TUV Partner 

 

VACIS Introduction
VACIS Automation Pvt. Ltd. (VAPL) is an Industrial Automation and Renewable Energy solution provider. We specialize in delivering small and medium-sized automation and renewable energy projects for both Indian and global customers.

We are based in Pune, where our Engineering and Project Execution Center is also located. Currently, we have successfully delivered, or are in the process of executing, some multiple major domestic and global projects and programs, including:

Our Projects

Automation

Process Automation

  • Gerresheimer, USA
  • Salt Lake City, USA
  • P66, USA
  • Canadian Natural, Canada
  • Aditya Birla, India
Renewable Energy

Renewable Energy

  • Swiss Park Vanijya, India – Implementation/migration of Rockwell and ABB PLC SCADA system for 5MW solar plant
  • CEPCO Industries Ltd. – SCADA system and I&C for 5MW solar power plant
  • UJJAS Energy Ltd. - SCADA system and I&C for 5MW solar power plant

Project Overview:




Objective:




Project Execution:




Responsibilities:

Project Phases

Hover over any button to view detailed information about our project implementation process.

Technical Solution (DCS)




Safety Management




Human-Machine Interface (HMI)




Distributed Control System (DCS):

Challenges faced and solution provided

During the course of execution of these projects, multiple challenges were faced by the project team. But, the team has effectively provided reliable technical solutions for these challenges. Some of the challenges are listed below.

Working hours (IST to PST)
The team has provided PST cover to support the refinery team.
Standardized Solution
  • Different engineers in different areas.
  • Created C300/HMI guides.
  • Developed templates and libraries.
  • Document template library.
Design Review Challenges
Used Bluebeam Revu to allow 15 days for online comments and feedback.
Migration of complex PLCs
Detailed reverse engineering done to ensure robust migration.
Migration of AMCLs
Custom CL code reviewed, migrated using C300 blocks. CAB for non-migratable logic.
Migration of Custom Shapes
Replaced using Honeywell or custom EPKS ASM-compliant solutions.
Impact Identification
Impact report created for systems/process/networks, with alternatives for tags.
Online Cutover Tags
Critical tags identified and dual homing applied for seamless commissioning.
72-Hour Outage
Detailed test plans, procedures, and schedules to manage outage.
Learnings from LAR Phases
Maintained central Excel DB to track lessons learned in each phase.
Implementation Phases
Feasibility
  • Site surveys and requirement gathering
  • Prepared BOD and SOW documents
Assessment & Design
  • Assessed existing systems
  • Designed scalable DCS migration plan
System Configuration & Testing
  • Configured Experion PKS R320
  • Performed FAT and real-time testing
Installation & Integration
  • Installed new DCS hardware/software
  • Integrated with existing systems
  • Performed Site Acceptance Testing (SAT)
Training & Commissioning
  • Trained operators and maintenance staff
  • Commissioned system with minimal disruption

Result

Enhanced Process Efficiency: Improved process control led to a 12% increase in production efficiency. It also reduced process variability and improved overall product quality.

Increased Safety and Reliability: Automated safety functions contributed to a 25% decrease in safety-related incidents. Additionally, enhanced system reliability reduced unplanned shutdowns by 20%.

Operational Cost Savings: Optimization of process parameters and predictive maintenance brought significant cost savings. The project also achieved a 15% reduction in energy consumption.

Improved Decision Making: Real-time data analytics enabled better insights and more proactive decision-making. The enhanced alarm management system helped reduce operator workload and improved response times.