The delivery of a modern energy management system to Assmang's Machadodorp Ferro-Chrome works has been successfully completed, with significant benefits in terms of cost and energy management achieved.
The decision for replacement of the existing demand management system was based on decreasing reliability, as well as escalating maintenance costs of the existing demand management system. At the outset of the project, it was agreed that a demand-based energy management system, capable of performing load control on a prioritised basis, was required. This would allow the electric arc furnaces to be controlled according to pre-defined demand patterns. This involved implementing a management system that taps down the furnaces on a prioritised basis, starting with the lowest-priority unit. Furnace priority is determined through numerical selection, furnace efficiency and process conditions such as the curing process of the electrodes.
The system was implemented together with Electro Systems, a systems integrator for Rockwell Automation. Rockwell Automation designed and engineered the demand management system and RSEnergyMetrix, while Electro Systems performed the engineering and commissioning of the RSView32 scada and also assisted with system commissioning, network and panel installation and did all the retro-fitting of the 23 power monitors - that included live changeover from the existing power monitors.
The Maximum Demand and Energy Management system is structured around an Allen Bradley ControlLogix 55L63 ControlLogix PLC (programmable logic controller) system combined with state-of-the-art Allen Bradley Power Monitor 3000 units. These crucial components from Rockwell Automation provided a high performance platform for multiple types of control, such as sequential, process, drive or motion control - all on the same platform and in any combination. The software consists of the versatile RSView32 scada package combined with the RSEnergyMetrix scaleable Web-based energy management system.
"Because the platform is modular, the system can be easily expanded, with significant savings in terms of training and engineering," explains Corrie van Rensburg, Rockwell Automation project manager. "Engineering productivity is increased with advanced configuration tools, memory structure and symbolic programming that require less coding and memory. At the same time, the client's investment is secure, as both ControlLogix and Power Monitor hardware comes with flash-upgradeable firmware."
The flexible platform permits multiple processors, networks, and input/output to be mixed without restrictions. As the application grows, devices can be configured and controlled using the Netlinx architecture, with information being collected across Ethernet, ControlNet, DeviceNet or Foundation Fieldbus networks. Linking Rockwell Automation's RSView 32 scada (supervisory control and data acquisition), the ControlLogix PLC and Power Monitor 3000 units with RSEnergyMetrix, a scaleable Web-based energy management system, it is possible for Assmang to view all power system parameters at the Machadodorp Works in realtime via the Ethernet plant network. With state-of-the-art features, including 10/100 MB Ethernet IP connectivity, these power monitors made it easy for the system to scan data cyclically from each unit for data capture and logging by the RSEnergyMetrix software package, which incorporates reporting and trending functions.
RSEnergyMetrix is a scalable Web-based suite of energy management software that offers complete energy information and management; captures, analyses, stores, and shares energy data across the entire enterprise and combines data communication tools, client-server software, and Microsoft's .NET Web technology to feed energy information straight to the relevant managers. This groundbreaking software solution incorporates several novel concepts, such as automatic data re-population. Data is also logged in the power monitors, and the auto data repopulation feature allows data to be retrieved from the power monitors in case of a network failure. This feature is so evolved that, in large systems, it could function as the primary means of data logging. RSEnergyMetrix can e-mail device and communication alarms to the relevant individuals for immediate corrective action to be taken. With advanced charting, billing and reporting functionality, the software bundle truly powers the entire energy supply and demand management procedure.
"The end result is a 300 kilotonnes per annum ferro-chrome smelter facility with advanced energy consumption management based on demand, with a Web-based data logging and retrieval system that allows cutting-edge control, reporting and trending," van Rensburg summarises. "This makes it possible for the Assmang Works to base control on preset tariff periods, or new tariff structures as they are introduced. It has combined reliability with the flexibility that one only gets from live, Web-based reporting and trending. The client also has the peace of mind resulting from local support on all components of the solution, as well as a structured upgrade path."
For more information contact Jeff Sandison, marketing communications manager, Rockwell Automation, 011 654 9700, jksandison@ra.rockwell.com
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