Premier Foods Salt River Mill upgrade
September 2005
System Integration & Control Systems Design
Premier Foods Salt River Mill has been running for more than 30 years. Essentially the mill converts wheat into flour and is attached to a large Blue Ribbon bakery. The original PLC system architecture was based on a token ring network of which the hardware components have become obsolete. Furthermore the scada architecture at the time of tender was not locally supported. The urgency of the upgrade would render immediate spare PLC components.
A decision was made to keep the PLC vender (Omron) and upgrade using its latest technologies (CJ1G CPU with Ethernet IP). Wonderware was chosen as the preferred architecture for the management information system (MIS) and its Industrial Application Server (ArchestrA) as the redundant plant layer to facilitate a speedy upgrade path and ensure a solid standard for the Premier Foods Group (using intelligent objects and symbols).
The Omron PLC architecture allowed for a serial communication link to its existing fibre-optic token ring network. This gave an immediate gateway to the inter-PLC communication database. This means as each PLC node is replaced a stable network backbone is maintained.
ArchestrA was the preferred choice because Wonderware's Industrial Application Server allows for a scalable single application development environment using object-based technologies to create a process model of the entire factory. ArchestrA uses Microsoft .Net's software development platform, providing seamless integration between operations and business intelligence. This ensures fast, uninterrupted application development to the existing realtime platform.
Industrial SQL Server is the chosen Historian and when used together with ArchestrA is a mere filling-in-the-blanks process. This database compression engine uses Microsoft SQL server technology as its backbone.
Hirschmann intelligent industrial Ethernet switches have been selected for the upgraded copper and fibre-optic LAN. It provided easy to use configuration software tools to aid in the set up and implementation.
Issues addressed
The issues arising involved serial communications to the legacy weighing systems. This was achieved easily through the use of an Omron universal communication card allowing easy protocol macros to be developed and downloaded.
For more information contact Andrew Rennie, AMR Automations, 021 534 0838, [email protected], www.amr.co.za
Further reading:
Modernising Vertical Filter Press Machines with Future-Focused Control Systems
System Integration & Control Systems Design
Project and Industry
Pressure Filter Specialists approached us to modernise vertical filter press machines for the Minerals and Metals industry. The goal was to improve reliability, reduce downtime,
...
Read more...
Project & industry
System Integration & Control Systems Design
Project and Industry
This project involved delivering a complete electrical, instrumentation, and automation solution for a new OEM drum-twister machine, replacing an ageing unit in a major cabling production
...
Read more...
It’s a risky business not to challenge standard language
System Integration & Control Systems Design
On the surface, contracts all look alike. Once you’ve seen one, you’ve seen them all, or so it seems. Maybe so, but hidden within the standard language can be language that shifts the other party’s risk to you.
Read more...
Containerised Electrical & Control System Powers Paste Plant in Botswana
System Integration & Control Systems Design
Delivering a complete, containerized solution for a mine’s paste plant in Botswana, this project stands as a model of modern EC&I execution — integrating electrical, control, and automation systems into
...
Read more...
Control system upgrade: Smelting
SAM Systems Automation & Management
System Integration & Control Systems Design
Systems Automation & Management recently completed a major control system upgrade in the smelting industry. The project was delivered on budget and achieved a positive ROI for the client.
Read more...
Gottwald drives upgrade: Ports and harbours
Abacus Automation
System Integration & Control Systems Design
In the ports and harbours sector, Abacus Automation completed a significant modernisation of a Gottwald crane, improving both operational reliability and serviceability.
Read more...
Mining industry upgrade: From ageing systems to maximum capacity
System Integration & Control Systems Design
Iritron recently undertook a major upgrade in the mining sector, focusing on washing and screening plants, jigs, thickeners, tailings, water systems, conveyors and reclaimers.
Read more...
Agogo Integrated West Hub Project: FPSO/subsea offshore Angola
Moore Process Controls
System Integration & Control Systems Design
The Agogo Integrated West Hub project represents a historic milestone in the FPSO and subsea industry, achieving first oil offshore of Angola. This project is the first FPSO deployment since ANPG’s establishment in 2019, and the first major project for Azule Energy since 2022.
Read more...
Integrated Robotics and Control Systems Deliver 45% Production Boost at Aquazania Waters Project and Industry
Process Dynamics
System Integration & Control Systems Design
Project and Industry Process Dynamics designed and commissioned a state-of-the-art Reverse Osmosis
(RO) water purification and automated bottle filling plant for Aquazania Waters in Linbro Park, Johannesburg.
...
Read more...
Project and Industry
System Integration & Control Systems Design
The Sicomp Control System Upgrade focused on modernising a 1985 power generation control system with more than 3 000 I/O points. The plant faced increasing system failures and risk to operational continuity,
...
Read more...
printer friendly version