Global Renewables Lancashire (GRL) - Mechanical Biological Treatment
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Business Challenges
As with many projects, time is a critical factor. In this instance, Capula were tasked with the responsibility of designing, installing and commissioning a complex networked process control system for the new-build waste treatment facility under tight timescales. Capula’s track record in meeting such demanding requirements was a key element in why they were chosen.
In addition, the facilities operators need to submit regular, detailed reports in order to meet the tight regulatory requirements. Capula will provide reporting facilities to capture data directly from the process control system and provide accurate and concise information as necessary. Awide variety of reports were required, from silo levels and percolation temperature profiles, to plant yield and efficiency key performance indicators.
How We Helped
With many years’ experience within the waste, energy and process industries, Capula designed a control system based on Siemens S7 PLCs and WinCC SCADA. Switched Ethernet and Profibus fieldbus networks were used extensively across the site to link the control system to numerous intelligent motor control centres, variable speed drives and instrumentation to allow control of the entire facilities from sorting waste to energy production. The WinCC SCADA system provides a graphical overview of the entire process, accurately showing, in real-time, the status of process devices in all plant areas. All plant data is logged and stored for retrieval and analysis, therefore assisting in plant optimisation.
The majority of plant devices and field instrumentation, including PLCs, VSDs and remote I/O are connected via a number of Profibus DP and PA networks, minimising field cabling and increasing the amount of data available for each individual device. Approximately 400 Siemens Simocode devices, located within the MCCs, were configured by Capula. A significant amount of cabling was reduced through
the use of these devices and, in addition, the quality of diagnostic information returned to site technicians is considerably improved.
The Profibus PA network connecting all intelligent instrumentation also enables the retrieval of detailed device information, further increasing plant status knowledge. As network manager, Capula was fully responsible for all Package Plant communications over the plant network. Many plant items are delivered with their own PLC for local control, and it was Capula’s responsibility to network each PLC and manage the network data.
Furthermore, the education centre at the Leyland site is to feature a live view-only Capula SCADA terminal, showing what’s happening in the plant in real-time.