Steelmaking WTP Automation Upgrade

  • Metals

Steelmaking WTP Automation Upgrade

BlueScope Steel wanted to fully automate the BOS (Basic Oxygen Steelmaking) Water Treatment Plant to reduce risks due to an old control platform and improve consistency of slurry density being sent to the de-watering plant. Upgrading the control system would allow them to operate more efficiently, have fewer unplanned downtime events, also  lowering maintenance costs due to having better data from the plant about its operation.

Triple i were engaged to work closely with the BlueScope engineering team to produce the detailed design. The scope included designing the new system, writing the functional specification and test procedures, designing the new PLC and field I/O panels, designing the new Ethernet I/P network, selection and supply of the PLC and field instruments.

Scope

  • designing the new control system
  • writing the functional specification and test procedures
  • designing the new PLC and field I/O panels
  • designing the new Ethernet I/P network
  • selection and supply of the PLC and instrumentation hardware
  • PLC programming
  • i/o mapping to the main BOS plant Macroview system
  • testing of new Macroview WTP screens
  • FAT and commissioning
  • Work to be done whilst plant fully operational and then 48 hour window to do cutover and commissioning.

Control Systems

  • PLC5 to ControlLogix migration using conversion chassis
  • Re-use of I/O existing wiring where possible
  • PLC5 code conversion utility and testing
  • New Point I/O in field termination panels via Ethernet/IP to CLX PLC
  • Replace old Dataliner and Panelview with new Macroview Operator client screen
  • Use of I/O mapping standards to ensure consistency of code with existing control system
  • Construct all new control and I/O panels and install next to current system ready for cutover
  • Extensive testing of the system prior to installation and cutover.

Deliverables

  • Replacement of legacy systems significantly reduced risk due to obsolete control hardware.
  • Plant started up without delay and had a smooth changeover of the system due to a thorough planning and testing regime.
  • Automation reduced line blockages and downtime and provided a more consistent Slurry product to the De-Watering Plant.
  • The whole system was cutover, tested and re-commissioned within the required 48 hour window, with no issues, on budget and on time.

“The upgrade has meant improved consistency of the slurry density being sent to the Dewatering plant.  Consistency of product is the key”

— BOS WTP Process Engineer