Compressor Control System Upgrade at Smelter Facility

BESTECH's project at a smelter facility involved a significant upgrade to the compressor control systems. By integrating new controllers and installing advanced SG controllers on key compressors, we enhanced the facility's compressed air supply. The introduction of a new Allen-Bradley ControlLogix PLC, coupled with a local HMI screen, streamlined operations and provided operators with improved monitoring and control capabilities. This upgrade exemplifies our commitment to implementing modern technologies to optimize industrial processes.

The project focused on upgrading and enhancing the compressor control systems in a smelter facility, requiring the integration of new Ingersoll-Rand controllers and the installation of two new SG controllers. The goal was to improve the compressed air supply and streamline control processes using modern technology.

BESTECH completed both preliminary and detailed engineering for this project. We upgraded existing compressors with new controllers and installed SG controllers on compressors No.3 and No.5. A key aspect of the project was implementing a new programmable logic controller (PLC) to manage compressor on/off sequences and controls, with information transmitted over the smelter’s control LAN. The PLC featured a local human-machine interface (HMI) screen for operators to monitor and respond to alarms efficiently.

Key Features:

Integration of new Ingersoll-Rand controllers on existing compressors.
Installation of SG controllers on key compressors for improved air supply.
Implementation of a new Allen-Bradley ControlLogix PLC for enhanced control.
Utilization of a Modbus network for streamlined communication.
Elimination of outdated wiring systems and integration with the new PLC.
Local HMI screen for operator interface and alarm management.

This project successfully upgraded the compressor control systems, improving efficiency and reliability in the smelter’s operations. The modernized control system provided enhanced monitoring capabilities and operational flexibility, reflecting BESTECH’s expertise in industrial automation.