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Integration of a PLC and SCADA control and reporting system with an existing DCS.

Komati Mill was built 20 years ago as a fully automated sugar mill utilising a factory-wide Distributed Control System (DCS) to achieve a high level of factory automation. During this interval, the process control industry has seen rapid growth in technology and many components of the control system hardware have become obsolete. Faced with this scenario, Komati Mill has been prompted to consider a cost effective migration pathway to accommodate the newer technology. In 2010, the mill embarked on a phased project to replace the obsolete Legacy DCS system with a PLC and SCADA system. The project included the implementation of a Management Execution System (MES) to monitor and report the availability and productivity of the plant from real time feedback. The project roll-out commenced with a Manufacturing Application Alignment (MAA) study which provided a roadmap of the technology and functions needed, based on the Key Performance Indicators (KPI) of the mill. The migration path comprised five phases, and is currently in the third phase. The solution at the end of phase two includes integration between the old Legacy DCS, the new DCS, the new PLCs, LIMS and manual operator inputs. It also provides real time monitoring and reporting of the extraction plant Lost Time Available (LTA) and throughput, as well as a daily crush prediction model. This information is fed back to the manager’s desk as a single point of information on a web portal.