Track Record
Proven Success Through Experience & Innovation
Explore the track record of Automation & Control Systems Sdn. Bhd. and discover our history of successfully delivered projects across multiple industries. This page highlights our past achievements, showcasing reliable engineering solutions, technical expertise, and long-term partnerships built through performance and trust. From automation systems to control solutions, each project reflects our commitment to quality, innovation, and customer satisfaction.
Lotte Petrochemicals Fire Jockey Pumps’ Control Panels Upgrade
As with any other petrochemical facilities, safety is of utmost importance and can never be compromised.
For the same reason, Automation & Control Systems Sdn Bhd was awarded the contract to replace some of the legacy diesel engine fire pump control panels at Lotte Petrochemicals, Pasir Gudang with Firetrol.
Before Retrofit
After Retrofit
Petronas Optimal
The obsolete Peak 150 at Petronas Optimal plant was replaced with the latest Peak 200.
Batang AI HEP
The 30 year old analog turbine governor and hydraulic pilot control to the inlet guide vane requires retrofitting as spares are obsolete.
Replacement work covers:
1.
Demolishing the old analog governor control and install the new digital governor control panel with indicators and readout meters.
2.
Removal of existing hydraulic pilot control and replace it with universal pilot control manifold to interface with existing main distribution valve.
New installation covers:
1.
Proximity sensor on the existing speed sensing gear
2.
Installed the LVDT to provide the position feedback of main distributing valve
3.
Installed the MLDT on the actuator of wicket gate to provide position feedback.
WOODWARD HUMAN MACHINE INTERFACE (HMI) – TOOLKIT
A new HMI provides the user to operate the controls, as well as monitor the status of the hydro turbine generator via PC-based HMI’s that run on the developed software package. The HMI also indicates the real-time operating data, trending, alarm display, and controller configuration.
HYDRO TURBINE GOVERNOR CONTROL
The state-of-the art Woodward MicroNet Plus controls the 28MW generator hydro turbine.
It is the electronic brain to control the turbines hydraulic control system, and interfaces with the plant’s DCS.
AVR/Excitation Systems Retrofit
Sarawak Energy Bhd’s Batang Ai Hydro Electric Power Plant required the retrofitting of the existing Meiden static excitation system on four (4) units of their hydro turbines (4 x 27MW). The existing Meiden static excitation system is obsolete and has limited manufacturer’s support.
Automation & Control Systems Sdn Bhd replaced the obsolete system with ABB UNITROL® 6080 D4 Dual Channel Static Excitation System. The works include design, engineering and supply of ABB UNITROL® 6080 D4 Dual Channel Static Excitation System, on-site installation, site commissioning and training.
Kalamuku Mini Hydro Governor And Power Management Control Retrofit
The Kalamuku mini hydro generator is a Nikki Corpn Pelton type rated at 535 KW x 2 units. Sarawak Energy Sdn. Bhd has requested for a retrofit proposal to change out the mechanical/hydraulic governor as the old system is obsolete.
Moreover, the station is located in a remote area and it needed a type of smart governing system that can gauge the dam’s level to maximize its generating capacity. The new recommended system shall also be much more robust and require minimal maintenance.
A Woodward 828 digital control system was the choice with load dependency on dam water level.
The new controls perform speed control, auto synchronizing, and load control to optimize generation capacity.
The all-electric actuators replaced the hydraulic actuator that controls the needle and the deflector. Speed sensing is achieved using magnetic pick-up.
Lotte Petrochemicals Governor’s Retrofit
Lotte Petrochemicals has a requirement to upgrade their ageing mechanical-hydraulic governor, the Woodward PG-PL to a sophisticated redundant digital governor, to improve on the hydraulic distribution system to the actuation, and to replace the safety trip protection of the Siemens extraction steam turbine driving a propylene 2-stage compressor.
OLD TRIP BLOCK
The Lotte’s operators found the old hydraulic trip block complicated to operate.
The high pressure (HP) and the low pressure (LP) left and right servovalves are hydraulically operated through complex servo mechanism.
In order to increase the reliability and the availability of the turbine, Lotte Petrochemicals decided to retrofit to the existing mechanical control systems.
A stainless steel cabinet with a pressurized purging system was used to house the Woodward 5009FT digital governor, HMI and Protech GII.
Woodward 5009FT – This is a completely redundant digital controller. This steam turbine controller includes specifically-designed algorithms and logic to start, stop, control, and protect industrial steam turbines or turbo-expanders, driving compressors, generators, or pumps.
Woodward Quicktrip trip block assembly is designed for use in gas or steam turbine shutdown systems for quick and reliable dumping of the turbine’s trip oil header. It uses low-pressure (5–25 bar / 73–363 psi) hydraulic trip oil headers. The trip block assembly’s 2-out-of-3 voting design provides a very high level of system reliability as well as compliance with industry standard API-670. Quicktrip is designed to allow turbine controls and/or turbine safety systems to quickly dump (bleed off) hydraulic header pressure during emergency trip or normal trip conditions.
When applied in conjunction with Woodward’s ProTech-GII logic solver, the QuickTrip allows operators to independently test each trip leg to verify operation and trip time.
Petronas Chemicals MTBE- PDH
This retrofit project was to replace 2 units of the obsolete Woodward 5009 and Protech to the latest 5009FT and Protech GII respectively on their Reactor Effluent Compressor turbines. As the predecessor 5009 and Protech was operating reliably with no issues for the last 15 years, naturally the client wanted Woodward as “the control of choice.”
Sungai Selangor Waterworks
The ageing emergency generator control panels at two different water treatment facilities were having reliability issues and is constantly plagued with false trips. Most of the parts are obsolete and this made operational readiness as backup power more difficult. As one of the critical water treatment plant serving the Klang Valley, they cannot afford a blackout.
The panels were replaced using Woodward’s Easygens 3200 for power management controls such as automatic mains failure starting, auto synchronizing, automatic load sharing and generator protection. A Woodward LS-5 is used for synchronizing with the grid.
PetroChad
Supplied a generator control panel that enables Auto Mains Failure start, auto-synchronization, auto loading/unloading, generators’ protection and load share with the utility. The Woodward Easygen 3000 series and LS-5 were used for this application.
Petronas Ammonia
The original BAFCO actuators for this extraction turbine were worn and there is no local support for aftersales service. Spares were hard to obtain as this model is no longer available. Automation & Control Systems Sdn Bhd solution for the customer was to retrofit it to Woodward EHPS and Parker Hydraulic Cylinder actuator with redundant LVDT feedback.
United Plantations Bhd
United Plantation at Ulu Bernam wanted a very complex power management system that enables both new Prime Mill and Optimill which are located about a kilometre apart to load share and assist in providing back up power when needed.
In this project, we use the Woodward easYgen 3000XT is a all-in-one powerful package, multi-function and economically sustainable for genset control includes engine start/stop, AMF Operation (Automatic Mains Failure), synchronization, logic programming, with genset protection as well.
In addition, the Woodward LS-5 were used in combination with the easYgen-3400/3500. The LS-5 devices manage synchronization, loading and un-loading on each bus segment. With this package, they are able to control complex power management applications with multiple incoming Utilities (Mains), bus tie-breakers and gensets. At the same time, these controls provide protection for gensets, Utilities and all bus segments.
This power management scheme enables Optimill’s 2.8 MW steam turbine generators x 2 units, 1.1 MW steam turbine generator x 1 and a 800KW diesel engine to load share via fibre optic with the Prime Mill which consist of 1.2MW steam turbine generators x 2 units and a 1MW Biogas engine x 1 and the utility mains (when needed).
It was indeed a challenging project albeit a satisfying achievement by our team.
PRODUCTS BRANDS
