classic | mobile
 

Search...

SA Instrumentation & Control Buyers' Guide

 

Afrilek: Engineering high controller availability at the train loading station of a manganese plant
December 2014, System Integration & Control Systems Design


This client’s core business is the mining and exporting of manganese ore by means of a truck and shovel open cast pit operation and materials handling and train loading systems. Afrilek was approached to implement a greenfield project that required high levels of controller availability at the train loading section.

The entire solution concept and system design was undertaken in-house by Afrilek, with technical input from the respective hardware and software suppliers. The scope of work included engineering, procurement and commissioning of the complete plant control system and instrumentation in terms of the corporate (optimisation/ERP) layer, operational (scada) layer, control (PLC) layer, field (I/O and device) layer, along with overall communication and integrated safety.

Afrilek chose the latest hardware technologies to ensure future upgrade and expansion compatibility. A standard control system library provides operator visual uniformity and future upgrade compatibility. Seamless integration to motor drives and intelligent switchgear is provided with add-on control system libraries and SIL2 rated safety is achieved as per customer requirements. Combined use of existing and new fieldbus network technologies ensures current and future system stability and the effective energy management will result in future financial gain for stakeholders.

Implementation

The collection and recording of electricity, fuel and water consumption data, together with the visualisation of the energy/resource flow, is a key aspect to attain higher energy efficiency and effective resource management. Siemens resource management component, B.Data, has been integrated with the PCS 7 control system to acquire all resource information directly from the monitoring and control devices at the I/O and level. Access to this data is made available to third-party MIS systems via the OPC protocol, which is available in the additional Simatic Open PCS 7 component.

The scada architecture comprises engineering workstation, redundant server pair, Historian and multiple operator stations. Three area-specific PLCs (one Simatic CPU 416-5 H system and two CPU 410-5 single systems) have been allocated to control the entire plant. The controllers acquire device status directly from the field devices and send commands to the field in order to control the plant according to status. This is achieved via the software that is programmed to control not only the starting and stopping of the plant, but also the safety functions needed to achieve a safe state for the protection of personnel and equipment.

I/O modules distributed in the field are connected to the sensors and actuators to provide the bus signals to the controllers. Intelligent switchgear, consisting of simocodes and drives, are used to control and protect the motors in the field.

Integration between the various control system levels is achieved via the control bus – an industrial Ethernet platform that interfaces the controller to the scada level, and the fieldbus which interfaces the I/O and device levels to the controllers. The fieldbus utilises both Profibus and Profinet architectures.

Safety

Safety is implemented at different levels within the system. At the field level, safety devices such as pull-ropes and emergency stops are physically wired to special safety modules that are incorporated in the control level. The status of the safety devices is sent from the safety modules to the failsafe controller via the fieldbus. The failsafe controller contains the safety software programmed into the controller. The switchgear has intelligent failsafe hardware that can detect the safety telegram and de-energise the conveyor motor when required.

Project progress was tracked and measured based on outlined tasks and deliverables which form part of the implementation. These tasks and deliverables were assigned deadline dates based on complexity and other factors. Milestone dates were set out to be used by both the client and the contractors for measuring progress.

The initial timeline has been adjusted on numerous occasions due to process requirement design changes. The project has been ongoing for almost three years and the latest targeted completion date is mid-2015. Afrilek will provide post-commissioning support on-site for an agreed period and thereafter via remote telephonic assistance.

For more information contact Su-Anne Willemse, Afrilek, +27 (0)11 372 9340, su-anne@afrilek.com, www.afrilek.com


Credit(s)
Supplied By: Afrilek Automation
Tel: +27 11 372 9340
Fax: +27 11 453 1016
Email: sales@afrilek.com
www: www.afrilek.com
Share via email     Share via LinkedIn   Print this page

Further reading:

  • Moore’s integrated solutions find favour in various applications across the globe
    August 2017, Moore Process Controls, System Integration & Control Systems Design
    Moore Process Controls is a privately held company, with a track record spanning 32 years. As testimony to its outstanding delivery record much of the business is from repeat customers – in some cases ...
  • Autotronix celebrates 20 years of project engineering and plant control excellence in South Africa and USA
    August 2017, Autotronix, System Integration & Control Systems Design
    Autotronix, a midsize EPC company based in Durban, with offices in Vereeniging, celebrates its 20-year anniversary this year. Launched by project engineers Collin Chetty and Haroon Bassa, Autotronix from ...
  • Fast and flexible format changes paired with high speed
    August 2017, Beckhoff Automation, System Integration & Control Systems Design
    PC-based control platform revolutionises vertical form-fill-seal machine concept.
  • HMI systems for marine engine room operation
    August 2017, Stahl Esaco, System Integration & Control Systems Design
    The operating conditions in an engine room posed a particular challenge to the design of an HMI system. These conditions necessitated a closed explosion-protected system that would also be able to withstand ...
  • The expanding scope of automation events and alerts
    August 2017, System Integration & Control Systems Design
    Detecting, reporting, and responding to abnormal situations or events are all important functional elements of a complete process automation strategy. Traditional control systems present this information ...
  • Ai2SA integrates weighing machine via Profibus DP
    August 2017, Ai2SA, System Integration & Control Systems Design
    Architects Integrating Industry (Ai2SA) was recently contracted to resolve the integration of Process Automation UniPro 4 weighing units with a Mitsubishi Q-series PLC. The company was called to site ...
  • Advanced traffic management system
    August 2017, RJ Connect, System Integration & Control Systems Design
    An advanced traffic management system (ATMS) integrates multiple technologies to monitor and control traffic flow. Real-time traffic data collected from cameras and speed sensors is sent to a traffic ...
  • Hybrid safety I/O module
    August 2017, RET Automation Controls, System Integration & Control Systems Design
    Turck’s TBIP offers another hybrid safety block I/O module that combines standard and safety outputs in a single device – in this case for Ethernet/IP and CIP Safety. The TBPN model for Profinet/Profisafe ...
  • TwinCAT OPC UA: standardised communication with information modelling from controller to cloud
    Technews Industry Guide: Industrial Internet of Things 2017, Beckhoff Automation, System Integration & Control Systems Design
    As a long-term active partner of the OPC Foundation, Beckhoff was among the earliest adopters to implement the OPC UA standard in many innovative ways.
  • Wireless gas detection
    July 2017, Pepperl+Fuchs, System Integration & Control Systems Design
    It is simple to integrate WirelessHART products, and integration in the host is performed in the same way as wired HART devices. This makes it easier for the customer to install, operate and maintain ...
  • Scada systems vs IIoT solutions
    Technews Industry Guide: Industrial Internet of Things 2017, Define Instruments, System Integration & Control Systems Design
    In some applications the benefits of an IIoT solution can outweigh those of a traditional scada system.
  • Afrilek achieves ISO 9001:2008
    July 2017, Afrilek Automation, News
    Automation solutions specialist, Afrilek, recently achieved ISO 9001:2008 certification in record time. The certificate was received within four months of starting the process. The conformance process ...

 
 
         
Contact:
Technews Publishing (Pty) Ltd
1st Floor, Stabilitas House
265 Kent Ave, Randburg, 2194
South Africa
Publications by Technews
Dataweek Electronics & Communications Technology
Electronic Buyers Guide (EBG)

Hi-Tech Security Solutions
Hi-Tech Security Business Directory

Motion Control in Southern Africa
Motion Control Buyers’ Guide (MCBG)

South African Instrumentation & Control
South African Instrumentation & Control Buyers’ Guide (IBG)
Other
Terms & conditions of use, including privacy policy
PAIA Manual





 

         
    classic | mobile

Copyright © Technews Publishing (Pty) Ltd. All rights reserved.