July 2011System Integration & Control Systems Design
Rockwell Automation won the tender to upgrade the compressor systems at Harmony Gold Mining’s (Harmony) number 7 and 8 shafts in Evander in mid-2010. The upgrade was the result of the mine’s optimisation strategy and its drive to do so in the most energy-efficient way possible.
According to Riccardo Fachin, Rockwell Automation’s systems and solutions business project manager, saving energy with compressors is not an often utilised solution in industry and this was a unique opportunity to showcase its possibilities. “We held discussions with Harmony’s electrical personnel on what extra equipment should be installed with a view to measuring and reporting energy usage and eventually, savings,” he explains.
The number 1 compressor, a 1987 Demag VK 32C with a discharge pressure of 6,7 bar and an inlet of 35 000 cubic metres per hour and synchronous motor (2900 kW 6,6 kV), needed an upgrade on the electrical MV switchgear as well as the control system. “The mechanical upgrade consisted essentially of new electrically controlled inlet and outlet vane valves for surge control. The electrical upgrade consisted of new 6,6 kV switchgear, while we re-used the oil cooled reactor starter,” says Fachin.
“Automatic solid-state DC excitation was accomplished on the existing synchronous motor with the use of a DC control and power monitoring system from Rockwell Automation, a system that proved its reliability when the power factor was held at unity under all load conditions. However, the real test was not only to prove energy saving, but also provide an accurate model of the much needed surge control when there was no information available on the existing system.”
Rockwell Automation engineers installed a new Allen-Bradley ControlLogix PAC complete with GEM standard ICS-Triplex compressor control software into the new MCC ready for connection to the instrumentation. The compressor control software allowed engineers to calculate and implement the most appropriate surge control for the number 1 compressor, and also two of the others. Control of the inlet vane through the surge algorithm provided a considerable saving of energy.
To collect all relevant information such as pressure, temperature, power factor, power usage, airflow, trips and alarms, the FactoryTalk View scada system was installed. During the first month of operation, the energy saving from compressor number 1 was significant and Harmony was particularly impressed with the newly installed control software.
“Plans are afoot to upgrade other compressors working on the same manifold,” says Fachin. “The ICS-Triplex software and Allen-Bradley ControlLogix will allow for proper load sharing and shifting between compressors, allowing even more substantial energy saving in the future.”
Enhancing carbon capture drilling efficiency with PowerFlex drives Rockwell Automation
Motion Control & Drives
To meet the growing demand for carbon capture and storage, Drillmec needed to make drilling ingress points for carbon capture faster, safer and more cost efficient.
Read more...PCS Global PCS Global
System Integration & Control Systems Design Project and industry:
PCS Global led a digital infrastructure initiative in a southern African data centre setting, aiming to merge several essential operational systems into one cohesive platform. ...
Read more...Seamless migration from ET 200M to ET 200SP HA for future-ready automation Moore Process Controls
System Integration & Control Systems Design Project and industry:
Moore Process Controls undertook a modernisation initiative spanning the mining, petrochemical, and oil & gas sectors. This project involved upgrading legacy Siemens ET200M I/O ...
Read more...Sustainability as strategy Rockwell Automation
IT in Manufacturing
In today’s business landscape, sustainability has become a powerful driver of business differentiation. Rockwell Automation partners closely with customers to embed sustainable, data-driven solutions into their manufacturing operations.
Read more...Modernising critical water systems without disruption Rockwell Automation
SCADA/HMI
The region of Waterloo needed to upgrade its SCADA and PLC systems across 157 water facilities while ensuring continuous water availability for over 60 000 residents. Their success story, powered by Rockwell Automation technology, shows that modernisation doesn’t have to mean disruption.
Read more...Project & Industry
System Integration & Control Systems Design Project: Upgrading essential automation and SCADA systems at a coal mine. Outcome: A modern, stable automation and SCADA environment with reduced technical debt and easier support, ready for expansion. ...
Read more...Install and commissioning time cut by 50% thanks to digital twin insights Rockwell Automation
IT in Manufacturing
ECM Technologies, a world leader in the design and manufacture of innovative and modular low-pressure carburising industrial furnaces, has developed a solution that removes many of the installation and commissioning challenges relating to the development, testing and deployment of large-scale heat treatment plants.
Read more...Major digital transformation project for Isuzu Motors
System Integration & Control Systems Design
Isuzu Motors South Africa, in partnership with NoMuda and S4 Integration, has kicked off a major two-year digital transformation project to modernise its production environment.
While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.
printer friendly version