MechChem Africa July 2018

Desalination plant facilitates continuous smelter operations

Rockwell Automation’s IntegratedArchitecture is being used to control and drive the water production from a desalination plant installed to supply the cooling demand for a continuous smelter operation.

W ater specialist company, NuWater, has developed and installed a two-megalitre de- salination plant at a smelter plant in KwaZulu-Natal (KZN), South Africa. Rockwell Automation sub-Saharan Africa, through the collaboration of its PartnerNet- work programme participants, authorised distributor CraigCor Distribution and its Rockwell Automation recognised system integrator (RcSI) M&M Electronics, supplied automation products and conducted pro- gramming and HMI development for use in the desalination plant. The desalination plant facilitates continu- ous smelter operations in the face of water shortages due to the severe drought that saw local dam levels drop to alarmingly low levels. NuWater incorporated the Integrated Architecture system into its automation and control development by means of Rockwell Automation programmable logic controllers (PLCs), its human-machine interface (HMI) with visualisation control software, variable speeddrives (VSD) and industrial networking equipment, as well as the powering switch- gear componentry. Integrated Architecture system-enabling products installed include: a ControlLogix

more potential fault points. When wired in this series connection, customers lose the ability to distinguish information fromeach device. With GuardLink, safety devices are easily connected in series while providing access to individual device diagnostics. This systemprovides safety, diagnostics, remote reset and lock command over a single, four-conductor cable with up to 32 devices per link. In addition, customers can greatly reduce installation cost, with up to 38% reduction in wiring when using GuardLink. The GuardLink technology seamlessly integrateswithAllen-BradleyGuardmaster safety relays and components, allowing us- ers to access status information throughout their entire safety system. The connection of safety deviceswith smart taps enabledby “The existing equipment already had MCCs and control centres, whichwe decided to refit with the latest Rockwell Automation product portfolio. Although many manufac- turershave similar product offerings, it ishard to find robust and reliable equipment that canwithstand the rigours of working in these oftenwet andhumidenvironments,” henotes. “Water industry professionals around the world face an increase in challenges due to stringent government regulations and age- ing control systems,” says Jacques Jacobs, L73 processor; distributed I/O mod- ules for ten stations that utilise POINTIO modules; one main network redundan- cy through device level ring (DLR); 22 PowerFlex 755 VSDs that can supply up to 110 kW of power to the pump motors; and Rockwell Automation Moulded Case circuit breaker switchgear. “As our and other water-stressed nations turn to seawater desalination as a solution to process anddrinkingwater, it is advantageous to be leading the way in terms of our product offering,” says NJ Bouwer, chief business de- velopment officer for NuWater. He adds that most of the equipment offered to the smelter was refurbished to help make sure that the short lead times required could be met.

The NuWater- developed two-megali- tre desalination plants at the KZN smelter. Authorised Rockwell

Automation distributor, CraigCor Distribution, and RcSI M&M Electronics, supplied automation products and conducted programming and HMI development for use in the desalination plant. account manager – OEMs for Rockwell Automation. “This causes tighter water qual- ity standards and rising labour, operating and maintenance costs. “The Rockwell Automation vision of The Connected Enterprise is what helps over- come some of these challenges. Through the Integrated Architecture system and the connection of smart devices, new windows of opportunity into processes open. Data and analytics enable better and faster decision- making, while seamless connectivity spurs new collaboration.” Rockwell Automation Inc. makes its cus- tomers more productive and the world more sustainable. Headquartered in Milwaukee, Wisconsin, Rockwell Automationemploys ap- proximately22000people serving customers in more than 80 countries. q GuardLink technology and standard cabling toaGuardmastersafetyrelayallowsgreater visibility into the system, down to individual guard doors and e-stops. “When an e-stop or interlock switch is operated, the individual safety signal is sent to the Guardmaster safety relays,” explains Christo Buys, business manager of Control Systems, for Rockwell Automation sub-Saharan Africa. That information is then communicated seamlessly across The Connected Enterprise via theGuardmaster network interface, making it easier and fastertodiagnoseandrepairproblemswhen compared to traditional wired systems.” The GuardLink safety system fully integrates with the Logix platform in the Rockwell Software Studio5000application. Its design and wiring reduction allows for simple plug-and-play installation. q

New GuardLink safety system Rockwell Automation has introduced the Allen-Bradley Guardmaster GuardLink safety system, a new safety-based com- munications protocol that helps operators reduce and improve machine diagnostics anddowntimewhile increasingproductivity. Traditionally, safety devices are wired to separate safety inputs, which require significantly more wiring and introduces

32 ¦ MechChem Africa • July 2018