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.
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.
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.
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.
The primary focus of the project was the migration of the outdated PLC system used in the control and automation of the 100-ton Gantry Crane.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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
The objective of the project was to upgrade the Inverters/Softstarters from an industrial plant to Mitsubishi F800 Series.
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.
The scope of the project was ambitious, involving the migration of various power capacities to the latest Mitsubishi F800 Inverters. The equipment upgraded included:
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.
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.
Watch the video below for full details of Ultech Engineering project history: