SERCK Controls has installed a real-time environmental monitoring system, based on the Serck SCX6/ClearScada product, at the Ashton open cut coal mine, located in the Hunter Valley region of New South Wales. Ashton, located 14 kilometres northwest of Singleton, includes an open cut and underground coal mine, coal handling and preparation plant, and rail siding.
The Serck system comprises up to 10 Serck RTUs, including the eNET model and the PDS Compact 500 model RTU. Data is gathered from two pumping stations, weather stations, and vibration and dust particulate monitors using and collated by the SCX6/ClearScada for mandatory local and web based reports.
The SCADA communicates to the RTUs via GME UHF radios and repeaters. RTU communication is via the DNP3 protocol.
Serck Controls provided engineering services including all RTU programming, hardware procurement, factory testing, installation, site testing and commissioning.
Serck has also assisted with the unmanned operation of the Teralba Coal Seam Methane (CSM) power station at Teralba, NSW.
The power station comprises eight generators to provide 8MW of power generation. Its control system utilises process control, telemetry and SCADA software and hardware supplied and installed by Serck Controls. To assist with the unmanned operation of the power station, Serck Controls used the inbuilt features of the SCX6/ClearScada software package to provide automated features such as alarming, daily emailing and faxing of production reports and alarms.
Once a start has occurred, the control system adjusts the speed of the variable speed drives (VSD) to maintain manifold pressure, while also controlling a vent valve. As a result, a specified constant methane volume is extracted from the mine supply, no matter how many generators are running.
The SCX6/ClearScada monitors and controls system ancillaries such as clean and dirty oil pumping, air compressor regulation and gas cooling.
The control system also interfaces to power meters, variable speed drives, protection relays and Serck RTUs.
Serck Controls has also been involved in the WA Water Corporation’s desalination plant on the Burrup Peninsula.
The plant consists of three mechanical vapour compression (MVC) units and associated chemical dosing equipment supplying 150 kL/hr.
The process control system is based on Siemens S7 PLCs and provides plant level coordination. Remote I/O modules are distributed around the plant at key locations via Profibus/fibre optic communications.
The plant SCADA is based on Serck SCX6/ClearScada, whose redundant server configuration is utilised for high system availability.
The SCX6/ ClearScada communicates to the S7 PLCs via Ethernet TCP/IP using the Siemens S7 protocol.
Serck eNET RTUs and Trio TC-450ER data radios provide connectivity to the seawater intake pump station for process interlocking. The RTUs communicate using the Modbus TCP protocol.
Each desalination plant MVC unit has a local control OIP consisting of a Siemens 10 inch touchscreen panel.
The custom designed water sample stations (turbidity, conductivity, ORP, temperature) analyse the seawater to the MVC units, brine discharge and final product distributed to the Burrup fertiliser plant.