Industrial Automation and Flow Monitoring Solutions for Mining & Coal Handling
Modern mining and bulk material industries require reliable, compliant, and energy-efficient engineering systems. Our Industrial Automation and Flow Monitoring Solutions are designed to deliver high-accuracy measurement, automated control, and sustainable operation in harsh industrial environments.
From remote solar-powered slurry monitoring systems to PLC-driven coal handling automation, we provide end-to-end engineered solutions that ensure operational efficiency, environmental compliance, and long-term reliability.
Solar-Powered Flow Monitoring System – Tharparkar, Sindh
As part of our Industrial Automation and Flow Monitoring Solutions portfolio, we executed a remote slurry water monitoring project in Tharparkar, Sindh.
Project Background
Mining operations required continuous measurement and reporting of slurry discharge at a location nearly 40 km away from the main facility. The project required compliance with international environmental standards defined by the United Nations.
Key challenges included:
No grid electricity at discharge point
Harsh mining environment
Continuous flow monitoring requirement
Minimum 7 days standalone power backup
Engineering Solution – Solar-Based Area Velocity Flow Monitoring
To address these challenges, we designed a fully autonomous system under our Industrial Automation and Flow Monitoring Solutions framework.
Area-Velocity Flow Measurement System
Installed on a 26-inch slurry drainage pipeline
Designed for slurry-laden water
Suitable for partially filled pipelines
Accurate measurement under variable flow conditions
High stability in unstable flow profiles
This ensured reliable data acquisition and environmental reporting.
Solar Power & Standalone Operation
A fully independent solar energy system was engineered to support uninterrupted monitoring.
Solar System Components
High-efficiency solar panels
Battery bank with 7-day autonomous backup
Charge controller
Surge and isolation protection
This configuration ensures zero-grid dependency and continuous data logging.
Electrical Panel & Protection Design
Our Industrial Automation and Flow Monitoring Solutions include industrial-grade electrical infrastructure:
Outdoor-rated control panel
Protection Distribution Board (DB)
MCBs and fuses
Surge protection
Proper earthing system
All components were selected as per international electrical standards such as IEC compliance.
Installation, Testing & Commissioning
Complete on-site installation
Flowmeter calibration
Power system verification
Accuracy validation
Final commissioning approval
Project Impact
Accurate slurry discharge monitoring
Compliance with environmental regulations
Renewable energy integration
Maintenance-free remote operation
Scalable system architecture
This project demonstrates our expertise in Industrial Automation and Flow Monitoring Solutions for remote mining operations.
Three-Way Chute Automation – Coal Handling System
As part of our Industrial Automation and Flow Monitoring Solutions expertise, we executed a fully automated Three-Way Chute system for coal handling.
Putter Motor Installation
Two putter motors (3kW, 380V) were installed for automated coal diversion.
Second-floor motor diverts coal to Belt 2022 (SR-2 via TT-2)
First-floor motor diverts coal to Belt 2042 (Old Stockyard) and Belt 2023B (SR-01)
This enabled flexible and controlled coal routing within the plant.
Power, Control & Fiber Infrastructure
Power and control cables from LV ECR near Coal Sampler-01
Fiber optic provision between MMD-1 and MMD-2
Cable trays and ducts installed at TT-1
All routing designed for safety, reliability, and maintainability.
PLC Programming & SCADA Integration
Advanced PLC programming was implemented using systems compatible with Siemens automation platforms.
The existing WinCC SCADA system was modified to include:
Real-time monitoring
Alarm management
Belt and chute interlocking logic
System status visualization
This ensured centralized control and improved operational safety.
Safety & Protection Systems
Limit switches for gate position feedback
Tilt switches for chute blockage detection
Emergency shutdown push button in field
Complete interlocking verification
These features enhance system reliability and prevent operational hazards.
Commissioning & Documentation
Motor functionality testing
Interlock verification
Electrical protection validation
Complete documentation including:
Electrical drawings
PLC logic diagrams
SCADA architecture
Key Benefits of Our Industrial Automation and Flow Monitoring Solutions
Automated and precise material handling
Renewable energy integration
Reduced manual intervention
Improved operational safety
Environmental compliance
SCADA-based centralized monitoring
Long-term system reliability
Our Engineering Capabilities
We provide complete Industrial Automation and Flow Monitoring Solutions including:
Solar-powered flow monitoring systems
Mining automation solutions
Coal handling system automation
PLC & SCADA programming
Electrical design and commissioning
Environmental compliance instrumentation
Our engineering approach focuses on sustainability, compliance, and high-performance industrial automation.
Conclusion
Our Industrial Automation and Flow Monitoring Solutions combine renewable energy integration, advanced PLC control, and intelligent SCADA monitoring to deliver reliable performance in mining and bulk material handling industries.
From solar-powered slurry flow measurement to automated three-way coal chute systems, we ensure:
Environmental responsibility
Operational efficiency
Regulatory compliance
Long-term system stability