- 1. The Lesedi PV plant_ and Letsatsi PV plants are two of the
three largest PV plants on the African continent. Ages scope of
supply included: The proposed system consisting of the following
elements were requested: 1. INFRARED DOMES in the access and at
strategic points. 2. THERMAL CAMERAS in the perimeter and in the
principal internal roads. 3. VIDEO MONITORS & VIDEO ANALYZER 5.
Access Control with Biometric Readers 6. Control Centre in the
O&M Building 7. IR Detector, in the inverters buildings and in
the O&M buildings. 8. Guard Tour System. 9. Complete manual to
operation and maintenance Product used in the project Scope of work
to be done Fiber Network Installation of fiber cable Installation
of splice boxes Installation of patch leads Complete manual for
operation and maintenance of the system Training Total value of the
project upon completion 1.9 million Duration of the project 3
months
2. Enclosure Built 8x Floor Standing PLC Enclosures 2x Network
Enclosures for Control and PLC room 13x Power Distribution
Enclosures 23x Junction Boxes 33x Instrument Solenoid Bank
Enclosures PLC Inputs and Outputs 288x Analogue Inputs 224x
Analogue Outputs 896x Digital Inputs 384x Digital Outputs Drives
Control Engineered 58x Variable Speed Drives 1x Direct Online
Starter 2x Soft starters Project Value Supply and Engineering R4.2M
Completion Hardware Supply Complete Software Engineering Complete
Commissioning July 2014 Foskor is a proudly South African producer
of phosphates and phosphoric acid with international exposure.
Foskor unlocks shareholder value through the profitable,
responsible and sustainable beneficiation of phosphate rock into
either phosphoric acid or phosphate-based granular fertilisers sold
globally. Founded in 1951, Foskors Mining Division in Phalaborwa
mines phosphate rock, from which Foskors Acid Division in Richards
Bay produces phosphoric acid and phosphate- based granular
fertilisers for local and international markets. The opencast mine
in Phalaborwa has the capacity to produce 3 million tonnes per
annum of phosphate rock concentrate from 35 million tonnes of ore
mined per annum. Once crushed, milled, concentrated and dried, most
of the phosphate rock concentrate is railed to Foskors processing
plant in Richards Bay, 800 km away on the KwaZulu-Natal coast. The
D Stream Flotation Plant Replacement (DSF) project originates from
the Foskors infrastructure replacement strategy. This project will
ensure that the installed flotation capacity remains at a level
which makes it possible to produce circa 3 million tons of
concentrate per annum (mtpa), therefore protecting the production
strategy of the Phalaborwa operations. The project consists of new
600 tph flotation plant. AGE Technologies JHB was awarded the
Supply, Engineering and Commissioning of the complete PLC and Scada
Control System. The Control System consists of Schneiders Quantum
PLC and Adroit Scada System communicating through Hirschman
switches. The project also consisted of the supply and manufacture
of the Festo instrument solenoid bank enclosures. 3. As Tharisa
Mine is the largest known single chrome resource deposit in the
world, the Group is well positioned to benefit from the projected
growth in demand for chrome, which is primarily used in stainless
steel manufacturing. MDM Engineering contracted AGE Technologies to
supply in all the requirements of the Tharisa Expansion project.
Ages scope of supply included: Supply of all Siemens PLC hardware
(S7-300 & S7-400) Supply of all Siemens SCADA software (WinCC)
RIO Panel supply & manufacturing (34 panels) Ethernet &
Profibus fiber network installation, splicing, testing,
certification and drawings (Est. 6000m fiber and 900 splices)
Supply, installation, configuration and commissioning of 4x
Wireless Ethernet radios that links to 4x pump stations (4IPNET
Radios) 2x Commissioning engineers to assist with I/O testing &
process commissioning (I/O count 1546) General supply of cable,
junction boxes & any other equipment needed throughout the
project Configuration of all networks running through OLMs and the
setup of the OLMs Product used in the project Multi core Instrument
cable to the value of R400,000.00 Siemens OLM Outdoor Fibre cable
(total of 18.7kms) Network Switches (3 port & 6 port) All fiber
equipment inc. adapters, connectors, pigtails & cable Scope of
work to be done Fiber Network Installation of fiber cable.
Installation of splice boxes. Installation of patch leads Supply
IPDBs Installation of a Profibus over fiber network Total value of
the project upon completion 5.9 million Duration of the project 8
months 4. Solution provided to company The physical structure was
constructed by FAMAK in Poland and shipped to Mozambique. The
electrical design and construction (wiring, cabling, PLC software
and MCC cabinets) took place in South Africa. It was assembled in
Beira, and the electrical and instrumentation installation
commenced after. AGE Technologies did PLC and SCADA software
development and will be responsible for commissioning. Products
used in the project PLC control system: Siemens S7-300 PLC with
ET200S Distributed IO Motor control: Siemens SIMOCODE's and Siemens
Micromaster VSD's Instruments: majority is supplied from Schneider
but includes Siemens, Rockwell and Weidmuller All Cabling used on
the Stacker predominantly from Jaycor and Africa Cables Relevant
information MCC's were constructed by Raise and Lower AGE provided
3 containers, operator cabin with all equipment inside, all PLC and
networking equipment, all electrical cables, equipment, drives,
relays, circuit breakers & switchgear One 630 kVA, 6.6kV/400V
transformer People involved in the project Norman Jackson Project
Manager - Design Paul van Rooyen Project Manager - Electrical
Design and hardware Gabriel van der Merwe Project Technician -
SCADA, Instrumentation Design, Hardware Karlin Gomo- PLC
Programming and Functional Design Specification Project Scope &
Objectives AGE Technologies was responsible for the design
manufacturer of the entire electrical and instrumentation
requirements of the Stacker Machine that was installed at the new
coal terminal in Beira Harbour, Mozambique. AGE Technologies
provided the PLC and electrical control systems. 5. AGE
Technologies JHB (Ltd) together with Instrumentation &
Electrical Consultants had to supply King Shaka International
Airport with Equipment & Design of an Redundant Fibre Profibus
and Profinet Networks with Siemens S7-400 Hot Standby PLC in SIL3
Safety and Standard I/O. Duration of the project Started 1 May 2010
and ran for the duration of 5-7 months. The problem was to provide
Siemens Equipment that could be integrated into a reliable
fail-safe system for the Fuel Storage System at the Airport.
Solution Provided We provided them with a Siemens S7-400 Hot
Standby PLC with Redundant networks and Dual Redundant WinCC SCADA.
Products in the project Siemens S7-400 Hot Standby PLC, SIL3 Safety
ET 200 IO Stations, Standard ET200 IO Stations, Redundant WinCC
SCADA, Dual Redundant Profibus Networks, Dual Redundant Profinet
Networks Scope of work AGE was responsible for assisting with the
design of the PLC/SCADA system, to make sure that a working system
was offered to the end user, and to supply the actual PLC hardware
and SCADA software packages. IEC did the actual system integration
and wrote most of the application software. Some software for
leak-detection was written in Germany. 6. Age Technologies JHB- a
member of the Age of Africa Technologies Group - were commissioned
by ESKOM to come up with a simple yet intelligent design for the
ash conveyor protection system at their Kendal Power Station in
Mpumalanga. Design Owing to the length of the ash handling
conveyor, the protection system had to incorporate enhanced fault
finding and accurate trip site location . This unique design in
long-line conveyor protection is a world first. All of ESKOM's
criteria were met and incorporated all the other aspects of
conveyor related alarms such as belt rip, misalignment, and blocked
chute detection, yet there are no electronics in the field.
Duration The system, which took six months and comprised 66 man
months from conception to completion, is so efficient and easy to
maintain that AGE are pleased to report their client is extremely
pleased with the reliability of the plant. Scope AGE's brief
included the overall project management, PLC engineering using a
Siemens Su110 PLC, equipment supply, installation and
commissioning. The project, which was repeat business for AEG with
ESKOM, was completed on time and within budget. 7. In line with
their philosophy of client relationship marketing, AGE Engineering
undertook this project at Fry's metals of Wadeville during their
annual end-of-year shutdown. Although small in size the process to
be automated was quite sophisticated from the point of view of all
the different processes that had to be brought together. Lead
reclamation has it's own characteristics and AGE Engineering had to
firstly familiarise themselves with the reclamation process. Once
that was done they had to write the process software for the ingot
pouring, handling and stacking system. In addition to the InTouch
SCADA package, ControlWize made use of a Microsoft SQL Server with
an Access data base for the train handling facility at the load-out
station. The project included management, PLC engineering,
equipment supply, installation and commissioning and took one
man-month to execute. Being a shutdown there was no margin for
error and the automation, using an Allen Bradley S5 PLC, went off
smoothly with no technical hitches experienced at handover. 8.
ESKOM identified the need for the replacement of the coal stacker/
reclaimer control system at their dry cooled power station near
Ellisras in the Northern province. Overview AEG's construction
division were awarded the project to design, supply and install
such a system to provide plant alarm status, monitoring and
reporting. This was repeat business for AEG who also executed the
station MV switchgear project and the overland Ash Handling
conveyor systems. The project was carried out during the transition
period from AEG to AGE Engineering and was completed ahead of the
prescribed contract period. Duration of project The 12-month
contract, which comprised 64 man-months effort, included the full
project management, PLC engineering using a Modicon 'A' series PLC,
full equipment supply, installation and commissioning. Significant
feature of this project was the design, by one of AGE's engineers,
of unique connection terminals - housed in the PLC cabinet - which
comprised full lightning protection on all inputs and outputs. This
type of terminal has now become a standard in the electrical
industry 9. Zimplats was established by Delta Gold Limited (Delta)
in 1998 to take over its platinum interests. In May 1999 the
company purchased BHPs interests in the Hartley Platinum and the
Mhondoro Platinum Joint Ventures which included a concentrator and
smelter. AGEs Scope of work to be done Capturing of Plant wide
process Data and Historizing for minimum period of twelve months
Alarm & Fault Logging which will detail the precise reason for
Plant Stoppage to enable the Technician to rectify the fault with
minimum down time Up to date PLC and SCADA software New Plant
Computers and Servers with web reports available for Plant
Managers. The enhancement of the electrode slipping system enables
it to measure the actual state of the electrode slipping system.
The new program functions just as the existing program with the
additional benefits: Shorter slipping times Any given movement,
de-clamping, raising, clamping or lowering takes only as long as
required. Reliability of the electrode slipping system is improved.
Error conditions are alarmed on the SCADA Significant Features of
the project AGE Technologies offered the following enhancements and
benefits to their current system Plant wide Server/Client topology
which centralizes their Data for easier Alarming, Data Retrieval
and Reporting and Backup. First Up Alarming programmed into their
PLCs, with clear Alarm and Fault messaging at their SCADA Clients
Fixed format Daily Reports for the Smelter Plant and the
Concentrator Plant Device Status and Interlock Display Dash boards
to assist operators. Upgraded two obsolete TSX17 PLCs to Modicon
M340 under Unity Software. Conversion of Concept PLC programs to
Unity by upgrading PLC firmware Removed redundant MB+ network that
was no longer required. Auto-save Change Management Software, that
automatically keeps all their PLCs and SCADA software backed up and
tracks any software changes that is being implemented. Archestra
System Platform Software and Unity PLC Software Training for
Engineers/Technicians New latest Dell Computers (Severs and Work
Stations) for their entire Plant Operations. Onsite System
Commissioning Duration of the project 8 months Budget R 2 ,495
024.00 10. Set amongst the beautiful rolling hills and valleys of
the KwaZulu-Natal midlands, the largest waterworks in KZ Natal and
most modern in the country, Umgeni Water's Midmar Dam Waterworks,
was successfully commissioned, on schedule, in October 1996. Built
on the site of the old Mill Falls waterworks outside Howick, the
first phase of 250 Ml/day will be augmented to an ultimate capacity
of 1000 Ml/day by 2005, when predicted water demand is expected to
be around 450 million cubic metres per year. AEG were originally
awarded the subcontract to main contractor Aquazur but owing to the
disruptions within AEG at the time, leading up to their ultimate
sale, AGE was contracted to complete the contract. In order to
minimise disruptions to the contract AGE Engineering made use of
all the existing AEG personnel, some of whom were sent for training
in Germany in order to commission the MCC's bus system. Duration
The multi-million rand project was 14 months in duration and
comprised 130 man-months effort. AGE Engineering's scope included
Project management, PLC engineering, equipment supply - including
the sophisticated Motor Control Centres, installation and
commissioning 11. Background The brewery has ten Cellars. Each
cellar is divided into different tanks, in which the fermentation
takes place. Glycine is passed through tubes wound round the tanks
to control the temperature during the brewing process. A solenoid
valve is used to open and close flow of glycine. Pt100 at the top
and bottom of each tank are used to monitor the temperature. The
temperature is either monitored using the Top/ Bottom PT100 or both
PT100s. should any of the PT100 fail the PLC will switch the
control completely to the healthy one. Each of the tanks can be in
one of the following modes: Ready, Filling, Fermentation, Chill or
Cleaning in Progress (CIP) AGEs Scope of work to be done The plant
is divided into three Control systems, i.e. Cellar 1&2, Cellar
3-8 and Cellar 9&10. A SCADA (Supervisory Control And Data
Acquisition) system will provide a graphical overview of the whole
control system. An Ethernet TCP/IP network will link the three
Systems and the SCADA. Significant Features of the project HMI will
provide the operator with status of each Cellar and Tank SCADA
system will provide a graphical overview of the plant, with the
status of each tank. A graph of all temperatures and operator
inputted information will be available. The fermentation manager
will be able to change the operating mode of a tank, and with a
login password he can also change the temperature set points. A
historical log will also be kept of all tank batches that have been
brewed Keeping data for each batch is important for quality
purposes. The Mode of operation of each tank will be colour coded -
determined by its background Colour in the overview page. A Siren
and alarm lamp will be installed at each control system to warn the
operator of an alarm condition Products used Modicon TSX Premium
from Schneider Electric PLC software - PL7 Pro for TSX Premium PLC
HMI - is an EZTOUCH, Modbus/TCP 8 Slim panel SCADA System - Intouch
version 9, with 1000 tag licence Spider, 5 port 10/100 Ethernet
switches for each Control system Duration of the project 6 months
Total Value R 605,906.34 12. Background Botswana Ash (Pty) Ltd
began operating in April 1991. The mine is located at Sua Pan,
which is approximately 180 kilometres from Francistown in northern
Botswana. The Company produces Soda Ash and Salt. All the
activities of the mine are undertaken at Sua Pan from production
through to marketing and sales and administration. The primary
market for Soda Ash is South Africa, where most of the products are
used in the glass industry. They also produce fine and coarse salt.
Like Soda Ash, the Salt products are sold within the continent.
Production capacity is 650 000 tonnes per annum. AGEs Scope of work
to be done To upgrade of old absolute TSX-17-20 Telemecanique PLCs
to the newest Schneider M340 PLC with UnityPro Software for the
Soda Ash Stacker as well as the Salt Reclaimer. AGE Technologies
also replaced all panels on site. In the Salt Reclaimer the panels
was replaced by stainless steel panels to help prevent rust. The
upgrade included Supply of all Hardware Software Engineering &
Installation and Commissioning Products used Schneider M340 PLC
with UNITYPRO Software CPU34020 MODBUS ETHERNET Radio telemetry
System PLC, Termister Relays & Output Devices Supply Breakers
Emergency Bypass Keyswitch New Panel Electrical Drawings plus Field
PLC Application Software Development according to the FDS documents
HMI Application Software development PLC/HMI Onsite PLC software
Commissioning Duration of the project 6 weeks Total Value Soda Ash
Stacker R 420 000 Salt Reclaimer R 350 000 13. Xstrata are one of
the world's largest global diversified natural resource companies
and a major producer and marketer of more than 90 commodities.
Their presence at each stage of the commodities chain provides us
with superior market insight and access to opportunities. They have
a strong footprint in both established and emerging regions for
natural resources. SCOPE OF WORK: Product Included: IMPALA PLANT -
Supply and Install an Enermax plus Meter with Modem for remote
metering outside 400v Substation in Metering box. Supply 400V, 3
phase 4 wire 5Amp Enermax Plus meter with external memory. Supply
cell modem for meter and sim card. Supply 3 x 1500/5 metering
current transformers. 2. WONDERKOP PLANT - Supply and Install an
Enermax Plus Meter with Modem for remote on 11KV Incomer panel.
Supply 110V, 3 Phase 4 wire 5Amp Enermax Plus meter with external
memory. Supply cell modem for meter and sim card. Supply 3 x 5/5
metering interposing current transformers 3. EPL PLANT - Supply and
Install an Enermax Plus Meter with Modem for remote on 11kV Incomer
panel. Supply 110V, 3 Phase 4 wire 5Amp Enermax Plus meter with
external memory. Supply cell moden for meter and sim card. Supply 3
x 5/5 metering interposing current transformer. K2.5 PLANT - Supply
and install an Enermax Plus Meter with Modem for remote on 11kv Fdr
panel. Supply 110V, 3 Phase 4 wire 5Amp Enermax Plus meter with
external memory. Supply cell moden for meter and sim card. Supply 3
x 5/5 metering interposing current transformer. 5. K4 PLANT -
Supply and install an Enermax Plus Meter with Modem for remote on
11kV panel. Supply 110V, 3 Phase 4 wire 5Amp Enermax Plus meter
with external memory. Supply cell moden for meter and sim card.
Supply 3 x 5/5 metering interposing current transformer. 6. WPL
PLANT - Supply and Install an Enermax Plus Meter with Modem for
remote on 11kV Incomer panel. Supply 110V, 3 Phase 4 wire 5Amp
Enermax Plus meter with external memory. Supply cell modem for
meter and sim card. Supply 3 x 5/5 metering interposing current
transformer. 7. Remote data base for all remote meters Supply 1 x
Meter reader that interface with modem, including software
Significant features of the project Remote access from anywhere in
the country with cellular coverage to all metering data achieved.
Software interface gave the ability to generate electrical bill for
energy consumption audit. Duration of the project 4 weeks Total
value of the project upon completion R156,000.00 14. AGE
Technologies JHB (Pty) Ltd. secured the contract to assist Arcelor
Mittals planning department with the design, project management and
commissioning of the automation system required at the
Vanderbijlpark works Continuous Casting plant. Scope of work to be
done Was the equipment supply and product training of Modicon
Quantum PLC's and FactoryLink SCADA. However, the whole project was
to be executed during a planned shutdown period and required
careful planning in order to minimise disruption at the changeover.
Products used The PLC was programmed in hot stand-by configuration
and it was decided to make use of standard terminal cabling in
order to facilitate a smoother transition. Duration of the project
The project was five months in preparation and comprised 3
man-months effort in execution. 15. In one of the longest ongoing
contracts on AGE Engineering's order book, their contract to
provide automation packages to Pretoria City Council pump stations
must rate as their longest. Started in mid 1995 - whilst still
operating as AEG Construction - their brief was to supply an
automation system to 5 pump stations within the greater Pretoria
metro pole. The first one completed was at the Fountains station,
followed by Garsfontein, Elardus Park, Klapperkop and finally
Mooikloof over a period of four-and-a-half years. The project was
run out of Pretoria's department of water environment and executed
as five separate contracts. AGE's brief was to provide the project
management, PLC Engineering using Modicon Compact and Micro PLC's,
the equipment supply, installation and commissioning. What started
out as first-time business for AGE developed into a long-term
relationship and resulted in repeat business. 16. Main contractor
CHI Control appointed AGE Engineering to carry out the PLC
engineering, equipment supply and commissioning of the man riding
and ore belts project at Randgold's Lorraine Gold Mine in the Free
State. This project, although only one month in duration was very
sophisticated in that it called for an interface from the Modbus to
the Allen Bradley soft starters Scan Port. The Allen Bradley PLC
interfaced to an AFE SCADA data panel via Modbus an AFE data panel
interfaced to an existing SCADA via Modbus