systems remained up-to-date and compatible with modern industrial standards.
2. Enhanced Control Capabilities: The migration aimed to leverage the advanced features of Siemens WinCC SCADA, providing the plant with enhanced control capabilities, real-time monitoring, and improved visualization of critical processes.
3. Improved Reliability and High Availability: The introduction of redundant servers and a UPS power supply was aimed at enhancing the overall reliability and availability of the SCADA system, minimizing downtime and ensuring continuous operation.

Benefits of the Migration

1. Modernized Control System: The migration to Siemens WinCC SCADA brought the cement plant's control system to the forefront of modern industrial automation. The plant gained access to advanced features, improved diagnostics, and better visualization tools.
2. Increased Efficiency: The migration of over 5000 IO points ensured a seamless transfer of data, contributing to improved operational efficiency and streamlined data management.
3. High Availability: The implementation of redundant servers and a UPS power supply significantly increased the availability of the SCADA system, reducing the impact of potential disruptions and ensuring continuous operation.
4. User-Friendly Interface: Siemens WinCC SCADA provided plant operators with a user-friendly interface, facilitating intuitive control and monitoring. This improved interface contributed to quicker decision-making and enhanced operator efficiency.

The successful migration of the Cement Plant SCADA system from Wonderware InTouch to Siemens WinCC in February 2020 showcased Ultech Engineering's capabilities in managing complex automation projects. By modernizing the control system, Ultech Engineering not only addressed the challenges of obsolescence but also provided the plant with a reliable, high-performance SCADA platform. This project exemplifies our commitment to delivering solutions that elevate industrial processes, improve efficiency, and ensure long-term sustainability in the face of technological advancements.

4. Booster Pump Telemetry System Project Brief

In May 2021, Ultech Engineering undertook a transformative project involving the design and implementation of a state-of-the-art Booster Pump Station Telemetry System. This project was commissioned to enhance the monitoring and control capabilities of the booster pump station and the high-level tank located at Marudi, Sarawak. The Telemetry System aimed to provide real-time insights into key performance indicators, enabling centralized monitoring from the central office situated in Miri, Sarawak.

Scope of the Project

The project encompassed the supply and implementation of a Telemetry System, which comprised two remote stations strategically placed at the Booster Pump Station and the High-Level Tank in Marudi. The primary goal was to establish a reliable and efficient communication network between these remote stations and the central office, facilitating seamless data transmission for comprehensive monitoring and control.

Key Features

1. Remote Monitoring Stations: Ultech Engineering installed two remote telemetry stations, strategically positioned at the Booster Pump Station and the High-Level Tank in Marudi. These stations served as the eyes and ears of the system, capturing real-time data on crucial parameters.
2. Centralized Monitoring in Miri: The central office located in Miri, Sarawak, became the nerve center where data from the remote telemetry stations was consolidated and analyzed. This centralized monitoring hub allowed for quick decision-making and response based on real-time insights.
3. Performance Monitoring: The Telemetry System was designed to monitor key performance indicators critical to the efficient operation of the booster pump station and the high-level tank. Parameters such as supply flow rate and tank level were continuously tracked, providing a comprehensive view of the system's performance.
4. Data Accessibility: Through the Telemetry System, stakeholders in the central office gained easy access to crucial data without the need for on-site visits. This not only streamlined operational efficiency but also contributed to significant cost savings by reducing the necessity for physical inspections.

Benefits of the Telemetry System

1. Enhanced Operational Efficiency: Real-time monitoring of key performance indicators allowed for proactive decision-making, leading to enhanced operational efficiency of the booster pump station.
2. Reduced Downtime: The ability to promptly identify and address issues based on real-time data minimized downtime, ensuring continuous and reliable operation of the pump station and the high-level tank.
3. Cost Savings: The Telemetry System reduced the need for frequent site visits and manual data collection, resulting in substantial cost savings over the long term.
4. Improved Resource Allocation: The centralized monitoring in Miri facilitated optimized resource allocation, ensuring that personnel and resources were deployed where they were most needed.

The successful implementation of the Booster Pump Station Telemetry System by Ultech Engineering exemplifies our commitment to leveraging cutting-edge technology for the improvement of industrial processes. This project not only enhanced operational visibility and control but also demonstrated the practical application of telemetry solutions in optimizing resource management and reducing operational costs. Ultech Engineering continues to be at the forefront of delivering innovative solutions that bring tangible benefits to our clients.

5. Inverter/Softstarter Upgrading Project Brief

The objective of the project was to upgrade the Inverters/Softstarters from an industrial plant to Mitsubishi F800 Series.

Introduction

In July 2022, Ultech Engineering embarked on a transformative project, showcasing our proficiency in modernizing industrial facilities through the migration of outdated Inverter/Softstarter systems to the cutting-edge Mitsubishi F800 Series Inverters. This initiative aimed not only to replace aging equipment but also to enhance the overall efficiency, reliability, and control of the plant's machinery.

Project Scope

The scope of the project was ambitious, involving the migration of various power capacities to the latest Mitsubishi F800 Inverters. The equipment upgraded included:

• 1 x 400 kW Inverter
• 1 x 160 kW Inverter
• 2 x 132 kW Inverters
• 1 x 75 kW Inverter
• 3 x 55 kW Inverters
• 1 x 37 kW Inverter

Technical Integration

A key challenge addressed by Ultech Engineering was seamlessly integrating the new Mitsubishi F800 Inverters with the existing plant Programmable Logic Controller (PLC). This integration was achieved using the Industrial PROFIBUS protocol, ensuring robust communication and synchronization between the PLC and the upgraded inverters.

Benefits of Migration

1. Enhanced Performance: The migration to the Mitsubishi F800 Series brought about a significant improvement in the overall performance of the plant's machinery. Advanced control features and precision offered by the new inverters translated into smoother operations and increased productivity.
2. Energy Efficiency: The latest Mitsubishi F800 Inverters are designed with a focus on energy efficiency. By upgrading, the plant not only reduced its energy consumption but also contributed to a greener and more sustainable operation.
3. Reduced Downtime: The migration process was executed with meticulous planning, minimizing downtime during the transition. Ultech Engineering ensured a seamless switchover, allowing the plant to resume operations swiftly with minimal disruptions.
4. Remote Monitoring and Control: The integration with the plant's PLC and use of Industrial PROFIBUS protocol enable remote monitoring and control of the inverters. This not only facilitates real-time diagnostics but also enhances the plant's overall control capabilities.

The successful completion of the Inverter/Softstarter upgrading project stands as a testament to Ultech Engineering's commitment to delivering solutions that go beyond mere equipment replacement. By leveraging our expertise in automation, we not only modernized the plant's machinery but also contributed to its long-term operational efficiency and sustainability. This project exemplifies our dedication to staying at the forefront of technological advancements and providing our clients with solutions that make a tangible difference in their industrial processes.

Stay tuned as we embark on this exciting journey through the world of general industry automation, showcasing our dedication to shaping a smarter, more efficient future for all.

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