Synergy Coal Crushing Plant

Tasks Completed

  • Detailed Design Specification – Software
  • Detailed Communications Design Network Drawings (Autocad)
  • Protection and interlocking database and programming
  • FAT/SAT Test, with Simulator
  • Control / Communication Logic and HMI Design and Implementation
  • On Site Commissioning
  • As Built Documentation
  • Operator Training

About This Project

The Muja coal crushing plant has not been used for several years. The plant will mostly be decommissioned. Most of the switchgear in the coal crushing plant switch room will be removed, but there are some belts that remain and are used by the coal plant operators on a daily basis.

The crushing plant is currently controlled by a Siemens S5 PLC. This PLC will be decommissioned along with all the other redundant equipment. The remaining equipment still required by operations will be controlled by the Coal plant T3000 DCS system.

In a previous project; Stockout tower DCS upgrade, signals that was communicated between coal crushing and Stockout was changed to be hardwired signals so as to keep necessary communications between the Stockout PLC and the crushing plant.

As part of the DCS integration, an ET200 remote IO Rack will be installed locally at the crushing plant. Once the equipment and associated IO have been identified, it will be removed from the S5 PLC and wired to the local S7-300 ET200 remote rack. The equipment controls will then be programmed in the DCS as required