Multi-Brand PLC Logic Programming
Turnkey programming in Ladder Logic (LD), Function Block Diagrams (FBD), and Structured Text (ST). We program Siemens (TIA Portal V16/17/18/19), Allen-Bradley (Studio 5000), Schneider (EcoStruxure), Delta, and Mitsubishi.
- Clean, modular, well-commented code logic
- Interlock safety routines & fail-safe emergency logic
- Complete offline simulation and on-site testing
- Handover of source code backup without lockouts
SCADA System Development
High-performance SCADA applications designed for central control rooms using Wonderware InTouch, Siemens WinCC Professional, Ignition, and FactoryTalk View.
- Dynamic 2D/3D plant process mimics with real-time status
- Alarm banner with historical timestamps & acknowledgement
- Trending graphs for temperature, pressure, and motor load
- Automated Shift/Daily production PDF reports
Pharma 21 CFR Part 11 Systems
Specialized compliance engineering for pharmaceutical and bulk drug plants requiring electronic signatures, multi-level password security, and tamper-proof electronic records.
- Unalterable Audit Trail capturing all operator actions
- Dual electronic authentication (Sign-off & Verify)
- Encrypted SQL Database backup and disaster recovery
- Complete GAMP-5 validation documentation (IQ/OQ/PQ)
Electrical CAD & EPLAN Design
Comprehensive engineering drawings created on AutoCAD Electrical and EPLAN Electric P8. We provide Single Line Diagrams (SLD), multi-line schematics, loop diagrams, and cable schedules.
- Panel General Arrangement (GA) layout & door cutouts
- Terminal block strip drawings with ferrule numbering
- Itemized Bill of Materials (BOM) with manufacturer part codes
- As-Built drawing sets after commissioning
Calculations & Switchgear Sizing
Mathematical verification of panel designs according to IS/IEC standards to avoid overheating, voltage drop, and switchgear under-sizing.
- Busbar short-time withstand kA and temperature rise calculations
- Cable sizing with derating factors & voltage drop checks
- Enclosure thermal dissipation and fan/AC BTU sizing
- Transformer and DG fault level study
Machine Retrofit & Modernization
Upgrading old machines with frequent electrical breakdowns. We replace complicated mechanical timers and contactor-relay circuits with compact PLCs, touchscreen HMIs, and VFDs.
- Obsolete PLC replacement (Siemens S7-200/300, AB SLC500)
- Star-Delta motor to VFD conversion for energy savings
- Complete rewiring, wire re-ferruling, and new sensors
- Fast weekend or scheduled holiday turnaround
Site Erection & Cable Laying
Our trained site engineers and certified wiremen handle mechanical panel placement, base channel grouting, cable tray installation, armored cable pulling, glanding, and termination.
- GI/perforated cable tray erection and support structures
- Double-compression brass glanding & heavy-duty lug crimping
- Clean wire dressing, labeling, and heat shrink sleeving
- Strict adherence to industrial EHS & safety protocols
Testing & Pre-Commissioning
Rigorous testing before powering on to protect expensive machinery. We perform both cold testing (continuity, insulation) and live hot testing (loop check, logic simulation).
- Megger Insulation Resistance test (500V/1000V)
- Phase sequence verification & motor bump rotation test
- Analog loop simulation (4-20mA / 0-10V signal injection)
- Pre-commissioning punch list clearance report
Thermal Imaging Audit
Infrared thermographic scanning of running electrical panels, busbars, cable joints, contactors, and ACB contacts using high-resolution FLIR/Fluke cameras without stopping production.
- Early detection of loose connections, overloading & hot spots
- Thermal heat maps with exact temperature delta (°C)
- Prioritized corrective action report for maintenance team
- Valid for insurance risk audits & safety certifications
Power Quality & Harmonic Audits
On-site logging with Class-A Power Quality Analyzers over 24 to 72 hours. We analyze voltage dips, sags, swells, transient spikes, and Total Harmonic Distortion (THDv & THDi).
- Identification of harmonic sources (VFDs, UPS, Furnaces)
- Solutions to prevent capacitor bursting and transformer heating
- IEEE 519 compliance verification report
- Sizing recommendations for Active & Passive harmonic filters
Annual Maintenance (AMC) & Breakdown
Comprehensive and non-comprehensive AMC packages for control panels, switchgear, and automation systems across Thane, Kalyan, Bhiwandi, and Navi Mumbai MIDC belts.
- Scheduled preventive maintenance (cleaning, re-torquing)
- Guaranteed rapid on-site emergency breakdown response
- PLC & HMI backup archiving in safe cloud storage
- Priority availability of replacement switchgear & relays
Turnkey SPM Automation Projects
Complete electrical and automation partnership for Machine Manufacturers (OEMs). We take responsibility for panel building, sensor integration, pneumatic logic, and PLC programming.
- Automatic batching, mixing, filling, and packaging logic
- Servo motion control for high-speed indexing & cut-to-length
- Operator touchscreen interface with recipe management
- Full documentation, wiring schematics, and operator manual