Solar-Powered Flow Monitoring & Automated Coal Handling Solutions
Sustainable Engineering Projects by Techno Control Team
Introduction
Industrial operations in mining and bulk material handling demand reliable, compliant, and environmentally responsible engineering solutions. From remote slurry water monitoring to automated coal diversion systems, modern industries require smart instrumentation, automation, and power-efficient designs.
This article highlights two major engineering projects executed by the Techno Control Team, showcasing expertise in solar-powered environmental monitoring and PLC-based industrial automation, while ensuring international compliance, safety, and operational efficiency.
Remote Slurry Water Drainage Monitoring Project – Tharparkar, Sindh
Project Background
Mining operations in Tharparkar, Sindh faced a critical challenge in managing slurry and drain water discharge from a remote mining site.
As per UN environmental compliance requirements, the client was obligated to continuously measure, record, and report the volume of discharged water at a location nearly 40 km away from the main facility.
Project Challenges
No grid electricity at the discharge point
Harsh outdoor and mining conditions
Requirement for continuous and accurate flow measurement
Mandatory minimum 7 days of standalone power backup
Engineering Solution – Solar-Powered Area Velocity Flow Monitoring
To overcome these challenges, a self-powered, solar-based flow monitoring system was designed and implemented, ensuring maintenance-free and uninterrupted operation in a zero-grid environment.
1. Area-Velocity Flow Measurement System
System Features
Installed at the outlet of a 26-inch slurry drainage pipeline
Suitable for slurry-laden water
Handles variable flow conditions
Works in partially filled pipelines and open channels
Ensures high accuracy even in unstable flow profiles
2. Solar Power & Standalone Operation
Solar Power Components
Fully independent solar energy system
Designed for minimum 7 days of autonomous backup
Included solar panels
Battery bank
Charge controller
Power protection and isolation system
This guarantees uninterrupted data logging even during low sunlight conditions.
3. Control Panel & Electrical Protection
Electrical Safety Measures
Custom outdoor-rated control panel for mining conditions
Protection Distribution Board (DB) installed with:
MCBs and fuses
Surge protection
Proper earthing and isolation
4. Cabling, Enclosures & Field Accessories
Installation Standards
Weatherproof enclosures and junction boxes
Outdoor-rated power and signal cabling
Proper glands, conduits, and mounting systems
Designed for long-term reliability and minimal maintenance
5. Installation, Testing & Commissioning
Complete on-site installation
Flowmeter calibration and functional testing
End-to-end system verification for accuracy and power reliability
Project Impact & Environmental Compliance
Accurate slurry water flow measurement
Full compliance with UN environmental reporting standards
Reliable operation in remote, zero-grid locations
Solar-powered and maintenance-free solution
Scalable architecture for future expansion
This project reflects strong expertise in environmental instrumentation, renewable energy integration, and remote mining solutions.
Three-Way Chute Automation & Coal Handling System
Project Overview
Efficient coal handling requires precise diversion, automation, and safety interlocks.
The Three-Way Chute Project was designed to automate coal flow between multiple conveyor belts using electrical drives, PLC automation, and SCADA integration.
Scope of Work Executed
1. Putter Motor Installation
Motor Configuration
Installed two putter motors (3kW, 380V) for chute gate operation
Second floor motor diverts coal to Belt 2022 (SR-2 via TT-2)
First floor motor diverts coal to:
Belt 2042 (Old Stockyard)
Belt 2023B (SR-01)
Enables controlled and flexible coal routing
2. Power, Control & Fiber Cabling
Cabling Infrastructure
Power and control cables routed from LV ECR near Coal Sampler-01
Provision for fiber optic cable between MMD-1 and MMD-2
Installed cable trays and ducts at TT-1 for organized routing
3. Field Instrumentation & Safety Devices
Safety Components Installed
Limit switches for motor position feedback
Tilt switches for chute blockage detection
Emergency shutdown push button for abnormal conditions
Ensures operational safety and fault prevention
4. PLC Programming & SCADA Integration
Automation & Monitoring
PLC logic developed for MMD-1 and MMD-2
Automated interlocking of belts and chute
Modified existing SCADA (WinCC) screens for:
Real-time monitoring
Alarms and system status visualization
5. Commissioning & Documentation
Complete commissioning of motors and interlocks
Electrical protection verification
Delivered documentation including:
Electrical diagrams
Control logic
PLC & SCADA architecture
Project Benefits
Smooth and automated coal diversion
Reduced manual intervention
Enhanced operational safety
Improved system reliability and uptime
Centralized monitoring via SCADA
Our Engineering Expertise
These projects demonstrate our strength in delivering end-to-end EPC-style industrial solutions, covering:
Environmental flow monitoring systems
Solar-powered instrumentation
Mining and bulk material handling automation
PLC & SCADA programming
Electrical design, installation, and commissioning
We focus on sustainable, reliable, and future-ready engineering tailored for harsh industrial environments and regulatory compliance.
Conclusion
From remote solar-powered slurry flow monitoring to automated three-way coal chute systems, the Techno Control Team delivers innovative, compliant, and high-performance industrial solutions.
Our approach ensures:
Environmental responsibility
Operational efficiency
Long-term reliability
Complete client satisfaction