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Based in North Staffordshire, Deltamex Computing provides PLC / SCADA software solutions for industrial automation systems covering a wide variety of applications. The Company provides a highly competitive, flexible service to fulfill clients requirements. The complete project Lifecycle, starting from user requirement specification, code generation, on site commissioning testing and associated documentation can be catered for. Projects undertaken range from simple packaging plant control systems requiring only a small amount of I/O up to large complex applications for the processing of hazardous chemicals using multiple PLC's interfaced to ESD systems. We have now completed projects in the oil & gas industries. PLC Hardware used for recent projects has mainly been Allen Bradley SLC500, PLC5 and ControlLogix 5000. Supervisory software mainly Wonderware intouch, and Allen Bradley Panel view Some past projects are summarised below. |
Water Treatment
Replacement of the control system for 16 Rapid Gravity Filters at Chigwell Water Treatment plant
The control system comprises an Allen Bradley SLC500, Panel view for the local MMI, and modbus communications to a SCADA system. The I/O for each filter is monitored/controlled using individual IFM ASI bus controllers communicating via Profibus DP back to the SLC (using an SST module). The requirements of the control are for the automatic initiation of draining, air scouring, and backwashing of the filters using a prioritized queuing system, also to control the flow through each filter bed in order to maintain the channel level by balancing the total flow in to the total flow out . A slow start sequence is also used on each filter to allow a return to service at a pre determined rate. A new facility of "flexi- washing" is also included which allows the operator to configure the wash sequence using the MMI to allow each filter to have a different wash for example simultaneous or sequential air scour and backwash or backwash with 1 or 2 pumps , reduced backwash flow period, and an optional cross wash (opening the inlet while the backwash is in progress).
Replacement of the control system for 16 Rapid Gravity Filters at Hanningfield Water Treatment plant A similar project to the above , but without the flexi-wash facility.
Pumping station control - Langford
The control and monitoring of 6 11kV DOL raw water pumps, the flow & position control of intake valves from 2 rivers, Sump level control and control of a number of other smaller pumps and equipment. Uses an SLC 500 PLC , and Allen Bradley Panel view terminal for the MMI.
Pumping station control - Abberton
Controls the transfer of water from a reservoir to a treament works using 5 variable speed pumps. The system allowes the operator to remotely stop/start each pump, and run the system either in manual or auto. Manual mode allows the operator to select the speed demand for the group of running pumps. Auto mode varies the speed demand to maintain the required flow using a PID. Bumpless transfer is implemented when switching between speed & flow modes.
Dissinfection - (Langford ,Layer & Langham)
Automation of Post contact Chlorine dosing of freshwater treatment plant using SLC500.The control system allows manual and auto modes of operation - manual mode controls the dose rate of each chlorinator, auto mode maintains the required dose concentration allowing for changes in flow and compensates for changing final residual. Control and monitoring of the system is either Locally from a Panel view or remotely from SCADA.
Chemicals
Control system for a new Liquid Liquid extraction plant control System at Rawcliffe Bridge
The most ambitious project we have ever undertaken. The project is a continuous plant that processes woolgrease into Woolwax Alcohol and Lanfa. 50 PID control loops are used to control temperatures, pressure, pH, flows and levels, with many of the loops operating in a cascade configuration. The loops , operator interface, and other plant devices are managed by 40 control sequences. The I/O for the plant is devicenet for the fixed and variable speed motors, and controlNet 1797 FLEX Ex I/O for most of the remaining devices eg Analogue inputs, RAV's etc. There is also an ESD system that uses modbus to communicate back to the main PLC. The control system comprises of a Rockwell ControlLogix PLC , and Wonderware Intouch SCADA. The PLC-SCADA comms uses Wonderware's DAserver running on 2 PC's configured with the DraX Master/Slave hot standby I/O swapping system. Plant simulation was used extensively for both software development , and for operator training. Despite being the most complex plant on the site, the resulting control system is also one of the best value for money projects in operation there.
Alkoxylation plant control System - Rawcliffe Bridge
The system controls the reaction of Ethylene Oxide in a purpouse built loop reactor plant. Hazardous nature of Ethylene oxide required ESD (Emergency shutdown system) , and 2 PLC's for control / monitoring. Requirements were for the development of PLC software to control flow of EO into reactor to maintain safe operating, and development of software for pre treatment of raw materials and post treatment of products. Allen Bradley PLC5's used for control with INTOUCH SCADA and INBATCH material tracking system. This Large complex project required extensive commissioning and support for plant operators. Also included is a control system for the pumped Offloading of EO/PO from road tanker to storage for above mentioned system . A particularly comlex aspect of the plant is the temperature control of the reaction. The reactants recirculate in the reaction vessel, and the temperature is controlled using an oil heat exchanger. Two separare control loops either heat or cool the oil to a temperature determined by a master loop that maintains the reaction at the required temperature. Additional loop "smartness" has been implemented so that at the end of the reaction , the cooling required to keep the exotherm reaction in check does not over cool the product.
Alkoxylation plant control System & Effluent plant- Singapore
Provided control software for a Sister plant to the Rawcliffe plant in Singapore , and also software for an Effluent Plant that served the Alkoxylation plant.
Lanolin plant control System - Rawcliffe Bridge
Commissioning and software development of a Lanolin plant control system using ControlLogix PLC and Intouch SCADA. This system had approx 800 I/O comprising of traditional 1771 I/O (using 1756 DHRIO module), and the remainder on controlnet (using 1756 CNB/D module). Approx 100 PLC control seqeunces and 25 control loops (flow, temperature & pressure) were used for the operator control of the plant .
Loop Reactor - Leek
Control system for of an Esters Loop reactor pilot plant to control the recirculation temperature during and after the reaction. Temperature adjustment is provided by a hot oil heat exchanger, and the oil either heated or cooled using separate control loops to a temperature sufficient to achieve the required reaction temperature . The control system Implemented using an SLC500 PLC and Intouch SCADA.
Food and Drink
Project to upgrade an existing Coffee plant evaporator control system from MOD 30 controllers to ALLEN BRADLEY PLC 5’s and an IP21 SCADA system. This required the development of PLC code for approx. 30 flow, level and temperature control loops including several cascaded loops, and associated control functions, interface of the control to the SCADA system, running client works tests, then commissioning of the system, and operator training on site. The system had to be installed during a 1 week shutdown period.
British Sugar Newark plant
Development of a packaging plant control system using ALLEN BRADLEY SLC500 and RSVIEW SCADA.Requirments were for the detailed design of the control system, writing of PLC code, specification of SCADA interface, Customer acceptance tests , and commissioning of system.
For further information email Mark Leigh
Company No. 3105148, VAT Reg No. 661 5754 22 , Tel 01782 720744 (Office), 07971 171599 (Mobile)
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