DAC 2021_12

32 n CONTROLS. HMIs AND SOFTWARE November/December 2021 www.drivesncontrols.com Controls upgrade boosts uptime at Widnes recycling plant I ncinerator bottom ash (IBA), a by- product of the power generation process at waste-to-energy plants, contains valuable non-ferrous and ferrous metals as well as aggregates that, when extracted, can be used in the construction sector. IBA processing facilities need to handle large volumes of feedstock efficiently, whilst recovering the metals, thus helping to create a circular economy of materials. A company called Blue Phoenix, which specialises in transforming residue ash, was experiencing issues with the control system at its plant in Widnes, Cheshire. Most of Blue Phoenix’s facilities use similar control systems and equipment to ensure reliability as well as consistent performance across processes and sites. This standardisation also helps operators to interact effectively with, and monitor, different plants using the same procedures and tools, regardless of their location. But the Widnes site had a different control system from the other installations, resulting in a lack of uniformity and operational challenges. The company noticed that, over time, the control system – and, by extension, the plant itself – was not as reliable and user- friendly as the other ones. “The recycling processes often stopped and on top of that it was difficult to find the cause of a fault as troubleshooting was not easy, which led to increased downtime,” recalls Blue Phoenix’s operations director, Nigel Mitchell. With the plant running almost continuously, the company needed to sort out the problems and to minimise downtime. It contacted York-based Total Automated Solutions (TAS), an automation system integrator with which it had been collaborating for more than ten years, but which had not provided the control system for the Widnes site. Advanced controls are essential for optimising the activities and maximising uptime at IBA plants, while also allowing operators to address anomalies and conduct troubleshooting rapidly. In addition, the automation components must not be affected by the high concentrations of metal particulates in the air, or other challenging environmental conditions at IBA facilities. To update the controller set-up at the Widnes facility and to bring it in line with the other Blue Phoenix plants, while minimising costs and downtime, TAS suggested upgrading the existing PLC to one equipped with modules that would support the EtherNet/IP network that was already in place at the facility. This meant that TAS would not need to make any network modifications, and could ensure effective communications between the new PLC and all of the drives operating across the site. The upgraded control system consists of a Mitsubishi Melsec iQ-R PLC with three Ethernet/IP modules and GT SoftGOT2000 PC-based HMI software, which is being used to control and visualise the recycling processes, while helping to identify and correct anomalies. The PLC was installed and configured during a planned downtime window of only two hours, and has enhanced the reliability and accessibility of the plant control system. Craig Simmons, Blue Phoenix’s support systems coordinator, reports that the company is“extremely happy with the new control system. The plant is now much easier to manage and aligns with our other IBA processing sites. We can also rely on higher visibility and accessibility, which support better diagnostics. Ultimately, it is now much easier to maintain the facility and its activities.” Following the successful implementation, TAS is now supporting the development of Blue Phoenix’s first IBA plant in Australia with a control system using Mitsubishi PLCs, Scada technology and HMIs. n When the operator of a Cheshire waste-to-energy plant experienced problems with a critical control system, it commissioned an upgrade that re-used the same communications network, allowing the new controller to be installed during two hours of planned downtime. The controller upgrade at Blue Phoenix’s waste-to-energy plant has improved its reliability, uptime and troubleshooting capabilities.