Automated control system for slop cleaning units (solution)
Reduced total cost and delivery time due to “One-Stop-Shopping” of the control system including electrical design meeting ATEX directive and Norsok standards.
Task/Challenge
The customer had decided to build a prototype of an automated water cleaning unit they knew the process for very well. It was documented in terms of a P&ID and a written process description.
They needed a control system with HMI displays, process algorithms and dynamic regulations of electrical motors and pneumatic operated valves to get the product functionality their customers demanded.
Customer goals
Succeed with the prototype and extend their equipment rental fleet with several automated water cleaning units exceeding governmental and industry cleaning process requirements, to Norsok Z-015 standard and ATEX zone 1 certified.
Trade Tech delivery
Automated control system including hardware and software to Norsok Z-015 standard and ATEX zone 1 certified.
The P&ID, process description and orally explained functionality was converted into small separate steps / sequences by use of logic diagrams drawn in Visio. This made the process picture easier to understand and discuss for the customers process knowledge specialist and our software programmers.
It ended up with many regulation loops and several independent and automatic process sequences including start/stop sequences etc.
With the above as the basis, our project engineers guided the customer in choice of sensors, pumps, valves etc. and designed the automated control system hardware, software and HMI according to applicable rules and regulations.
The control system hardware was built in our Ex-certified workshop, the software was coded and downloaded to the PLC and HMI screen prior to a comprehensive internal test and FAT was conducted.
The electrical design and installation in the unit was supervised by us to assure compliance with the ATEX directive and Norsok standards.
Finally, a full-scale system test was conducted to verify the total system.
Achievements
The test of the prototype went smooth with very few corrections/tuning before all design criteria were met and provided the customer with the unique product they had foreseen and several more units were built shortly after to expand their business. A key success factor for this achievement was the excellent cooperation between the customers specialists knowing the water cleaning process and our automation, electrical and software project engineers.
Reduced total cost and delivery time due to “One-Stop-Shopping” of the control system including electrical design meeting ATEX directive and Norsok standards.
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