Pretoria Portland Cement Co. Ltd.

PPC replaced their existing 30-year-old electrical and control systems with a sophisticated technology based on System Platform and Historian– a major upgrade that took more than a little courage and commitment.

Pretoria Portland Cement Co. Ltd.

PPC replaced their existing 30-year-old electrical and control systems with a sophisticated technology based on System Platform and Historian– a major upgrade that took more than a little courage and commitment.

Goals

  • Replacement of legacy control system
  • Establishing a centralized control room
  • Ensuring the effective measurement of KPIs, logging and trending
  • Installing a distributed PLC network
  • Translating the old system into PLC / SCADA control
  • Adding a new Historian server
  • Replacing all redundant electrical equipment
  • Installing new instrumentation

Challenges

  • Replacing 30 years of control system evolution in five weeks while maintaining operations and mitigating potential interruptions
  • Migrating operators who, for decades, have known exactly which button to push

Results

  • Achieved PPC objectives within time and budget constraints
  • Systems made best use of the existing PPC investment
  • Operator buy-in, early ownership and easier change management through the ability to change the system to their liking cost effectively
  • Standards based on best practices will facilitate future upgrades
  • Four-screen design and navigation standard lets operators see everything at a glance

"For the first time in a very long while, we feel that we are in control of one of our primary production processes. Even more than that, we are now in a position to improve operations through trustworthy real-time information and trends. ." - Johan Saunders, Technical Advisor Pretoria Portland Cement Co.

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