MPC Company Profile

CCoommppaannyy PPrrooffiillee _____________________________________________________________________________________________________________________

TTaabbllee ooff CCoonntteennttss _____________________________________________________________________________________________________________________

Mission Statement .................................................................................................................................................... 1

Background ................................................................................................................................................................. 2

Services ......................................................................................................................................................................... 4

Experience ................................................................................................................................................................... 8

Project Profiles ....................................................................................................................................................... 28

Eskom Kendal – Fire Pump PLC Replacement ..................................................................................... 28

Anglo Platinum ................................................................................................................................................... 29

Samancor .............................................................................................................................................................. 32

Iscor (Arcelor Mittal) – Direct Reduction Plant Upgrade ................................................................ 36

FPSO Kuito ‐ Phase 1A .................................................................................................................................... 37

FPSO Kuito ‐ Phase 1C ..................................................................................................................................... 39

FPSO Kuito ‐ Density Profilers ..................................................................................................................... 40

FPSO Kuito ‐ Phase 2A .................................................................................................................................... 41

The Phase 2A for the Kuito comprised of new modules for the ................................................... 41

FPSO Kuito DCS Availability Project ......................................................................................................... 42

FPSO Xikomba .................................................................................................................................................... 45

FSO & MOPU Turkmenistan ......................................................................................................................... 46

FPSO Mondo ........................................................................................................................................................ 47

FPSO Saxi .............................................................................................................................................................. 48

FPSO Frade ‐ ICSS .............................................................................................................................................. 49

AKPO OFFLOADING BUOY ............................................................................................................................ 50

FPSO Espadarte .................................................................................................................................................. 51

PCS7 OS Upgrade ............................................................................................................................................... 51

MOPUSTOR .......................................................................................................................................................... 52

Talisman YME Redevelopment ................................................................................................................... 52

FPSO MONDO ‐ Subsea Control System................................................................................................... 53

FPSO SAXI BATUQUE ‐ Subsea Control System ................................................................................... 54

KIZOMBA ‐ Gas Gathering ............................................................................................................................ 55

Angola GIP ............................................................................................................................................................ 56

Angola GIS Fox Platform ................................................................................................................................ 56

TTaabbllee ooff CCoonntteennttss _____________________________________________________________________________________________________________________

Safripol .................................................................................................................................................................. 57

Palabora Mining Company ............................................................................................................................ 58

Polifin ..................................................................................................................................................................... 58

Sasol Synthetic Fuels ....................................................................................................................................... 59

Buzau Brew House and Cellars (Ursus) .................................................................................................. 60

Atlantic Methanol Production Company ................................................................................................. 61

Sasol Secunda ‐ Wet Sulphuric Acid DCS/ESD .......................................................................................... 62

Contact Us ................................................................................................................................................................. 63

MMiissssiioonn SSttaatteemmeenntt _____________________________________________________________________________________________________________________

1

Mission Statement

We will meet the demands and expectations of our customers to the highest standard of

quality and service within our industry. We care about our people and will maintain our

position as a fair employer. We will continually identify better ways of working through

innovation and involvement by taking advantage of the latest technologies available. We are

committed to improving the financial performance of our business by focusing on profitable

products in the appropriate markets, to maximize shareholder value.

The management of Matrikon Moore is committed to:

Implementing and maintaining a formal Quality Management System to develop a culture of continuous improvement that will focus on the needs of our customers and to provide them with acceptable products and services.

Ensuring that this policy is communicated and understood within our organization and that it is reviewed for continuing suitability

Ensuring the provision of adequate and trained resources to achieve our customers’ needs and expectations as well as organizational goals.

Assessing and reviewing our quality objectives, as defined in our business plan, customer needs and expectations and organizational goals to ensure continuous improvement of our organization to the satisfaction of all stakeholders.

BBaacckkggrroouunndd _____________________________________________________________________________________________________________________

2

Background

Moore Process Controls PTY (LTD) trading as Matrikon Moore was originally established in

South Africa as Moore Controls S.A. on September 1st, 1984. The company has grown from a

small regional sales office in 1984 into a leading, full‐service supplier and systems integrator of

large‐scale distributed control systems. In 2007 the company trading name was changed to

Matrikon Moore with the addition of the Matrikon agency to the company Portfolio. During

2008 two additional regional offices were established in key regional areas to better serve and

support our established client base. In 2010 Moore established a subsidiary in the US called

Moore Process Controls LLC to further enhance our support to our clients.

Matrikon Moore is one of the world leaders in providing global Industrial Automation and

Optimization turnkey solutions to a diverse range of industries including: Oil & Gas,

Petrochemical, Food & Beverage, Metals, Mining, Power and Water & Sanitation.

We take pride in providing an exceptional service experience to all of our valued clients by being able to respond quickly and efficiently to requests. We pride ourselves on being able to “go the extra mile” in order to ensure complete customer satisfaction. Matrikon Moore is an ISO certified company with online automated Document Management System which enables tracking project activities throughout the project lifecycle.

BBaacckkggrroouunndd _____________________________________________________________________________________________________________________

3

26 Years of consecutive growth and profitability

SSeerrvviicceess _____________________________________________________________________________________________________________________

4

Services

We have extensive turnkey and

engineering experience in DCS systems,

Safety Shutdown Systems, PLC Systems

and Field Instrumentation, and in

designing systems from concept

through to final documentation. All

systems are tested here at Moore

House before being transported to site

and Site Acceptance testing and

commissioning are scheduled to suit the

client’s program. We provide full

maintenance packages of the system

after installation, as well as full training

on the systems. Additionally we have

Qualified / Certified Safety Experts who

have undergone the international safety

training from TUV.

Matrikon Moore supplies distributed control & safety systems, field equipment, panels and all

related engineering services to the industrial sector. All products are manufactured in

accordance with quality standards prescribed by ISO 9001 and, in addition, have been certified

by approval agencies such as TUV, CSA, UL, FM, ABS and CE/CENELEC.

We further engineer simulation systems for the purposes of training personnel to ensure that

all personnel are trained and certified so that they may operate the plants safely and

effectively.

All our Services fall into one of the below categories:

Project Management

System & Application Design

System & Application Engineering

Installation & Commissioning

System Optimization

Support

Training


5

A wide variety of engineering services is available to help customers minimize the plant

resources required to install, configure, start up and maintain their instruments or systems.

These services include:

Project management and administration to make sure the equipment delivers and starts up on time and within budget.

Control strategy design, which takes advantage of the company’s process control expertise to identify the control needs, determine the most effective equipment and develop a control strategy that provides the most return from the process.

Site planning in which space limitations, environmental conditions and other factors influencing product or system performance are addressed.

Configuration to ensure that all resources are used to their maximum potential.

Staging to verify operation prior to shipment.

Installation and start‐up guidance to facilitate a smooth transition to on‐line operation.

Utilization review in which an instrument or system that has been running for a period of time is evaluated to determine if its resources are being fully utilized and if not, what changes are needed.

Moore Process Controls’ educational services cover the entire plant hierarchy. Courses are

offered for all levels of plant personnel to facilitate the most effective use of a product or

system. This includes:

Overview courses that provide management with a conceptual understanding of product or system functionality.

Detailed configuration courses for engineers to help them take full advantage of product functionality.

Operator courses which prepare plant operators for on‐line operation by educating them on the tools available and building their confidence.

Maintenance courses which train technicians on topics such as preventive maintenance, troubleshooting and parts replacement.

Foundation courses on process control fundamentals and instrument technology.

All courses are offered as standard modules to allow a curriculum to be customized. In addition,

completely custom courses can be developed for a particular plant to focus the training

program on their application, experience and interest. Standard and custom courses can be

taken at Moore Process Controls’ headquarter facilities in Midrand South Africa or they can be

held at the plant site.


6

Each product and system is supported by a flexible, varied pool of available support services.

These services have been developed to ensure long, trouble‐free operation. This is achieved by

offering many options for demand and contracted services.

All customers have access to demand services such as spare parts delivery and technical

assistance. They can also take advantage of a field support agreement for their instrumentation

or control system. The field support agreement allows services to be selected and combined to

obtain the right mix of support for the situation.

Some of the services offered by Moore are:

Software updates supplied as they are released to maintain access to the latest technology.

Scheduled preventive maintenance calls for greater insurance against loss of redundancy or downtime.

Third‐party equipment support to provide single‐source responsibility for a system.

Extended warranties that supply a risk‐free, known cost of ownership.

Disaster recovery assistance, which includes off‐site storage of databases and fast delivery of replacement equipment.


7

Moore is the exclusive Matrikon Partner in

South Africa. This partnership provides

access to highly experienced engineers

globally and detailed knowledge of how to

optimize production in all industries and

markets.

Moore has become a leading supplier in

asset management and predictive

maintenance solutions. Coupled with our

vast experience in rotating equipment

control we supply comprehensive

solutions that incorporate process

conditions, thermodynamic and advanced

vibration techniques with online root

cause analysis. These solutions are

designed to reduce maintenance

expenditure, increase asset availability and optimize production.

Coupled to this the large experience in compressor control and anti surge protection allows

Moore to supply a complete package on large assets with world class leading edge technology.

EExxppeerriieennccee _____________________________________________________________________________________________________________________

8

Experience

Moore has completed projects for the following applications:

1. Process Control Systems

a. Boiler Control Systems

b. Compressor Control Systems

c. Furnace Control Systems

d. Material Handling

2. Safety Shutdown Systems

a. Critical Chemical Mixing Processes

3. Batch Systems

a. Brewing and Fermenting Processes

4. Integrated Control & Safety Systems

a. Mobile Offloading Production Unit (MOPU)

b. Floating Production Storage & Offloading Facility (FPSO)

See Project Profiles Section for more details.

PPrroojjeecctt RReeffeerreenncceess _____________________________________________________________________________________________________________________

9

Project ReferencesCompany Name Project Description Division Currency Value Year

Advalloy ‐ Div of Samancor Ltd

West Plant PCS7 Migration

APACS ZAR 5,076,409 2009


M12 Transformer Coolers

APACS ZAR 691,446 2009

Anglo Platinum Alarm Management

MC Plant Matrikon ZAR 611,646 2009

Chevron Brasil Upstream Frade

Ldta

Asset Management Healthcare

Matrikon ZAR 124,837 2009

Emfuleni Local Municipality

Sebokeng Watercare works

Siemens Services ZAR 128,414 2009

Harmony Gold Mining Company

Harmony Gold Mine

Compressor Control ZAR 149,627 2009

Honeywell Honeywell Integration

APACS ZAR 252,157 2009

Metalloys IEM Installation APACS ZAR 1,383,233 2009

Petro SA Production Accounting Workshop


Proconics (Pty) Ltd

WSA Polished Water

APACS Services ZAR 110,780 2009

Rustenburg Base Metals Refinery

BMR Expansion Siemens Services ZAR 338,410 2009

Safripol (Pty) Ltd IEM + Engineering

Hours APACS ZAR 405,350 2009

Safripol (Pty) Ltd Sasolburg Siemens Systems ZAR 129,365 2009

Sasol Polymers J46110 September 2009 Design C

Sasol Compressor PAS

ZAR 108,570 2009

Sasol Polymers PP Business

CCC Replacement Sasol Compressor

PAS ZAR 554,511 2009

Sasol Synfuels (Pty) Ltd



Turbo 2008‐2009 Support ServicES


ZAR 110,832 2009


U217 Phase 3 & 4 Config Services


ZAR 650,490 2009


U219 Vision to PCS7 OS Migration


ZAR 213,928 2009


10



SAS Reactor 10 Sasol Compressor

PAS ZAR 114,340 2009


U212 MBX's with IEM's


ZAR 183,024 2009

Sasol Technology (Secunda) (Pty)

Ltd

U228 Compressor Upgrade


ZAR 3,304,190 2009

SBM Atlantia FPSO Capixaba Relocation

APACS USD 753,343 2009

SBM Inc SBM Data Link for

Head Office Matrikon USD 135,378 2009

SBM Offshore Contractors Inc

FPSO Okha Offshore Projects Euro 2,636,208 2009


FPSO Frade Services Offshore Services USD 226,133 2009


SBM ‐ Mopustor Siemens Services USD 240,282 2009


FPSO Mopustor Siemens Systems USD 374,715 2009


(SBM PC)

FPSO Kuito IEM and Refurbished

APACS USD 193,416 2009


(SBM PC)

FPSO Mondo Shutdown 2009

Siemens Services USD 61,543 2009

Single Buoy Moorings Inc

Okha Simulator Offshore Projects USD 276,718 2009

ThyssenKrupp Engineering (Pty)

Ltd

WSA Commissioning


Vetco Gray Controls Limited

Kizomba Sat Wells Siemens Systems USD 1,042,653 2009


Maintenance Contract


ZAR 307,487 2008

Anglo Platinum IE Audit APACS ZAR 280,714 2008

Anglo Platinum PPL PCS7 Thin slice Siemens Services ZAR 123,060 2008

Anglo Platinum Anglo Platinum

Waterval Trending Siemens Services ZAR 321,251 2008


11


Anglo Platinum RBMR PCS7 Apacs

Migration Siemens Services ZAR 5,990,345 2008

Anglo Platinum RBME IE Siemens Services ZAR 2,736,800 2008

Anglo Platinum Simatic

PCS7/Apacs+ OS Performance Test

Siemens Systems ZAR 1,186,806 2008

Emfuleni Local Municipality



ZAR 303,034 2008

Gas Services International

Limited GSI Compressors Offshore Services USD 52,537 2008

Kenyuka ‐ Base Metals

M12 Documentation

APACS ZAR 133,101 2008

L & L Consulting Services Mining

New RPMCD REHAB APACS Services ZAR 157,064 2008

Petro SA Petro SA Matrikon Matrikon ZAR 1,426,613 2008


BMR Expansion Project : Primary

Leach APACS ZAR 324,222 2008


BMR Expansion Project : Boiler B

APACS ZAR 388,976 2008


BMR Expansion Project : RPMCD

APACS ZAR 426,008 2008


BMR Expansion Project :

Purification APACS ZAR 435,655 2008


BMR Expansion Project : Secondary

Leach APACS ZAR 959,866 2008


BMR Expansion Project : Cu Tank

House APACS ZAR 1,194,067 2008


Compressor Anti‐Surge

Commissioning APACS Services ZAR 117,639 2008


BMR Expansion Project : Two year

cover Siemens Services ZAR 2,366,000 2008


12



BMR Expansion Project : Industrial

Ethernet Siemens Systems ZAR 890,799 2008


BMR Expansion Project : PCS7 APACS+OS



BMR Expansion Project : NaSO4

Crystaliser Siemens Systems ZAR 1,146,880 2008


BMR Expansion Project : Nickel Tank House



BMR Expansion Project : NAL Thickener



BMR Expansion Project : PIR /

Telirium Siemens Systems ZAR 1,960,608 2008


BMR Expansion Project : Simatic

PCS7 OS Siemens Systems ZAR 2,861,759 2008


MC Plant Expansion Milling



MC Plant Expansion 201



U41 Air Driers Upgrade

APACS ZAR 1,089,680 2008


EHM Server3 & 6& Webserver

Matrikon ZAR 25,714,597 2008


U17 Phase 2 Relay Upgrade Services


ZAR 628,715 2008


U12 Phase 1 Config Services


ZAR 403,771 2008


Unit 241 & Unit 555 PCS7OS Migration


ZAR 1,892,014 2008


Historians @ Cold Separations


ZAR 2,788,759 2008


Replace CCC EAS with 353


ZAR 113,554 2008


13



U280 PAC353 Controllers Upgrade


ZAR 144,885 2008


(SBM PC)

FPSO Kuito SBM Operations

APACS USD 68,478 2008

Single Buoy Moorings Inc

FPSO Deep Panuke Offshore Projects Euro 1,738,599 2008

TWP Consulting (Pty) Ltd

RBMR RPMCD Effluent

technologies APACS ZAR 447,272 2008


Mondo MCS Subsea Project

Siemens Systems USD 1,022,596 2008


Kizomba Gas Gathering

Siemens Systems USD 648,263 2008


Support Services Siemens Systems USD 227,261 2008

Xstrata South Africa

Xstrata Coal South Africa

Matrikon ZAR 3,955,531 2008

Air Products Air Products Newcastle expansion


ArcelorMittal Mittal Coke & Chemical

APACS ZAR 115,089 2007

ArcelorMittal Mittal DR Site

Support APACS ZAR 155,168 2007

ArcelorMittal Maintenance Contract


ZAR 225,731 2007

ArcelorMittal Mittal Steel NDT Analysis system


ArcelorMittal Arcelor Mittal Newcastle Scale

Upgrade Siemens Systems ZAR 149,810 2007

Atlantic Methanol Production Co

Ampco InterventionMaintenance Contract

USD 26,485 2007

Belayim Petroleum Co (Petrobel)

Petrobel APACS+ & PCS7OS Migration

APACS USD 236,980 2007

Brewery Engineering

Buzau Brewery Batch Project Split



14


Brewery Engineering

Extension Phase 50 Siemens Systems ZAR 563,566 2007

Brewery Engineering

Brewery Engineering Cellars

OP Extension Siemens Systems ZAR 151,350 2007

Cabinda Gulf Oil Company Ltd

Delta Compressor Upgrade

APACS USD 155,429 2007

Dow / Sanachem Service Level Agreement

Maintenance ZAR 120000 2007

Dow Agrosciences SA (Pty) Ltd



ZAR 185,780 2007

E H L Consulting E H L Consulting West Bay Rectifier


E H L Consulting E H L Consulting

Frazer Pump House Upgrade

Siemens Services ZAR 126,488 2007

E H L Consulting Mortimer Simatic PCS7 Migration

Siemens Services ZAR 1,653,464 2007

E H L Consulting E H L Consulting UG2 Tailings

Siemens Systems ZAR 118,688 2007

East Driefontein Mine

East Driefontein Mine


High Tech Processing (Pty)

Ltd

URSUS Brewery ‐ Brewhouse


NCP Chlorchem (Pty) Ltd

NCP PLX‐APACS Equipment

APACS ZAR 829,752 2007

Petrobel Petrobel Upgrade

Project PCS7 USD 210000 2007

Risimati Engineers Milling

Optimisation Config / Comm


Risimati Engineers MC Plant Capacity

Expansion Matrikon ZAR 183,481 2007


RBMR MC Plant PV Investigation

APACS ZAR 105,910 2007


RBMR Install smoke detectors



15


Sasol Polymers Secunda

Sasol Polymers Matrikon



Processdoctor Training



ProcessMonitor Pilot



U41 PA Compressors


ZAR 2,849,409 2007

Sasol Synthetic Fuels, Secunda

Wet Sulphuric Acid Plant

APACS ZAR 3700000 2007


Ltd

Sastech PP1 Anti‐Surge Replacement


ZAR 212,303 2007


Mopo Risers APACS USD 110,371 2007


Maintenance & Support 2007


USD 470,724 2007




USD 79,293 2007


FPSO Frade Asset Management

Matrikon USD 579,472 2007


FPSO Frade ICSS Offshore Projects USD 4,010,792 2007


FPSO Saxi Offshore Projects USD 2,552,714 2007


New Mondo Simulator for

Luanda Offshore Projects USD 259,403 2007


AKPO Offshore Projects USD 1,518,879 2007


Frade Simulator Offshore Projects USD 845,175 2007


FPSO Mondo Offshore Projects USD 2,750,900 2007


Talisman Mopustor Siemens Systems USD 2,801,016 2007

ThyssenKrupp Engineering (Pty)

Ltd WSA Unit 518 APACS ZAR 5,282,875 2007


16


Ursus Breweries SA

Brewery Engineering OP Installation


Ursus Buzau Cellars and Brew

House

Buzau Brewery Phase 50 Expansion

PCS7 ZAR 1600000 2007

Vetco Saxi Subsea PCS7 USD 311000 2007

Vetco MCS Simulator PCS7 USD 70000 2007


Saxi MCS Subsea Project



Vetco FPSO Mondo Simulator Sub



Vetco Gray Saxi Training Simulator



Vetco Gray Saxi Test Rig



IEM Supply and Installation

APACS ZAR 213,844 2006


Supply and install Local equipment

APACS ZAR 1,097,188 2006

Air Liquide (Pty) Ltd

Air Liquide PCS7 OS Upgrade

APACS ZAR 606,010 2006

Alliance Marine Services LP

Maintenance Contract FPSO

Trinity


USD 10,000 2006

Ampco Annual Support Agreement

Maintenance USD 45000 2006

Anglo Platinum Union Section C&I

Audit Siemens Systems ZAR 112,800 2006

ArcelorMittal NIM Replacement

with IEM APACS ZAR 708,776 2006

ArcelorMittal Mittal Steel Coke Plant Boiler House

APACS ZAR 493,319 2006

ArcelorMittal Mittal DR MM/DCS Modbus Interface

APACS ZAR 120,013 2006

ArcelorMittal ProcessNet Training

and Support Matrikon ZAR 155,000 2006


17


Atlantic Methanol Production Co

Ampco Annual Service Fee


USD 28,020 2006

Campbell Davies Consulting

Campbell Davies Compressor Upgrade


Chevron Texaco Fox Control Room

Upgrade APACS USD 30000 2006



Dow Agrosciences SA (Pty) Ltd

Maintenance Agreement


ZAR 112,400 2006

Dow Plastics KO APACS Profibus

Devices APACS ZAR 600000 2006

Eskom Lethabo Power Station

Alarm Philosophy Matrikon ZAR 100000 2006

Foster Wheeler South Africa (Pty)

Ltd Sasol WRF Blowers Compressor Control ZAR 1,603,355 2006


Ltd High‐Tech Angola Siemens Systems ZAR 161,503 2006


Ltd Brewery in Uganda Siemens Systems ZAR 243,823 2006

Hi‐Tech Processing

CIP Plant Angola Siemens ZAR 150000 2006

Hi‐Tech Processing

Uganda Brewery Siemens ZAR 180000 2006

Iscor Limited Vanderbijlpark / Mittal Steel SA

NIM Replacement APACS ZAR 800000 2006

IST Nuclear Pelindaba HTF

Blower Compressor Control ZAR 200000 2006

Natref Natref 352 to 353

Upgrade Sasol Compressor

PAS ZAR 469,271 2006

NCP Chlorchem (Pty) Ltd

Upgrade AS‐488 to PCS7

Siemens Systems ZAR 600,000 2006

Polifin Limited Maintenance Contract


ZAR 384,205 2006


18


Risimati Engineers RBMR Milling Optimisation

Project APACS ZAR 500,000 2006


RPMCD Plant APACS Upgrade

APACS ZAR 1,366,147 2006


ACM+ Anti‐surge Implementation

APACS ZAR 277,780 2006


Tank House Rectifier Upgrade

APACS ZAR 1,094,002 2006

Rustenburg Platinum Mines

Ltd

RPMCD Plant Upgrade

APACS ZAR 1400000 2006

Safripol (Pty) Ltd Dow Plastics K0

Upgrade APACS ZAR 400,000 2006

Safripol Sasolburg KO Upgrade APACS ZAR 600000 2006

Samancor L2 Sub DeviceNet to

Profibus APACS ZAR 800000 2006


Replace ProcessSuite with

PCS7 OS APACS ZAR 262,657 2006


Sasol ‐ PDOC Upgrade & Training



Sasol ProcessGuard Matrikon ZAR 918,686 2006


U230 KC101 Speed Control


ZAR 1,060,940 2006


U217 Compressor Control Upgrade


ZAR 200,169 2006


U217 Compressor Control Upgrade


ZAR 2,174,058 2006

Sasol Technology Project Landlord Compressor Control ZAR 2400000 2006


Ltd U212 BTX Project APACS ZAR 199,942 2006


Ltd Project Landlord Compressor Control ZAR 2,000,000 2006

SBM Mondo Training

Simulator PCS7 USD 124000 2006


19


SBM Saxi Training Simulator

PCS7 USD 124000 2006

SBM FPSO Mondo PCS7 USD 2000000 2006

SBM FPSO Saxi PCS7 USD 2000000 2006

SBM FPSO Frade PCS7 USD 2000000 2006

SBM FPSO AKPO Telemetry/Navaids USD 396000 2006

SBM Espadarte PCS7

Upgrade PCS7 USD 703000 2006

SBM Annual Service & Standby Contract



FPSO Capixaba PCS7OS Upgrade

APACS USD 68,443 2006




USD 182,533 2006


Espadarte PCS 7 OS Upgrade

Offshore Projects USD 335,989 2006


Espadarte Radio Comms



Espadarte Power Redundancy



Turkmenistan Commissioning 1

Offshore Services USD 75,000 2006


Espadarte DCS Coverage



Espadarte Support Service


Sentrachem NCP Chloorkop

AS‐488 to PCS7 Upgrade

Siemens System ZAR 900000 2006


House Ursus Brew House PCS7 ZAR 3200000 2006

Vetco Mondo Subsea PCS7 USD 400000 2006

Westinghouse Electric South Africa (Pty)

Pelindaba HTF Blower


Air Products Newcastle Plant

Upgrade PCS7 ZAR 450000 2005

Ampco PCS7 Upgrade PCS7 USD 145000 2005


20




Chevron Texaco KWIP 2 APACS USD 200000 2005



Fluor Daniel Indeni Refinery Mycro ACS Replacement

APACS ZAR 300000 2005

Iscor Newcastle Heat Furnace Upgrade

APACS ZAR 300000 2005


Ltd

Atmos Leach Relocation

APACS ZAR 150000 2005


Ltd

Tank House Extension

APACS ZAR 200000 2005


Ltd

Boiler Stacker Abatement

APACS ZAR 500000 2005

Samancor LI5 Radio Link

Profibus APACS ZAR 200000 2005


U212 BTX Project APACS ZAR 200000 2005


WRF Air Compressors

Compressor Control ZAR 1600000 2005


Unit 41 Upgrade APACS ZAR 2200000 2005


Unit 217 Compressor Control

Upgrade Compressor Control ZAR 2200000 2005

SBM Training Simulator APACS USD 180000 2005

SBM Turkmenistan APACS USD 560000 2005



South African Breweries

Air Compressor Optimization



21



House Ursus Cellars PCS7 ZAR 3800000 2005

Air Products Argon Plant APACS ZAR 200000 2004



Chevron Texaco Water Injection

Plant ProcessSuite S/W USD 55000 2004

Dow / Sanachem 6218 New Condenser

Config, FAT, Commissioning

ZAR 100000 2004

Dow Plastics Varsol Recovery APACS ZAR 200000 2004

Dow Plastics Solvent Distillation

Project APACS ZAR 300000 2004

Dow Plastics New APS Server APS ZAR 400000 2004

Dow Plastics Site Compressed Air

System APACS ZAR 400000 2004

Dow Plastics Line 8 Upgrade APACS ZAR 800000 2004

Eskom Kendal Power Station

Fire Pump PLC Replacement

Siemens Systems ZAR 300000 2004


DCS Equipment Upgrade

APACS ZAR 550000 2004


DR Project Separation ESP

APACS System ZAR 1400000 2004

Polifin Limited Sasolburg

Upgrade of AU Plant

APACS ZAR 200000 2004


Poly II Extruder Reaction Upgrade

APACS ZAR 2600000 2004


Ltd

Tank House Rectifier



Ltd Boiler Optimisation APACS System ZAR 900000 2004

Sasol Polymers Poly 2 Reactor and

Extruder DCS APACS System ZAR 1900000 2004


U17 Phenosolvan APACS ZAR 350000 2004


22



Unit 212 APACS ZAR 1000000 2004



SBM Kuito DCS

Availability Project DCS USD 800000 2004


HCL Burner & Bertrams

APACS ZAR 450000 2004

Air Products Impala PSA

Hydrogen Plant ‐ Sasolburg





Ltd Loediger Dryer APACS DCS ZAR 600000 2003


Ltd De‐bottlenecking APACS DCS ZAR 8000000 2003

Samancor H1 Sub Station APACS System ZAR 200000 2003

Samancor Baghouse Project APACS System ZAR 1000000 2003

Samancor Orsi Replacement APACS System ZAR 2400000 2003



SBM FPSO Xikomba APACS System USD 2000000 2003




N2 Monitoring System

APACS ZAR 250000 2002


Ltd Boiler II No. 6 APACS DCS ZAR 200000 2002


Ltd Thioform APACS DCS ZAR 300000 2002


Ltd Caustic Leach APACS DCS ZAR 500000 2002


23



Unit 18 & Unit 218 ISSM

APACS ZAR 2000000 2002


Unit 218 APACS ZAR 3500000 2002

SBM FPSO Kuito Phase II APACS USD 276000 2002




HCL Burner Upgrade


Air Products Oxygen Plant ‐ Rustenburg


Chevron Oil ‐ Cabinda Angola

GS Fox Platform APACS USD 110000 2001


GS Platform APACS USD 160000 2001


Ltd SLR Plant APACS System ZAR 400000 2001


Ltd Effluent Plant APACS System ZAR 500000 2001


Ltd

Milling & Magsep Pilot Plant


Samancor Fuji Replacement APACS System ZAR 3000000 2001


Methanol Plant APACS R4 ZAR 600000 2001

SBM FPSO Kuito Phase

1C APACS USD 160000 2001

SBM FPSO Kuito Density

Profilers APACS USD 89000 2001



SBM FPSO Kuito / Espedarte


USD 96000 2001

Suprachem Battery 5 and Exhauster 6



24


Air Products Chambishi Projects

‐ Zambia APACS System ZAR 700000 2000

Dow / Sanachem MSMA Project APACS, Vision and

Batch ZAR 1300000 2000


Ltd Boiler Project APACS System ZAR 400000 2000


Ltd

Compressor Projects



Ltd Base Metal Refiners APACS DCS ZAR 6000000 2000

Samancor Upgrade APACS System ZAR 600000 2000

SBM FPSO Cabinda APACS ZAR 2400000 2000

Dow / Sanachem Tebuthiuron ProjectAPACS, Batch and

Historian ZAR 2400000 1999


Boiler Station DCS Replacement

DCS ZAR 3000000 1999


Ltd Cobalt Plant DCS APACS System ZAR 600000 1999


Rectisol East Quadlog

Quadlog ZAR 1000000 1999


Unit 018 Sulphur Plant

DCS ZAR 2000000 1999

Air Products Rand Water Compressor Control ZAR 200000 1998


Direct Reduction Plant

APACS, APS, UNIX ZAR 500000 1998


Direct Reduction Kilns 1‐4 & Boilers

1‐4

APACS Turnkey Project

ZAR 10000000 1998

Polifin Limited Secunda

Ethane Compressor Compressor Control ZAR 100000 1998


Polifin Unit 24 (Ethylene Recovery



Anti‐Surge Control Compressor Control ZAR 2000000 1998


25


Samancor West Plant, Arc Furnace, Sub

Station APACS System ZAR 2000000 1998

Samancor North Plant 2 off Arc Furnaces



Vacuum Blowers & Propylene

Compressors APACS & Quadlog ZAR 4000000 1998


Delta Auxiliaries DCS

APACS ZAR 100000 1997


Oil Platform Auxiliaries

APACS ZAR 2300000 1997

Delta "G" Scientific

Fluropharm Newco Project

APACS system ZAR 1100000 1997


Sinter Plants A & B APACS Control

System ZAR 1000000 1997

Palabora Mining Company

Zirconia Plant APACS Control

System ZAR 1800000 1997


Unipol Simulator (Honeywell Hispec)

APACS ZAR 500000 1997


Poly 2 Peletizer Upgrade

APACS ZAR 800000 1997

Safripol Sasolburg Batch Management & Enterprise Link

Supply & installation

ZAR 600000 1997

Safripol Sasolburg Safripol Granulation

Line 9 APS / APACS

System ZAR 900000 1997

Safripol Sasolburg Safripol KOB APS / APACS

System ZAR 1700000 1997

Samancor Elgen & Gas Plants APACS System ZAR 2200000 1997


Synthol East & West Feed Gas


Davsteel Bar Mill Reheat

Furnace Turnkey project ZAR 200000 1996


Sinter Plants 1 & 2 APACS Control

System ZAR 2500000 1996


Ethylene Booster Compressor



26


Sasol Sasolburg Sastech Reactor

Pilot Plant APACS System ZAR 600000 1996


SCI Hydron Compressor Control ZAR 100000 1996


Phenosolvan West Ammonia



Air Compressor DCS Installation

APACS ZAR 1000000 1996

Delta "G" Scientific

Control System Phase 2

APACS system ZAR 400000 1995


Copper Filter Plant Automation & Furnace Control

APACS ZAR 500000 1995

Safripol Sasolburg Safripol Granulation

Line 3 APACS ZAR 600000 1995


Chemical Works East & West



Desalination Plant APACS Turnkey

Project ZAR 1500000 1994


Flotation Sections 7 & 8

Mycro MMLC/MBC DCS

ZAR 800000 1994


Sands Treatment Mycro MMLC/MBC

DCS ZAR 1000000 1994


Secondary & Tertiary Crushers &

Fine Ore Bins

Mycro MMLC/MBC DCS

ZAR 1400000 1994


Tailing Thickeners & Hydro Separators

Mycro MMLC/MBC DCS

ZAR 1400000 1994


Poly 2 Unipol Reactor Control

System APACS & UNIX ZAR 5000000 1994

Safripol Sasolburg PP Catalyst Dilution APACS ZAR 200000 1994


Air Utilities East & West



Rectisol West Vacuum Blowers &

Propylene Compressor Control ZAR 500000 1994


27



Waterflush Crushers

Mycro MMLC/MBC ZAR 800000 1993


Autogenous Mills Mycro HLL DCS ZAR 1200000 1993


Concentrator Process Control

Mycro HLL DCS ZAR 2400000 1993


Oxygen Plant East & West



Ethylene Recovery Compressor Control ZAR 200000 1992

Air Products Air Products ‐ Newcastle


Iscor Newcastle Medium Mill

Reheating Furnace APACS ZAR 500000 1991

Natref Compressors load‐sharing & anti‐surge

LIL System ZAR 400000 1991

NCS Resins, Durban

Mycro LIL System System

Implementation ZAR 350000 1991

Iscor Limited Pretoria

LIM System ‐ Coke Ovens


Safripol Sasolburg Management Host Computer System

Mycro Support ZAR 500000 1990

Safripol Sasolburg Granulation Line 8

& Line 2 Mycro DCS &

Support ZAR 2900000 1990


Compressors LIL System ZAR 200000 1989

Safripol Sasolburg Polypropylene plant Mycro DCS ZAR 1900000 1989

Safripol Sasolburg High Density

Polyethylene Plant (HDPE)

Mycro DCS ZAR 2100000 1989


Compressors 16, 17, 18


PPrroojjeecctt PPrrooffiilleess _____________________________________________________________________________________________________________________

28

OLM

OLM

PS307

SM321

SM321

SM322

SM322

IM153

IM153

PS307

SM321

SM322

SM322

IM153

IM153

PS307

SM321

SM322

SM322

IM153

IM153

PS307

SM321

SM321

SM322

SM322

IM153

IM153

SM331

SM331

PUMP3 DIESEL PUMP1 ELECTRICAL PUMP2 ELECTRICAL PUMP4 DIESEL

3152DP

CP343

3152DP

CP343

MasterPLC

ReservePLC

MPI Red Link

50 meter Plastic Fibre

15 meter

15 meter

10 meter

10 meter

Master Profibus Network Reserve Profibus Network30 meter Plastic Fibre

EQUIPMENT ROOMCUBICLE2

EQUIPMENT ROOMCUBICLE1

Master Profibus Network50 meter Plastic Fibre (New Fibre)

Reserve Profibus Network30 meter Plastic Fibre (New Fibre)

Project Profiles

Eskom Kendal – Fire Pump PLC Replacement

Eskom, being South Africa’s Power Company supplying power to numerous types of clients and

industry, required the replacement of an aging PLC system on the KENDAL Power Station.

The Fire Pump system forms an integral and critical part for the safety of the Power Station. The

new design had to cater for high availability and reliability of the pump equipment to be

controlled. The design was for a 160 I/O S7 PLC, high complexity (Start‐up and Shutdown

sequencing) and advanced software redundancy to satisfy the required specification.

The software / hardware application was designed and tested (FAT) at Matrikon Moore Offices

before being implemented on site.

The project was successfully completed and handed over after Site Acceptance Test was

performed.

Major features and benefits:

Redundant ring topology which increased the availability and reliability of the system.

Start –up and shutdown sequences streamlined the availability of certain equipment under different conditions.


29

Anglo Platinum

The Anglo Platinum group is the world's leading primary producer of platinum group metals

(PGMs).

Rustenburg Base Metals Refiners (RBMR) processes converter matte from Waterval Smelter to

produce a precious metals concentrate and base metals refined products. The precious metals

concentrate is further refined at the Precious Metals Refiners (PMR).

The RBMR consists of two metallurgical plants: the magnetic concentration plant (MCP) and the

base metals refinery (BMR).

Matrikon Moore has been extensively involved in the replacement\upgrade and migration of

RBMR DCS systems since 1998. The following projects consisting of more than 12000 I/O in

total had been done or are currently in progress:

1. Cobalt plant – Initial installation of ProcessSuite 2.05 and APACS+. Migrated to PCS7

APACS+OS – Approximately 400 I/O.

2. BMR – Replacement of Outokumpu system in 1999 with ProcessSuite 2.05 and APACS+.

Migrated to ProcessSuite R4 and then to R5. Finally migrated to PCS7 APACS+OS in

2008/9 – Approximately 3500 I/O.

3. MCP – Replacement of Modicon PLC’s and Fix32 Scada system in 2004 with ProcessSuite

R5. Currently migrating to PCS7 APACS+OS – Approximately 3700 I/O.


30

4. RPMCD – Replacement and commissioning of Modicon PLC’s and Fix32 Scada system in

2007 with ProcessSuite R5. Migrated to PCS7 APACS+OS in 2009 – Approximately 750

I/O.

5. Tank house – Installation and commissioning of ProcessSuite R5 and APACS+ (2004‐

2007). Migrated to PCS7 APACS+OS in 2009– Approximately 250 I/O.

6. Efftech plant – Installation and commissioning of ProcessSuite R5 and APACS+ in 2008.

Migrated to PCS7 APACS+OS in 2009 – Approximately 100 I/O.

7. Extensively involved with the boiler and compressor installations and upgrades.

Installation of ProcessSuite R5 and APACS+. Migrated 7 boilers to PCS7 APACS+OS –

Approximately 1000 I/O. Migrated 3 Compressors to PCS7 APACS+OS – Approximately

300 I/O. Optimized anti‐surge control on all compressors.

8. Crystallizer – Green fields project, installation and commissioning of PCS7 ver. 7 in

2008/9 ‐ Approximately 600 I/O.

9. NCM Filtration and Sampling – Green fields project, installation and commissioning of PCS7 ver. 7 in 2008/9 ‐ Approximately 450 I/O.

10. New Milling & Magnetic Separation, WCM – Green fields project, installation and commissioning of PCS7 ver. 7 in 2008/9 ‐ Approximately 1800 I/O.


31

MCP Capacity Expansion Project (NCM Filtration & Sampling; Milling and Magnetic

Separation; WCM receiving and Thickener)

Matrikon Moore supplied, installed and commissioned a PCS7 control system for 2000 I/O and

170 Drives. This project was completed in two phases, the Nickel Copper Matt (NCM) Filtration

and Sampling and secondly the new Milling and Magnetic Separator areas. High plant

availability was achieved by incorporating redundant server architecture for each of the two

areas and integrating the two areas control systems into the rest of RBMR Industrial Ethernet

Ring.

The configuration for this project was implemented as per the S88 software structuring

principles for non‐batch applications which is based on the ISA S88.01‐1995 Batch Control

Protection of plant equipment and personnel was maximized, with the additional benefit of

ease of engineering and maintenance strategies. The integrated message system also ensured

short standing times and was further enhanced with the implementation of a Matrikon Alarm

Management system. This will ensure that the operators are not blinded with too many

unnecessary alarms and have enabled the DCS Engineers to easily detect and rectify nuisance

alarms in accordance with International benchmarks such as ISA 18.02.

The NCM Filtration and Sampling area has also successfully been interfaced with Anglo

Platinum’s Sample Preparation / Metal Accounting system. This area also allows for the bagging

of NCM after which it can then be sold or re‐introduced into the system at a later stage when

demand is up.

The MCP Capacity Expansion Project has increased milling and magnetic separation capacity,

from 64,000 to 95,000 tons per annum and has enabled the accurate capturing and recording of

vital information for the purpose of Metal Accounting. The MCP’s capacity is currently limited

at 75,000 tons per annum due to bottlenecks in the current leach section. Further studies have

already begun in order to find ways of removing these bottlenecks.

The project started in the second half of 2008 and was completed in the fourth quarter of 2009.

Final optimization of the plant is continuing through the first quarter of 2010.


32

Samancor

Samancor Meyerton Works, part of the BHP Billiton global group, line of business is the

production of Manganese. Matrikon Moore supplied and installed an 8 500 I/O system at the

Elgen Plant Turbine Boiler, North & West Plants Weighing system and Electrode Control & Gas

Cleaning.

The provision of a totally integrated control system connected three large plants that included a

power generation unit and three arc furnaces over a large distance (8 km). Protection of plant

equipment and personnel was maximized, with the additional benefit of ease of engineering

and maintenance strategies.

Plant Descriptions

The North Plant consists of:

Two 45 megawatt submerged furnaces including its Raw Materials Weighing system.

CO distribution plants.


33

Elgen consists of boilers and steam turbine to generate power for the North and the West plant furnace requirements. This system is divided into 2 parts namely:

Safety shutdown system for the boiler and turbine.

Utilities.


34

The West Plant consists of:

One 45 megawatt submerged furnaces including its Raw Materials Weighing system.

Gas distribution plants.


35

One OB converter with high speed lance control.


36

Iscor (Arcelor Mittal) – Direct Reduction Plant Upgrade Iscor (Mittal Steel) manufactures iron and steel, and their requirements were the supply and installation of a 5000 I/O system at four kilns and four boilers. Open architecture allowed integration of APACS DCS and UNIX based APACS+ Process Supervisor with the 20 000 I/O AEG PLC system, Schenck weighing control system & Sybase MIS. The improved plant control of all areas resulted in increased production, while ease of maintenance decreased downtime. There was also a decrease in volume of off‐spec product. The fully integrated system of the APACS , APS and the Schenck weighing equipment meant a single point of control and reporting making the efficiency of the operation staff more effective. The further integration of the Demin Water plant for the Boiler’s including all the analytical equipment for water quality was undertaken as an addition to the project. Remote control of the plant was the major benefit which allowed for better control of the water quality which reduced the boiler maintenance and breakdowns by 33%. Benefits:

Increased productivity.

Decrease in off spec product.

Better boiler efficiency which meant higher volumes of low pressure steam supplied.

Decrease in Boiler breakdowns due to more efficient Demin Water control.

Greater efficiency of the Raw materials handling supply chain.


37

FPSO Kuito ‐ Phase 1A

Size: 220,000 DWT Storage Capacity: 1,400,000 bbls Max throughput: 100,000 bbls oil per day

The Kuito project entailed ensuring that the FPSO was ready for first oil at the end of December 1999. Various production control systems of the FPSO had to be optimized, including integrating the normal process control system with the safety shutdown system.


38

Improvements were made to the system to ensure smooth start‐up and fault‐free operation by utilising the extensive process control experience that the MPC engineers obtained on similar projects. Some of the systems that were improved were:

The Fire and Gas System

Main gas compressors

Booster compressor

Gas injection compressor

Water injection system

Water treatment system

Process control system Optimization and fault‐free operation of the FPSO was achieved by applying process knowledge obtained from similar projects. Matrikon Moore provided start‐up assistance and 24‐hour coverage to help with any problems that arose on the existing equipment. By making use of the Matrikon Moore engineers for on going support, SBM ensures that the system is maintained and kept in good heath.


39

FPSO Kuito ‐ Phase 1C

This project entailed designing and integrating the Module 14 control system with the existing

control system onboard Kuito in a very short time frame. This included designing local control panels to SBM standards, ensuring that approval from ABS of the Fire and Gas System was obtained, and integrating the new module with the existing Fire and Gas / ESD system on board Kuito with minimal disruption to the operation of the plant.


40

FPSO Kuito ‐ Density Profilers

SBM’s requirements were for Moore to integrate the new Nucleonic density profiler into the control system. We did this by integrating the advance calculations required for these devices

into the Quadlog system. SBM now has access to the programs required by these profilers for

maintenance. No Third party software is required and there are no hardwired signals between

the control system and the profiler.


41

FPSO Kuito ‐ Phase 2A

The Phase 2A for the Kuito comprised of new modules for the Gas Compression – 2 x Solar Turbine Compressors (600 I/O) Module 21

Water Knockout Vessels 2 x Vessels with new Density Profilers (500 I/O) Module 20

Glycol unit (120 I/O) Module 4

The modules were manufactured in a Shipyard in Louisiana, USA. After designing the DCS

system additions, manufacturing panels and integration of the equipment, the complete

additions (hardware and software) were tested at Moore House.

After the successful Factory acceptance testing the equipment was shipped to the ship yard.

Moore personnel then traveled to the shipyard for the installation on the modules of the

equipment as well as for the commissioning of the software. After 6 weeks of commissioning

the modules were loaded onto barges and towed out to the vessel location in block 14 Angola.

These modules were lifted at sea and were reputed to be the heaviest lift ever done of a

module.

Once lifted and secured the modules were hot commissioned and placed into service. New

MNET networks and power supply cabling had to be routed to the new modules.

The additional modules increased the productivity of the vessel and extended the life of the

existing installation.


42

FPSO Kuito DCS Availability Project

Solutions and Benefits Provided:

M‐NET Repeater Panel

New Fiber Optic Modems installed to remove known temperature drift problem on the copper repeaters.

Online installation completed without any production downtime.

Signal drifting and reflections eliminated. Average noise level now – 20db (min required < ‐10 db)

Ambient temperatures inside the panel reduced, equipment lifespan increased.

Installation of Redundant power supply feed, increased network availability and reliability.

Significant signal improvements in the MNET network, due to increased dBmV signal strength output at 17db (min required > 10 db) of the fibre repeaters and terminating taps.


43

Power Supply Upgrade

The original installation included a common power supply for both the rack and field power

inputs. There were reported incidents of the main fuse blowing on the digital I/O cards. The

Siemens Factory advised segregation of the power as the isolation between the rack and field

was bypassed with the common supplies resulting in the backplane being exposed to any

problems in the field. All the main card fuses on the Critical Discrete Modules were also

replaced as the original fuses were subject to temperature and vibration fatigue.

New Power Supply panels were situated closer to the LCC’s which also eliminated the voltage drop problem caused by running 24Vdc over long distances.

Redundant power supplies installed to all LCC hardware within budget and on time.

Segregation of all field and rack 24Vdc supply

Significant system availability increase

2nd UPS feed installation completed to all LCC’s within budget and on time

Eliminated availability and reliability problems due to single UPS feed

Updated documentation supplied for all LCC power requirements

Elimination of unknown power supply factors due to supply of documentation

Cabinet Vortex Cooling

Cabinet vortex cooling installed within budget and on time

Hardware lifespan increased

Significant system availability increase


44

Fuse Replacement

Heat stressed fuses replaced on all CDM modules.

Significant system availability increase.

Controller Scan Rate and Free Memory (6 MB CCMX)

Program execution improvement of between 200% & 450%

Free Memory increase improvement of between 300% & 840%

Communication overruns minimized

Watch Dog Timer

Modifications to the watchdog soft list parameters were done to enable better communications.

By increasing the performance and optimizing the controllers scan times read communication errors have been eliminated.

Compressor Anti‐Surge & Load Sharing

On‐site inspection to determine system errors

Surge line calculation faults on Control Line detected & defined

Extensive calculations and checks on algorithm to expose errors

Compressor not protected from surge with existing Control Lines

New Control Lines calculated and Implemented

Compressor protected from Surge and system enhanced


45

FPSO Xikomba

Size: 290,000 DWT

Storage Capacity: 1,700,000 bbls

Max throughput: 90,000 bbls oil per day

Moore’s scope of supply included the engineering, configuration, project management, FAT,

and commissioning of the ICSS consisting of the Quadlog Safety System. Also included were the

design and fabrication of all indoor and outdoor panels, operator stations, operator desks and

the Control Network.

The overall execution time for this type of project was shortened by three and a half months

and the plant also came into operation 2 weeks earlier than planned. The Xikomba was started

up in November 2003, with an uptime of more than 95%.


46

FSO & MOPU Turkmenistan

Size: 12,000 DWT

Storage Capacity: 60,000 bbls


The system was made up of a Jack‐Up unit (MOPU – Mobile Oil Production Unit) and an Storage

and offloading facility (FSO – Floating Storage and Offloading)

The two systems are connected via a radio link for shutdown of either vessel in case of

emergency.

Bothe installations comprised Safety systems and the Process control.

The execution and implementation was done in a one year. First oil was on time.

Unique feature of the system was the integration of the Foxboro stand alone field controllers

into the ICSS via Serial link (RS485)


47

FPSO Mondo

Size: 273,000 DWT


Max throughput: 100,000 bbls oil / day

Matrikon Moore provided the complete supply, system hardware engineering, configuration, testing and delivery of the ICSS (Integrated Control and Safeguarding System) for the FPSO Mondo (configured I/O count of 2882 plus 20% spare, total Installed I/O 3479). Additionally there are

another 3000 Soft I/O configured for interfacing to the other packages on the vessel.

The system was designed using the Siemens PCS7 system utilizing the latest technology S7‐417‐

4 FH system. Due to the high level of availability and reliability required all processors were

redundant. The system was designed in such a way that there was no single point of failure for

the safety system. For the safety systems failsafe I/O modules were used and for the Process

Control standard I/O was used.


48

FPSO Saxi

Size: 310,000 DWT


Max throughput: 100,000 bbls oil / day

Matrikon Moore provided the complete supply, system hardware engineering, configuration,

testing and delivery of the ICSS (Integrated Control and Safeguarding System) for the FPSO Saxi.

This is the sister ship to the Mondo being located in the field in Angola.

The design premise, as well as most of the interfaces, was identical to the Mondo design.


49

FPSO Frade ‐ ICSS

Size: 236,000 DWT



Matrikon Moore was responsible for the complete supply, system hardware engineering,

configuration, testing and delivery of the ICSS (Integrated Control and Safeguarding System) for

the FPSO Frade.

Full PCS7 FH System (Failsafe and high Availability)

3500 I/O (plus 4000 soft I/O)

Full H‐System with F‐System Cards

Matrikon:

• Asset Management System – Compressors, Turbines, Heat Exchangers & Pumps

• Alarm Management System


50

AKPO OFFLOADING BUOY

TTeelleemmeettrryy // NNaavvaaiiddss // LLooaadd MMoonniittoorriinngg

The scope of supply was unique in that the communications between the Buoy and the main

FPSO had to be implemented via radio signals.

Siemens Radios were used for inter PLKC communication via the scalance radios. The added complexity to the project was that the radios had to do triangulation. Basically if the offloading tanker was moored at the buoy and it would weather vane between the buoy and the FPSO then a portable repeater on the Tanker would relay the signal. ESD communications was used across the radio signal making certification tough. All Siemens equipment was housed in ExD enclosures on the buoy to satisfy the requirements. This system on the buoy also runs on solar power to ensure that a 35 hour offload can be executed without a loss of power. All calculations and design was done by Moore process Controls. Very stringent Factory acceptance tests as well as Site acceptance tests were performed to meet the client’s requirements.


51

FPSO Espadarte PCS7 OS Upgrade

Size: 273,000 DWT



Matrikon Moore had to upgrade the previous generation HMI called ProcessSuite to the latest Siemens Platform PCS7 OS V6.1.

Due to the complexity and customization of the previous generation HMI a whole new symbol and faceplate library had to be generated and tested to be fit for purpose. The opportunity was also utilized to make some enhancements and optimizations requested by the client.

The second part of the upgrade was the upgrading of the old MNET (Token passing ring topology) to the Industrial Ethernet backbone running at 100MHz. This would allow for better throughput of information and will increase system response.

Additionally some Controllers (CPU) were upgraded with the latest generation Moore Quadlog 6MEG Accelerated Critical Control Modules (CCMx). This would also allow for more future expansion without compromising speed of response of the system.


52

MOPUSTOR Talisman YME Redevelopment


Max throughput: 100,000 bbls oil per day The brief was for the integration of all equipment packages into the ICSS. All packages should be started and stopped from the Central control room due to a principle of minimum manning. This was achieved by integrating most packages that have S7 PLC into the package servers on s7 Connections. Also other interfaces were Modbus or OPC. 4000 I/O (real hard) 4000 Soft I/O IEC 61508/ IEC61511 Compliant Safety analysis report generated to ensure that the design conformed to the set requirements. The system is built with 6 CPU’s for the complete system. Additional to the scope is the Power management system which is implemented in a S7 400 PLC with High speed I/O cards. Additionally the Gas Systems International safety systems were implemented by Matrikon Moore to ensure that the same level of safety is applied for the complete project.


53

FPSO MONDO ‐ Subsea Control System Scope of Services: Moore’s scope covered the configuration, installation and commissioning of a Siemens DCS to control all of the subsea equipment. Project Description The DCS hardware consisted of two Siemens 400‐H (redundant) systems, a pair of redundant severs’ and two clients. Approximately 200 000 soft I/O was used. The project required a fully customized system using Siemens PCS7 which included custom HMI overview, symbols, faceplates and functions blocks. The Siemens system linked directly to the Veto Gray subsea system via industrial Ethernet. The subsea layout included 3 drill centers, which consisted of a maximum of 14 production wells, 8 water alternating gas injection wells, 4 water injection well, 3 production manifolds and 2 water alternating gas manifolds. Roxar multiphase flow meters were included on every production well. The Siemens system was also required to interface and control the Hydraulic Power Unit (HPU) supplied by Anzett. The S7 PLC’s were responsible for all shutdown, interlock and automated control logic. Project Highlights • FPSO Mondo broke SBM uptime records with a 99.99% uptime in its first year. • Mondo was the first vessel that Vetco Gray incorporated a Siemens DCS system into subsea installation. • First SBM vessel to use Siemens PCS7 for top side and subsea installation.


54

FPSO SAXI BATUQUE ‐ Subsea Control System Scope of Services: Moore’s scope covered the configuration, installation and commissioning of a Siemens DCS to control all of the subsea equipment. Project Description: The DCS hardware consisted of two Siemens 400‐H (redundant) systems, a pair of redundant severs’ and two clients. Approximately 200 000 soft I/O was used. The project required a fully customized system using Siemens PCS7 which included custom HMI overview, symbols, faceplates and functions blocks. The Siemens system linked directly to the Veto Gray subsea system via industrial Ethernet. The subsea layout included 4drill centers, which consisted of a maximum of 16 production wells, 8 water alternating gas injection wells, 6 water injection well, 4 production manifolds and 2 water alternating gas manifolds. Roxar multiphase flow meters were included on every production well. The Siemens system was also required to interface and control the Hydraulic Power Unit (HPU) supplied by Anzett. The S7 PLC’s were responsible for all shutdown, interlock and automated control logic. Project Highlights: • Using experience gained from the Mondo project Saxi‐Batuque was completed in record time and on time. • Moore engineers were awarded accolades for their contributions during the offshore commissioning.


55

KIZOMBA ‐ Gas Gathering Scope of Services: Moore’s scope covered the re‐configuration, installation and commissioning of a Siemens DCS to control all of the subsea equipment. Project Description Utilizing the existing Mondo and Saxi‐Batuque systems, new control modules where incorporated in the existing project. A new manifold that is controlled by the Mondo MCS was the merger point for the Gas from the other 3 vessels. The project required the engineering work to be done on the online software, tested and then retro‐fitted to the live system. Project Highlights • Moore received well earned praises for the completion of the project to tight deadlines. • This project was as a model towards Moore’s ISO accreditation.


56

Angola GIP

Line of business: Oil and gas Projects: Fox GIP & Delta GIP ‐ 2000 I/O System Equipment: APACS and ProcessSuite. Benefits: Integrated Compressor & Process control

Angola GIS Fox Platform

Projects: Fox GIS System 600 I/O system Equipment: APACS and ProcessSuite. Solution: Automate the GIS platform and integrate the new control/shutdown system GIP platform with the same interface and operation. Benefits: Integration of the GIP platform with the GIS platform achieved making

use of the same interface and control system.


57

Safripol

Safripol are producers of high‐density Polyethylene and Polypropylene plastics. They were recently acquired by Dow Chemicals. Matrikon Moore was involved in the upgrade of the Poly

and Granulation plants to a 6000 I/O system. The solution was a phased installation of Mycro

352 single‐loop digital controllers. The benefits to Safripol were that the controllers were

replaced on‐line with no loss of production and the improved reactor profile control resulted in

a decreased volume of off‐spec product.


58


Palabora Mining Company’s line of business

is open cast copper mining. The project was

to supply and install a 10 000 I/O systems at

the concentrator, milling and flotation

plants, and to integrate a process model

with the DCS. The benefits for Palabora

Mining Company were optimised efficiency

of the milling operation and copper yield

was increased by 2%.

Polifin

Polifin produces petrochemicals, chemicals

and plastics. The project was to upgrade

Poly 2 to a 5000 I/O system. The existing

DCS was replaced with APACS and Unix

based APACS+ Process Supervisor. The open

architecture of the upgraded system allows

integration of the Unipol process model

with DCS. The resultant advantages are

optimized control of critical parameters and

increased production output. In addition,

system redundancy has reduced downtime.


59

Sasol Synthetic Fuels

Sasol Synthetic Fuels manufactures

petrochemicals and chemicals. They

required compressor control for their

Oxygen plant, air utilities, Rectisol and

many more. Matrikon Moore installed

Mycro 352 Digital controllers, APACS

and Quadlog safety shutdown systems

to provide process control and anti‐

surge control for multi‐stage

compressors with side‐streams. The

benefits for Sasol were decreased plant

outages and a reduction in compressor

maintenance. Automatic start‐up

reduced the time taken to reach full

capacity operation, and plant production increased.


60

Buzau Brew House and Cellars (Ursus)

Supply and scope of all instrumentation, design and layout of MCC, design and layout of all local

control panels, design and layout of all field junction boxes, cable schedules and cable rack

layout were supplied by Moore Process Controls. (1950 I/O.)

System used for automating the Brew house is as follows:

2 X Siemens PLC 417‐4 DP with 18 ET200 remote I/O racks.

Software installed on this project contained Simatic PCS7 V6.1 AND Simatic Batch V6.1 together with Simatic WinCC. Simocode PRO V starters and Danfoss frequency drives formed part of the control system

The operating and engineering stations were set up as follows, 1x Engineering station, 2 x

Redundant WinCC/Batch servers and 2 x Client stations each with WinCC Client and Batch

Software. Industrial Ethernet, Profibus and ASI were used for communication between systems.

The Brew house consists of the following areas:

Material Handling (conveyors)

Millstar

Adjunct cooker

Mashtun

Lautertun

Whirlpool

Wort Kettle

Wort Transfer

The Cellars consist of the following areas:

Yeast Plant

Fermentation Vessels consisting of 15 Vessels

Combi Vessels consisting of 8 Vessels

Storage Vessels consisting of 6 Vessels

Racking plant

CIP plant consisting of 6 Tanks

Filtration plant

Each of these areas consists of various temperature, flow control loops and frequency drives.


61

Atlantic Methanol Production Company

Atlantic Methanol Production Company in Malabo Equatorial Guinea West Africa extracts Methanol from waste fuels, and their requirements were the supply and installation of a PCS7/OS to replace the ProcessSuite Vision and Historian system. The system comprised of 66 Process Graphics, 120 Group Graphics and 1‐year redundant Archiving facility. Open architecture allows integration of APACS and Quadlog Safety Systems. The upgrade presently in progress to improve plant control of all areas has resulted in increased production, while ease of maintenance is achieved and downtime is decreased.

Monitor /keyboard /

Mouse

E ngineering off ices Monaco P.O. B ox 199

C1

Sht.no/Sh 1/9

V1

AMPCOPROPOSED HMI PCS7 OS ARCHITECTURE Draw ing N umber :

AMPCO HMI UPGRADE PROJECT

SCALEnone

Project

Drawing Size : A3

VIDEO CABLEVIDEO CABLE

TRACKBALL/KEYBOARDCOMPOSITE CABLE

TYPICAL OPERATOR INTERFACE CABLING

KEYBOARD OPTICAL MOUSE

21" CRT 21" CRT

MOORE PROCESS CONTROLS (Pty) LtdIndustrial Instrumentation and Distributed Control Systems

Moore House, 39 M onza Close, Kyalami Business Park, M idrand PO Box 6442, Halfway House 1685, R.S.A. Tel: (27) (11) 466-1673/9 FAX: (27) (11) 466-1618

OPS3PCS7 OSClientStation



ENG1APACS+/PCS7 OSEngineeringWorkstation

SERV1BAPACS+/PCS7 OSDatabase/ Graphics Server& Archive Server

Operator Sation 3

Engineering Workstation

KVM SWITCH

Operator Station 2Operator Station 1

SERV1AAPACS+/PCS7 OS

Database/ Graphics Server& Archive Server

M-BUSTO / FROM

MTC01

ETHERNET 1

ETHERNET 2

ETHERNET 3


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Sasol Secunda ‐ Wet Sulphuric Acid DCS/ESD The plant converts 4 to 6 % H2S in off gas from the gas Purifications Plants into Sulphuric Acid by combustion and catalytic conversion of SO2 to SO3. Acid vapour is then condensed to a liquid form in the Sulphuric acid condensers. HP Steam is produced as cooling medium from the combustor and reactor. This process reduces the Sasol Secunda Complex sulphur emission with 1.87 ton per hour. The production capacity of the plant is approximately 11,300 kg/h of acid (H2SO4) with a minimum purity of 96.5% and 76 ton/h of high pressure saturated steam (45 Bar with a temperature of 259˚C).

The control system was chosen to be a Siemens APACS+ DCS and a SIL3 Siemens Quadlog ESD with a Siemens PCS7 as the Human Machine Interface (HMI). The system serves 610 I/O and 41 Profibus devices. All analog devices are terminated on special Hart multiplexed field termination assemblies (FTA’s) and monitored by an asset management system. Matrikon Moore was responsible for the design, configuration, testing installation support and commissioning of the DCS/ESD system. The graphics on the OS were designed according to guidelines specified by Sasol. The system has multiple control loops and a complex burner management system.

CCoonnttaacctt UUss _____________________________________________________________________________________________________________________

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Contact Us

HEAD OFFICE MOORE PROCESS CONTROLS (PTY) LTD (Trading as MATRIKON / MOORE) 6/8 Monza Close, Kyalami Business Park, Midrand, Gauteng, South Africa Tel: +27 11 466‐1673/9 Fax: +27 11 466‐1618

BRANCH OFFICE ‐ VANDERBILPARK

MATRIKON / MOORE

169 Louis Trichard Boulevard,

SE 2, Vanderbijlpark, 1911, Gauteng, South Africa

Tel: +27 16 932‐4421 Fax: +27 16 932‐4424

BRANCH OFFICE ‐ SECUNDA

MATRIKON / MOORE

Hiz Place Building, C/O Mossie & Kiwiet Street

Secunda, 2302 Mapumahlanga, South Africa

Tel: +27 17 631‐2744

USA OFFICE MOORE PROCESS CONTROLS (LLC) 9595 Six Pines Drive, The Woodlands, Texas, 77380, USA Tel: +1 832 631 6349 Fax: +1 832 631 6000

E mail: [email protected]

E mail: [email protected]

Web: www.moore.co.za

Date post:	18-Nov-2014
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