Innovators of unique processing stills, FFS Refiners has installed its third Adroit scada system in Secunda where FFS process tar for world leaders Sasol Synthetic Fuels.
System integrators, Proworks, installed the Adroit system to replace the existing Genesis system. The Secunda operation had been running on DOS and was installed in 386s in the early 1990s - the levels of information and support for the system were no longer adequate to meet the company's requirements.
As FFS process tar for Sasol Synthetic Fuels on a toll basis, returning it with less water and solids, it required key performance data from its Adroit system. Logging and eventing information on loads and levels make it possible for FFS to manage its supply chain both up and downstream. Logging all its data, it can therefore control what is coming in and going out and FFS are able to supply data on an OPC basis.
The system handles all alarming and control automation and will soon be enhanced by the addition of remote access via an ISDN from Durban. This facility will be implemented on a call-out basis which should assist in the effective resolution of breakdowns.
The system is required to interface with the OPC at Sasol and will ultimately plug into the plant level Ethernet backbone. The Adroit scada is OPC-based and comes fully compliant with the system. Both Sasol and FFS will be able to receive realtime data on the types and quantities of raw product in the pipeline at anytime. The Adroit scada currently handles all sluice filters and eight filters in the predecanter process and is scheduled to handle another three in the near future. It will also be handling the full spectrum of utilities catchall filters as well as having the process control run through the scada at this live plant.
Proworks used limited scripting for alarm and information message displaying as well as small amounts of VB for fault reporting sheets and a calculator function. The system is operating on Windows 2000 professional.
The original Genesis was using approximately 1300 odd scan points - by using 1500 scan points, Proworks would be able to take over on a point-to-point basis leaving 3-4% redundancy. Instead, it opted to decrease the number of scan points to 750, while performing some retro engineering in the PRCs leaving FFS with a 50% redundancy on completion.
FFS replaced its standalone controller in Cape Town with its initial Adroit system. The Cape Town facility is FFS's largest profit centre and produces 8000 tons of product monthly. Gregg Hurter, senior project manager for FFS chose Adroit for its ease-of-use and its competitive pricing. The company installed the system in-house and it currently runs two stills at Fisserhok with an operating interface to monitor production through the scada system and its alarming package, including the facilities start/stop functionality, temperature and levels.
FFS's plants claim a global first in its use of innovative methodology and filters for heating waste lubricant oil in the production of alternative diesel. The Pietermaritzburg plant produces an additional 1000 tons of alternative diesel from waste oil, of which a large portion is monitored and controlled by the Adroit system that was installed by FFS to replace an unstable existing computer system.
Hurter saw the benefit of running all three stills on the same package, with Cape Town operating on Windows NT and the other two sites on Windows 2000. Hurter sees no need to upgrade to XP. He is particularly impressed with the object-oriented architecture, "Everything works the same way, the vector graphics are simple to use with a plethora of Wizards and pre-configured face plates."
FFS rely on Adroit's simple licensing process whereby the system integrator updates the rough codes in the hast, eliminating the need for other upgrade equipment and software. Its multisite operation requires that operators have national access to the product - and the system is supported by an effective and efficient help desk.
For more information contact Dave Wibberley, Adroit, 011 781 3513, [email protected], www.adroit.co.za
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