SGM Boiler LLP’s Transformation with Tulja Hi-Tech Solutions
Executive Summary
SGM BOILER LLP, a prominent Boiler manufacturer catering to the automotive, Power, Oil,
Pharma sector with a production capacity of 5 TPH To 20 TPH Pressure 175 Kg/sq.cm, faced
significant challenges with their traditional Boilers. These manual Control were heavily reliant on skilled operators, prone to breakdowns, and caused quality inconsistencies and production
delays. To address these issues, Tulja Hi-Tech Automations Pvt. Ltd. proposed a cost-effective
solution involving advanced Siemens PLC technology. The result was a remarkable
improvement in productivity, quality, and operational efficiency, enabling achieve higher client
satisfaction.
Background Information
- Client Name: SGM Boiler LLP
- Industry Sector: Boiler Manufacturing
- Product: Boiler (8 TPH, 175 KG/SQ.CM pressure, 500°C temperature)
- Location: MIDC, Chakan
Challenges Faced
- Heavy reliance on skilled operators.
- Manual operations leading to delays and inefficiencies.
- Inconsistent quality.
- Frequent breakdowns causing significant downtime.
- Reduced client confidence and hesitation to assign more work.
- Financial impact due to low production and Quality.
- Safety issue.
Client Challenges in Detail
Operational Issues
- Manual settings resulted in extended setup times—averaging 90 minutes before automation, which reduced to just 20 minutes post-automation
- Boilers were prone to serious safety issues due to lack of automation
Quality Issues
- Inconsistencies in steam output due to manual controls
- Frequent quality-related issues leading to resource wastage
Production Issues
- Low production output impacted delivery schedules
- Dependence on skilled operators increased the risk of delays during their unavailability
Financial Impact
- Decreased profitability due to inefficiencies
- Clients hesitated to place additional orders due to reliability concerns
Evaluation Criteria for Solution Provider
SGM Boiler LLP selected Tulja Hi-Tech based on the following criteria:
1.SGM Boiler LLP sought a partner with:
2. Extensive experience in complex Automation.
3. Proven expertise with over 20 years in the field.
4. Positive feedback from existing clients.
5. A thorough understanding of operations, electronics, and mechanical systems.
6. Cost-effective solutions that offered value for money.
7. Strong service support and quality workmanship.
8. Commitment to timely delivery and fair business practices.
Proposed Solution
Approach of Tulja
Tulja Hi-Tech proposed a robust boiler automation system using Siemens PLC and SCADA technology. The objective was to automate critical control functions, minimize dependency on manual intervention, and enhance safety, productivity, and steam quality.
Steps Taken
1.Study of Client’s P&ID
Conducted a detailed analysis of the client’s Process & Instrumentation Diagram (P&ID) to define a safe and logical operation sequence for both equipment and personnel
2.PLC Selection
- Evaluated multiple PLC controllers
- Selected Siemens PLC integrated with HMI and SCADA for seamless operation
3.Instrumentation Selection
- Based on experience and boiler requirements, selected reputed pressure, flow, and temperature sensors
- Chose flow control valves and VFDs for efficient boiler feedwater control
- Designed detailed electrical drawings using EPLAN software
- Created a comprehensive Bill of Materials (BOM) for instruments, control panel components, switchgears, cables, etc.
4.Documentation and Training
- Delivered a detailed user manual and system documentation
- Provided hardware and software backups to ensure data security and recovery
- Shared maintenance documentation to support autonomous operation
- Enabled SCADA-based recording of real-time parameters like flow, temperature, and pressure with automated report generation
This documentation reduced the client’s dependence on external vendors for troubleshooting and empowered the internal team for future upgrades and maintenance decisions.
5.Validation
Successfully conducted performance trials to ensure the upgraded system met all operational requirements
Results and Outcomes
Cost Savings: Achieved significant savings by avoiding full system replacement through strategic retrofitting
Productivity Gains: Boiler efficiency improved notably due to automation and precise controls
Quality Improvements: Steam quality stabilized, enhancing process consistency and end-product quality
Operational Benefits:
- Reduced dependency on skilled operators
- Documentation enabled the internal team to handle routine operations and maintenance independently
Financial Impact: Increased profitability and renewed client confidence in SGM Boiler LLP’s systems and capabilities
Conclusion
Tulja Hi-Tech’s innovative approach to provided SGM Boiler LLP with a cost-effective and efficient solution to their operational challenges. By replacing traditional manual processes with advanced PLC technology, the client achieved significant improvements in productivity, quality, and profitability. Additionally, the detailed documentation and training empowered the production and maintenance teams, ensuring long-term operational independence and success. This case highlights the importance of Automation as a viable solution for small and medium enterprises looking to optimize their operations without incurring high costs.
