DESCRIPTION:
Eltrex served as the general contractor for the installation of a new cooling system for seven rubber extrusion lines in a tire manufacturing plant. The project focused on enhancing energy efficiency by implementing a system that operates in different modes depending on the season:
Winter: The system utilized free cooling mode where the heating agent was cooled using a cooling tower in a closed circuit.
Summer: The heating agent was cooled using a 910 kW chiller.
INDUSTRY:
Tire Manufacturing
FOCUS:
The primary challenge was designing an energy-efficient cooling system that could adapt to seasonal temperature variations while ensuring seamless integration with the existing local automation systems.
OBJECTIVE:
The objective was to deliver a fully functional and energy-efficient cooling system for the rubber extrusion lines, capable of operating in different modes for optimal performance throughout the year.
SOLUTION:
- Siemens S7 1515-2 PN PLC for the main MCC panel.
- Siemens TP1900 Comfort HMI for operator interface.
- Siemens G120C Frequency Inverters for motor control.
- Schneider protection devices for electrical safety.
- Phoenix Contact switches and power supplies for reliable electrical connections.
- Siemens S7 1214C PLCs for local automation panels.
- WinCC SCADA for supervisory control and data acquisition.
PROJECT DURATION:
8 months
SCOPE OF WORK:
Electrical Design:
- 1 MCC panel with S7 1515-2 PN PLC, TP1900 Comfort HMI, Siemens G120C Frequency Inverters, Schneider protection devices, Phoenix Contact switches, and power supplies.
- 6 local automation panels featuring S7 1214C PLCs and Schneider protection devices.
- Creation of a block diagram for the entire automation system.
- Detailed electrical installation plans, including cable trays and fiber optic routes.
Automation:
- PLC software development.
- Configuration and commissioning of frequency inverters.
- HMI software development.
- Development and integration of WinCC SCADA software.
- Interfacing the system with the local automation of all six extrusion lines via digital IO and Profinet.
Installation:
- Complete electrical installation, cabinet manufacturing, and commissioning performed by Eltrex teams.