classic | mobile


SA Instrumentation & Control Buyers' Guide

Technews Industry Guide - IIoT 2018

Technews Industry Guide - Maintenance, Reliability & Asset Optimisation


Adroit used at CTC for high reliability
December 2006, SCADA/HMI

Shipping two million tons of woodchips per annum from its plant and port facilities at Richards Bay, the Central Timber Co-operative (CTC) is one of the world's biggest exporters of woodchips. When choosing a supervisory control and data acquisition (SCADA) system, systems integrators (SIs) Autotronix chose Adroit for its local support and reliability, thereby enabling CTC to meet its export demands. CTC purchases eucalyptus logs from local farmers and processes these into quality wood chips for the paper industry.

"Local support is very important for us and for our client. Because the plant is heavily involved in export, manufacturing downtime can cost the client heavily in demurrage charges [berthing costs]. We therefore needed a system that was highly reliable with uptime greater than 99,99999%, and chose Adroit because of its local support and because they deliver good value for money. We had already implemented Adroit on similar types of plants elsewhere making it re-usable software for us," says Collin Chetty, project engineer for Autotronix.

"CTC was the first of three wood chipping plant projects that we undertook in that area. We have extensive knowledge and experience in this industry, and hence could complete the project timeously. We were called upon again for these reasons to do an expansion," says Chetty.

"As project engineers, we must be able to expand the systems 'as and when' the plant expands and Adroit gave us that functionality. We also needed a good recording system for alarms and events that could be presented to CTC for swift problem reporting and maintenance scheduling."

Autotronix is a leading system integrator in southern Africa, engineering small to multimillion rand projects for diverse industries in the region. Using a multidisciplinary approach and focusing on factory automation, energy management and telemetry/data acquisitions systems, the company has developed both proprietary and open solutions for many industrial applications.

CTC's head office is based in Pietermaritzburg, KwaZulu-Natal. The plant, situated at Richards Bay, consists of a wood chipping line, a chip screening section and conveyor system to transport the chips to a storage area. The debarked logs are lifted onto a log deck conveyor and then onto a transfer belt conveyor, through a diverter and then fed rateably into two 96" (2,4 m) chippers. The chips are then transported via conveyors to the screen. The function of the screen is to remove all the undesirable chips. The chips are then sent to a stock pile. A M6 conveyor was constructed to provide additional capacity to the existing C5 conveyor, and to enable the concurrent loading of two vessels.

The enclosed conveyor is 589 m long utilising a 1,5 m wide conveyor belt running at 3,9 m/s with a design capacity in excess of 1000 T.P.H. The concrete 'U' beams enclosure ensures that there is no adverse impact on the adjoining town of Byrne and local bird life. It also ensures longevity of the conveyor system in the corrosive Richards Bay atmosphere. The complex conveyor belt structure links directly into the port system.

A second 460 ton pneumatic ship loader was constructed by CTC in 2004. This loader moves on a 21 m rail span the length of the 300 m jetty. The 40 m loading boom has a telescopic pipe which is capable of spanning the width of the wood chip bulk carriers. Loading is achieved by means of a 54000 CFM Roots Single Stage Centrifugal Blower blowing chips into the ship's hold - in this way, wood chip carriers can be loaded in 40 hours.

The automation consists of three Rockwell Control Logix PLC systems, server and Adroit SCADAs - one located at each of the two chippers, and the third at the export plant. The operators control the intake, chipping and transport via the Adroit human machine interface (HMI).

The systems architecture is in hot standby configuration because of the high uptime required. The two units are geographically separated by nearly 200 m, and the plant can be operated from either station, and the server was configured to hot standby using Adroit's agent server and UI on same machine, eliminating the need for additional workstations.

The SIs implemented a standalone architectural configuration using Ethernet, ControlNet and DeviceNet systems. Autotronix constantly upgrades the SCADA system to ensure that CTC runs on the latest Adroit version.

The 1500 tag point SCADA has the crushing plant on remote I/O using ControlNet, with all the starters on Rockwell's DeviceNet. Every starter brings back intelligent information, for example, current drawn and power consumed to the Adroit SCADA where it is trended. Autotronix did extensive scripting. Because of the nature of the plant they needed to display all sorts of faults and the status of the various intelligent drives, as well as the information that is filtered back in the form of state variables.

Rockwell Solution Control Logix programmable logic controllers (PLCs) talk to the Adroit SCADA via the Ethernet, and to each other at central processing unit (CPU) levels via ControlNet. Ethernet is used as a backup to maintain the network reliability providing Ethernet redundancy across the control network. Each of the drives had intelligent starters installed that were networked by DeviceNet.

The facilities are continuously manned. On-screen and audible alarm facilities have been implemented - with the audible alarm amplified electronically. Because these operations have two different operators, the alarm is filtered on two sides: wood chipping and export. The hot standby configuration of the system allows either operator to work both plants at anytime.

Instrumentation consists primarily of level transmitters, beltways, temperature transmitters for the chipper bearings, vibration transducers to monitor the health of the chippers and the chipper motor itself. CTC makes use of Adroit's trending facility to monitor all motor currents, and to continuously trend all beltways to ensure accurate loading of the ships. This is particularly important as the company is billed on the tonnages that pass through. Adroit provides a mechanism for traceability.

Autotronix used standard Adroit graphics for quick loading. The SI will also investigate the use of Opus reporting software to enhance CTC's access to shop floor information across the various levels of management and operation.

For more information contact Charles Hudgson, marketing, Adroit Technologies, +27 (0) 11 658 8100,

Supplied By: Adroit Technologies
Tel: +27 11 658 8100
Fax: +27 11 658 8101
Share via email     Share via LinkedIn   Print this page

Further reading:

  • Operator guided solutions
    December 2018, Adroit Technologies, IT in Manufacturing
    At parts assembly production sites, where parts are picked from stock, it is almost inevitable that picking mistakes will occur. As parts become more complex and their component types increase, the problem ...
  • Inductive Automation’s I­gnition technology offers potential to ­disrupt the market
    July 2018, Mzukulu Technologies, SCADA/HMI
    ‘Ignition by Inductive Automation’ is an industrial software platform with a variety of modules that can be combined to create custom HMI, scada and MES solutions.
  • New platforms for HTML5 visualisation
    Technews Industry Guide: Industrial Internet of Things & Industry 4.0, Phoenix Contact, SCADA/HMI
    Easy and flexible implementation of current and future demands.
  • Latest generation compact inverters from Mitsubishi Electric
    June 2018, Adroit Technologies, Electrical Power & Protection
    Mitsubishi Electric has now introduced its latest generation of compact inverters, the FREQROL-CS80 series.
  • Yokogawa’s open scada solution
    June 2018, Yokogawa South Africa, SCADA/HMI
    Scada systems are typically used for supervisory monitoring and control of remote and geographically distributed assets through a more open platform for interfacing with several makes and types of equipment ...
  • Schneider gets smart with new HMI solution
    June 2018, Schneider Electric South Africa, SCADA/HMI
    In a world where quick access to data has become the key to efficiency, Schneider Electric South Africa’s latest innovation in the Magelis range of HMI solutions, Magelis GTU, allows users to create the ...
  • Scada Review 2018
    June 2018, Technews Publishing (SA Instrumentation & Control), SCADA/HMI
    The subject projects of this year’s Scada Review are a worthy reflection of the effort put in by the respondent end-users, SIs and vendors. It is encouraging to see that even in these times of economic ...
  • Scada review 2018: Adroit Technologies
    June 2018, Adroit Technologies, SCADA/HMI
    End-user details    Name: Raymond Bosch    Designation: Electrical foreman cold stores    Company: Two a Day Group    Phone: +27 (0)21 859 7666    E-mail:       SI details    Name: Willie Cameron ...
  • Scada Review 2018: Wonderware
    June 2018, IS³ - Industry Software, Solutions & Support, SCADA/HMI
    End-user details    Name: Jaco van Heerden    Designation: Project C&I Engineer    Company: African Rainbow Minerals Limited    Phone: +27 (0)11 518 4199    email:       SI details    Name:...
  • Adroit Scada validated as an IoT platform
    May 2018, Adroit Technologies, SCADA/HMI
    Last year, Adroit Technologies expanded its offerings through its partnership with Sqwidnet, the licensed Sigfox Internet of Things (IoT) network operator in South Africa. From the mid-March, Adroit has ...
  • HMI modular system for hazardous areas
    May 2018, Pepperl+Fuchs, SCADA/HMI
    HMI systems must satisfy the strictest requirements if they are to be used in explosion-hazardous areas. With this in mind, Pepperl+Fuchs has introduced a wealth of new developments for its VisuNet GXP ...
  • Water – the heart of growth and sustainable development
    April 2018, SCADA/HMI
    World Water Day is celebrated on 22 March and each year it highlights a specific aspect of fresh water. This year’s theme is Nature for Water, and it will be amplified through the South African Department ...

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)
Terms & conditions of use, including privacy policy
PAIA Manual


    classic | mobile

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