Control system upgrade increases efficiency over the weekend

02/14/2006


Process Control

Upgrading and automating a management control system has increased efficiency, maintainability, and reliability at this large coal export terminal.

Columbus, OH —Upgrading an aging, coal stockpile management control system led to increased operational efficiency for Kinder Morgan ’s Pier IX Terminal in Newport News, VA. With the help of River Consulting , a management, consulting, and engineering company, the facility installed the new system in a weekend. Benefits include more automated functions, improved alarming, enhanced displays with faster identification of and recovery from faults, and better blending and loadout controls.
The terminal is a major U.S. coal export facility that can handle 12 million tons annually with design transfer rates of 8,000 tons per hr for shipping and 5,000 tons per hr for receiving from rail cars. The original control system, installed in 1982, was becoming obsolete. The upgrade was accomplished with the addition of a new processor and HMI. Existing I/O equipment was retained.
The project consisted of replacing the control system processor and pushbutton control panel with a new processor and PC-based HMI terminals. As a result, interface screens could be developed to provide more control, monitoring, and diagnostic ability for operators. Re-use of existing field I/O equipment eliminated the need for system rewiring. By re-using existing I/O devices and networks, and performing a full system simulation and factory acceptance test on the software prior to field installation, the equipment could be installed in the short time frame.
Operators can now see all system I/O devices and equipment status on screen. Troubleshooting and diagnostics are simpler. The new PLC program is more powerful, and automated blending logic allows for more accurate control of blending operations. The addition of an Ethernet communications module lets operational data be viewed from management offices and transferred to data storage for additional analysis.

—Control Engineering Daily News Desk
Jeanine Katzel, senior editor, jkatzel@reedbusiness.com





No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
2017 Lubrication Guide; Software tools; Microgrids and energy strategies; Use robots effectively
Prescriptive maintenance; Hannover Messe 2017 recap; Reduce welding errors
Safety standards and electrical test instruments; Product of the Year winners; Easy and safe electrical design
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Future of oil and gas projects; Reservoir models; The importance of SCADA to oil and gas
Diagnostic functions for system safety; Specifying industrial enclosures; Effective decision support for a crisis
Transformers; Electrical system design; Selecting and sizing transformers; Grounded and ungrounded system design, Paralleling generator systems
Natural gas for tomorrow's fleets; Colleges and universities moving to CHP; Power and steam and frozen foods

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me