SCADA for SULFURIC ACID RECOVERY - RealFlex Technologies Ltd.

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SCADA for SULFURIC ACID RECOVERY

CASE STUDIES

One of the major steel producers in the world manufactures alloy steel bars, seamless tubing and tapered roller bearings.

PROBLEM DESCRIPTION AND SYSTEM REQUIREMENTS:

The client's sulfuric acid recovery plant is the largest automated facility of its kind in the world. The sulfuric acid is used to remove oxidized scale and other surface contaminants from steel. If the acid is too cool, the steel won't pickle properly, if too hot, the acid will pit the steel and cause fuming problems. The firm needed a system to monitor and control the temperature of the acid, scanning each valve every 7-10 seconds.

REALFLEX SOLUTION:

RealFlex Control Sequence Language is used to interrogate valve alignment, pump status, and flow conditions throughout the pickling operation. Graphical displays of pipe schematics use a line coloration feature to change the color of the pipe depending on whether the pipe contains acid or water. This feature prevents the unnecessary burdening of PLC's. A series of if/then statements in CSL control changes in production conditions. The operating time of every valve is monitored, if the time exceeds acceptable limits, an alarm is registered. Motor starter response is monitored to verify correct operation.

RESULTS:

The system has proved reliable and little downtime has been incurred from hardware or software failures. Cost savings and improved product quality are realized due to the improvements in the production process. Steel quality and capacity has improved since situations are adjusted throughout the process to insure no abnormal situations arise.

REALFLEX SYSTEMS SOFTWARE:

RealFlex, Control Sequence Language (CSL)

DATABASE SIZE:

4500 points

PC HARDWARE:

Various computers

I/O HARDWARE:

2 GE Fanuc Series 6 PLCs, 5 GE Fanuc Optibasic Operator Interface Terminals, Dedicated bus controller

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