Mindarie Regional Resource Recovery Centre

Source Supply & Control System Components PLC Programming HMI Design & Programming Telemetry & Communication Networks Documentation Drawing, Design & Drafting Factory Acceptance Testing & Simulation Site Commissioning Technical Support & Site Visits Operator Training

Project:
Mindarie Regional Council – Regional Resource Recovery Facility

Customer:
Kerman Contracting / CCA Industrial / SITA

Description:
MRC is WA's largest waste management authority, managing the collection, disposal and treatment of waste generated annually by some 500,000 people living in its locality. The new RRF treats up to 100,000 tonnes of household waste annually, significantly reducing the volume of household waste sent to landfill, and convert about 70% of recovered material into market-quality compost.

Requirements:
KAPP Engineering was contracted by CCA Industrial to provide the engineering, design and commissioning for the Plant Control System. The PCS comprises of a Siemens S7-400 PLC communicating via three independent Profibus copper/fibre networks to S7-300 I/O racks, Simocode Drive Controllers, Micromaster VSD's and third party vendor packages. The SCADA system comprises of a fully redundant WinCC server pair with nine WinCC HMI clients located throughout the plant communicating via industrial Ethernet.

Solution:
With the experience gained from the control system design of the similar SMRC Composting Plant in Canning Vale the KAPP Engineering team provided a system designed with the operator in mind. The SCADA system was laid out and implemented with the "pop-up" concept which included detailed information on individual equipment by means of a pop-up menu. This left the P&ID style HMI pages clutter free and easy to navigate through.

The project was engineered as a Siemens Totally Integrated Automation (TIA) project which enabled a single point of tag entry and other advanced Siemens functions such as generic function blocks for all DOL, Soft Starter & VSD drives as well as process level control using Sequential Function Chart (SFC/GRAPH) programming. This enabled quick and efficient troubleshooting, program changes and diagnostics during dry and wet commissioning of the plant.

With the plant in operation 24 hours a day, 365 days a year; the 24-hour support provided by KAPP Engineering is critical to the owner operators SITA, resulting in reduced down-time. KAPP Engineering also provides remote site assistance via a broadband internet connection with direct access to WINCC Servers, often eliminating the need for a site visit.

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