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 Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Salary and career survey: Benchmarks and advice; Designing controls; Remote data collection, historians; Control valve advances; Hannover Messe; Control Engineering International
System integration: Best practices and technologies to help; Virtualization virtues; Cyber security advice; Motor system efficiency, savings; Product exclusives; Road to Hannover
Collaborative robotics: How to improve safety, return on investment; Industrial Internet of Things, Industrie 4.0: World views; High-performance HMI, Information Integration: OPC and OMG
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
PLCs, robots, and the quest for a single controller; how OEE is key to automation solutions.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
click me