Somnath.v

Grip Handle SPM. (Mate- BLR)

(Special Project Machine (SPM))

This project involved the end-to-end development of a Special Purpose Machine (SPM) designed for grip handle operations, tailored to meet specific industrial requirements. The system was engineered with precision, combining electrical and pneumatic automation under a unified control architecture. Custom machine design for grip handle processing. PLC programming for automated control sequences. Wiring layout planning and execution with meticulous wire dressing for safety and maintainability. Integration of pneumatic actuators, sensors, and control valves for mechanical operations. Deployment of electrical components including relays, contactors, SMPS units, and terminal blocks. Pneumatic System: Configured for actuation, gripping, and release mechanisms with precise timing and pressure control. Electrical System: Engineered for logic control, feedback processing, and operator interface. Control Panel: Designed with ergonomic layout, safety interlocks, and diagnostic indicators. HMI Interface (if applicable): For real-time monitoring and manual overrides. Entire project executed under direct supervision, ensuring adherence to industrial standards and best practices. Component selection and integration optimized for performance, durability, and cost-efficiency. Testing and commissioning carried out to validate system functionality and reliability under operational conditions. Total project valuation: ₹7 million, reflecting the complexity and quality of the solution. Delivered a high-performance, task-specific automation system that enhances productivity and reduces manual effort. Established a scalable framework for future SPM developments in similar domains

#HMI Programming
#Pneumatics
#Programmable Logic Controller (PLC)
#Electrical Wiring
#ELV
#Project Planning
#HMI Configuration
#Automation
#Control Wairing

Air Line and compressor. (PWPL)

(Air Line and compressor Installation.)

This project involved the design and deployment of a complete compressed air system at the PWPL plant, aimed at supporting various industrial operations with reliable and high-quality air supply. The system was engineered for durability, efficiency, and scalability. PPR (Polypropylene Random Copolymer) piping was used for the airline network due to its corrosion resistance and high-pressure tolerance. Multiple airline drops were installed throughout the facility to ensure accessibility and operational flexibility. PPR welding machine was used for pipe fusion at a controlled temperature of 320°C, ensuring leak-proof joints and long-term reliability. The total project value was approximately ₹3 million, reflecting the scale and quality of the installation. Precise layout planning to optimize airflow and minimize pressure loss. Secure mounting and support structures for all components. Compliance with industrial safety and operational standards. System tested for leakage, pressure stability, and moisture control. Delivered a robust and efficient air system tailored to the plant’s operational needs. Improved equipment performance and longevity through clean, dry air supply. Enabled future scalability for additional drops or equipment integration.

#Project Supervision
#Program Management
#Project Planning
#Problem Solving
#Vendor Management
#Air Compressors
#PPR
#Project Management
#Drier (Installation)

Air Line and compressor. (PWPL)

Industrial Dojo Mate & SADBID (For Training Purposes)

Industrial Dojo Mate & SAI&AIPL.

(For Training Purposes)

Industrial Dojo is a purpose-built training platform designed to upskill individuals in core industrial automation technologies. Developed from the ground up, the system combines hands-on hardware integration with intuitive software interfaces to simulate real-world industrial scenarios. The Industrial Dojo is currently operational within the maintenance department of the Mate (BLR) plant. It serves as a hands-on training tool for technicians, engineers, and interns to gain practical experience in automation systems. The platform enables scenario-based learning, including fault simulation, system recovery, and logic troubleshooting. Delivered a cost-effective, scalable, and immersive training solution. Enhanced technical competency among plant personnel. Established a foundation for continuous learning and innovation in industrial automation

#HMI Programming
#PLC Programming
#Electrical Engineering
#Electrical Panel Design
#Electrical Wiring
#Dojo
#industrial training
#Operational Programming
#Maintenance

DG Automation (SIA&AIPL)

(DG250kVA Automation)

This project focused on automating the operation of a Diesel Generator (DG) system that was initially functioning in manual mode, limiting its responsiveness during power outages and increasing operational dependency. The DG failed to start automatically during power failures. Investigation revealed the absence of an Automatic Transfer Switch (ATS), which is typically required for auto-start functionality. Market cost for a standard ATS system ranged between ₹2 to ₹3 lakhs, making it a financially impractical solution for the site. Automated DG start/stop control based on real-time power availability. Logic-based switching between grid and generator power. Fail-safe mechanisms to prevent false triggering or overload conditions. Scalable design, allowing future integration with remote monitoring or IoT modules. PLC Unit programmed with conditional logic for power failure detection and DG activation. Relay interface to control DG starter and breaker circuits. Manual override option retained for emergency or maintenance use. Status indicators for operational feedback and fault alerts. Achieved cost-effective automation without compromising reliability. Improved response time during power outages. Enhanced operational efficiency and reduced manual intervention

#Automation
#Project Management
#Project Planning
#Project Estimation
#Project Supervision
#Project Engineering
#DG Automation
#ATS (Automatic Transfer Switch)
#Automation project

DG Automation (SIA&AIPL)

CCTV Project (SIA&AIPL)

(CCTV Project Installation)

This project involved the installation and configuration of a comprehensive video surveillance system at the SIA&APIL plant, utilizing a mix of IP and non-IP cameras from multiple trusted brands. The objective was to enhance site security, monitoring capabilities, and operational visibility through a robust and scalable setup. The system was designed to support both online and offline modes, ensuring continuous recording and remote accessibility. Most installations featured IP cameras, offering high-resolution imaging and network-based control. DVRs and NVRs were successfully configured for seamless integration with the camera network, enabling centralized monitoring and playback. Remote access capabilities were enabled for authorized personnel via secure network protocols. The multi-brand approach ensured flexibility and compatibility across various zones of the plant. The system supports real-time surveillance, motion detection, and event-based recording.- All components were installed in accordance with organization’s safety and IT infrastructure standards, ensuring long-term reliability and maintainability.

#Networking
#Ipconfig
#Router Configuration
#Digital Video Recorder (DVR)
#(NVR) Camera Operation
#IP Cameras Installation
#IP CCTV
#PTZ
#Monitoring

Paint and Primer Booth

(Paint and Primer Booth BPCL- Piyala, Nashik, Kurnool)

This project involved the development of a fully automatic Painting and Primer Booth for LPG cylinders, initiated by the BPCL plant. The system is designed to deliver consistent surface coating and primer application through a fully automated, PLC-controlled process, ensuring high throughput and uniform quality. The system operates on a PLC-based architecture, enabling fully automated cycles for both primer and paint application. HMIs provide intuitive control interfaces for operators, including recipe selection, fault alerts, and maintenance logs. Pneumatic guns are programmed for uniform spray patterns, minimizing overspray and ensuring consistent coating thickness. All electrical and mechanical components are configured in accordance with BPCL plant standards, including flameproof certification for hazardous environments. The booth is designed for safe operation, with integrated sensors and interlocks to monitor pressure, temperature, and airflow. Automated cleaning and purge cycles are included to maintain system hygiene and prevent nozzle clogging.

#Painting booth
#Automation
#PLC Programming
#Renu
#HMI Configuration
#HMI Programming
#Pneumatics
#Project Supervision
#LPG bottling.

Paint and Primer Booth.

HYDROTESTING (HST) Unit Of (BPCL-Kurnool).

HYDROTESTING Of LPG CYLINDERS (BPCL-Kurnool).

HYDROTESTING (HST) Unit Of LPG CYLINDERS (BPCL-Kurnool)

This project involved the design and development of a fully automatic Hydrotesting (HST) unit for LPG cylinders, initiated by the BPCL plant. The system is engineered to perform high-pressure hydrostatic testing with precision, safety, and full automation, ensuring compliance with BPCL’s operational standards. The unit operates on a PLC-based architecture, enabling fully automated testing cycles with minimal manual intervention. Real-time data acquisition and system diagnostics are facilitated through integrated HMIs. Pressure testing is conducted at 25 bar, with continuous monitoring and feedback to ensure test integrity and repeatability. All components are selected and configured in accordance with BPCL plant standards, including flameproof certification and industrial-grade reliability. The system is designed for fail-safe operation, with built-in redundancies and safety interlocks. Hydrotesting procedures are executed with precision to ensure structural integrity and leak-proof performance of LPG cylinders.

#PLCs
#HMIs
#Relay cards
#Sensors
#Pressure sensors
#Pressure switches
#Analog modules,
#Hydrotesting (HST)
#Pressure 25 bar

PNEUMATIC TESTING UNIT OF LPG CYLINDERS (BPCL)

This project involved the development of a fully automatic Pneumatic Testing Unit for LPG cylinders, initiated by the BPCL plant. The system is designed to perform high-precision pressure testing in a controlled and automated environment, ensuring compliance with BPCL’s operational and safety standards. The system operates on a PLC-based architecture, enabling fully automated testing cycles with minimal human intervention. Integrated HMIs provide intuitive control interfaces for operators, including diagnostics, status indicators, and test logs. - Sensor feedback and pressure data are continuously monitored to ensure precise testing at 12 bar pressure, as per BPCL specifications. All components are selected and configured in accordance with BPCL plant standards, including flameproof enclosures and certified instrumentation. The system ensures repeatable accuracy, fail-safe operation, and data integrity across all testing cycles. - Designed for industrial robustness, the unit supports continuous operation in demanding plant environments.

#Pneumatic Testing Unit
#PLCs
#HMIs
#Relay cards
#Pressure testing 12 bar
#BPCL plant
#FLP
#PLC-based
#Sensors

PNEUMATIC TESTING UNIT OF LPG CYLINDERS (BPCL)

PNEUMATIC TESTING UNIT (BPCL)

SC Valve Screwing Machine (BPCL).

SC Valve Screwing Machine

SC Valve Screwing Machine BPCL-Kurnool, Nashik.

This project involved the design and development of a fully offline SC Valve Screwing Machine tailored for operations at the BPCL-Kurnool plant. The system is engineered to deliver precise and reliable screwing of SC valves onto LPG cylinders, utilizing a robust combination of pneumatic and hydraulic technologies. The machine operates in a fully offline mode, independent of external control systems or network connectivity. Designed for pneumatic-based actuation, ensuring energy-efficient and low-maintenance operation. Torque output and pressure parameters are precisely tuned to meet BPCL’s plant specifications. All mechanical and control elements are selected and configured in accordance with BPCL-Kurnool’s operational standards. The system ensures repeatable torque accuracy, minimizing risk of under- or over-tightening. Offline architecture enhances system reliability, making it ideal for standalone deployment in industrial environments.

#Hydraulic
#Pneumatic Solenoid Valve
#Hydraulic Pressure
#Hydraulic Cylinder
#Hydraulic Actuator
#Torque 21nm
#Pneumatic Cyclinders
#SC Valve Screwing
#Hydraulic Pump

PUNCH MACHINE OF LPG CYLINDERS

PUNCH MACHINE OF LPG CYLINDERS BPCL-Kurnool, Nashik.

This project involves the development of a fully offline Punch Machine for LPG cylinders, commissioned by the BPCL plant. The system is engineered to perform high-pressure punching operations in compliance with BPCL’s stringent safety and performance standards. The machine operates on a pallet-based mechanism, allowing precise alignment and handling of LPG cylinders during the punching process. It is designed for offline operation, meaning it functions independently of any centralized control system or network. The system is calibrated for pressure up to 15 tons, ensuring robust performance under industrial conditions. The integrated punch die is capable of stamping 4 to 5 words onto each LPG cylinder. This feature supports traceability, compliance labeling, and batch identification as per BPCL’s operational protocols. All components and operational parameters are aligned with BPCL plant standards, particularly for pressure handling, safety, and mechanical durability.

#Punch Machine
#Analog Pressure gauge
#Gauge
#Pneumatic cylinders
#Pneumatics Pallets
#BPCL plant
#Fluid Power
#Pallet-based
#Pressure 6 bar

Punch Machine (BPCL-Kurnool)

Foot Ring Machine (BPCL).

Foot Ring Machine (BPCL-Nashik).

Foot Ring Machine (BPCL-Nashik). >

This project encompassed the design and development of a fully offline Foot Ring Machine, specifically tailored for operations at the BPCL-Nashik plant. The system is engineered to perform precise and reliable repairs of foot rings on LPG cylinders, leveraging a robust integration of hydraulic technologies. The machine functions independently without external control systems, ensuring high reliability and ease of deployment in standalone industrial environments c- Designed with hydraulic-based mechanisms to deliver energy-efficient performance and reduce maintenance requirements. Torque output and pressure parameters are meticulously calibrated to align with BPCL’s plant specifications, ensuring consistent and accurate repairs. All mechanical and control components are selected and configured in strict accordance with BPCL-Nashik’s operational standards. - The system guarantees repeatable torque precision, effectively minimizing the risk of under- or over-pressing during operation. This offline architecture enhances system robustness, making it an ideal solution for industrial applications requiring autonomous and dependable performance.

#Hydraulic
#Hydrolic Solenoid Valve
#Hydraulic Pressure Switch
#Hydraulic Cylinder
#Hydraulic Actuator
#Torque 21nm
#Hydraulic Hose Pipe.
#Foot Ring repair
#Hydraulic Die (4 Head)

35/47.5_KG FILLING MACHINE WITH CORRECTION UNIT OF LPG CYLINDERS

35/47.5_KG FILLING MACHINE WITH CORRECTION UNIT OF LPG CYLINDERS BPCL-PIYALA, BALLABHGARH .

In this project, we combined electrical and mechanical equipment into a single, intelligent system, designed to automate the cylinder filling process with precision and safety. Communication was established through MODBUS, using RS‑232 and RS‑485 protocols, ensuring reliable data transfer between devices, while a Delta DVP‑Series PLC, programmed with ladder logic, acted as the central controller, orchestrating every step of the operation. The process begins with cylinders arriving on a chain conveyor, their positions detected by six sensors, each feeding information back to the PLC. Based on these signals, the pneumatic stopper engages, creating the required gap between cylinders, and ensuring that each one is positioned exactly at the set point. Once the cylinders are aligned, the stopper releases them one by one, allowing smooth movement along the conveyor, while the permanent stopper ensures proper sequencing. As each cylinder approaches its designated head, the lifter rises, clamps engage, and the cylinder is held firmly in place, all without interrupting the continuous motion of the conveyor. At this stage, manpower enters the process, operators pick up the filling gun, connect the plug valve, and enter the tare weight, after which the filling cycle begins. Each head follows the same routine, filling cylinders in sequence, while the PLC monitors the status. Once filling is complete, clamps are released, but the lifter continues to hold the cylinders momentarily, ensuring stability as the filling guns are removed one by one. Finally, all lifters lower, releasing the cylinders back onto the conveyor, which continues its smooth operation, carrying the filled cylinders forward. The true innovation lies in the seamless integration of automation and human interaction, where the PLC, sensors, pneumatic stoppers, and lifters handle positioning, clamping, and sequencing, while operators focus on safe and accurate filling. This hybrid approach reduces errors, increases throughput, and ensures safety, all while maintaining uninterrupted conveyor movement, making the system both efficient and reliable. CORRECTION UNIT:- Once all cylinders have completed the filling process, they move forward to the correction unit, which operates in a manner similar to the filling stoppers but is designed for a single head. Unlike the filling stage, where multiple cylinders are managed in sequence, the correction unit focuses on one cylinder at a time, ensuring that each is checked and adjusted with precision before leaving the line. As the conveyor brings a filled cylinder into position, the pneumatic stopper engages, counting and holding exactly one cylinder at the correction point. A sensor confirms its arrival, and the PLC signals the lifter to rise, securing the cylinder firmly in place. The clamp engages, locking the cylinder so that the correction process can begin without interruption from the conveyor’s continuous motion. At this stage, the operator enters the tare weight, and the JISL correction unit compares the actual contents against the set point. If the LPG inside the cylinder is found to be over the set point, the system automatically removes the excess as per the programmed threshold. If the LPG is found to be less than the set point, the correction unit initiates filling, adding gas until the cylinder reaches the precise target value. This process ensures that every cylinder, whether slightly overfilled or underfilled, is corrected to the exact specification defined in the JISL unit. Once the correction is complete, the clamp releases, the lifter lowers, and the cylinder is smoothly returned to the conveyor. The stopper resets, ready to count and position the next cylinder, maintaining a steady rhythm through the single-head correction stage. By integrating this correction unit into the automated system, the process achieves both accuracy and reliability. The filling stage ensures that cylinders are filled efficiently, while the correction stage guarantees that each cylinder meets the exact set point before leaving the line. Together, the filling and correction units create a complete cycle of automation, combining sensors, stoppers, lifters, clamps, and PLC control with human oversight, resulting in a system that is safe, precise, and highly efficient