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CHEMICAL FOOD AND BEVERAGE

WATER & WASTE WATER

POWER PULP & PAPER

OIL & GAS MINING FERROUS & BASE METALS

PETROCHEMICAL

Industrial Automationand Optimization

Matrikon Moore Company Overview

Matrikon Moore | 2 Matrikon Moore | 3

• Our services

• Conceptual architecture overview

• The main industries we serve

• Where we operate and deliver

• The project delivery journey

• Delivery successes

Matrikon Moore was founded in 1984 and is a privately held company, registered in South Africa. Our head office is in Johannesburg, with regional offices in South Africa (Secunda and Vanderbijlpark), Houston and London.

We provide a comprehensive set of services ranging from control-system design input to front-end engineering design (FEED) studies, right through to turnkey process-automation projects. Service scope also includes optimization and longterm maintenance services for offshore installations.

Sector focus in on offshore and onshore oil and gas production, with special emphasis on FPSO integrated control and safety systems (ICSS), subsea master control stations (MCS), and refining.

In addition to oil and gas we have significant installed systems in mining, ferrous and base metals, petrochemical, chemical, food and beverage, waster and waste water, power, and pulp and paper facilities.

Our customer base is global, including several of the oil majors, leading EPC providers, and blue-chip mining houses.

We have a long-standing reputation for engineering and service excellence, underpinned by our ISO 9001 and OHSAS 18001 certifications, and IEC61508 and 61511 recognition.

CONTENTS OUR SERVICESEach of the services listed can be delivered on a turnkey basis, as standalone solutions on existing installations, or as equipment supply only.

Process instrumentationThe full spectrum of process instrumentation is supported, including measurement of pressure, temperature, flow, level, acoustics and motion. Additional areas of supply include positioners, standalone process controllers, process recorders, wireless HART products, and instrument-related communication software and peripherals.

Equipment cubiclesEquipment cubicles and control-room furniture are designed in 3-D using the latest E-Plan software and techniques. The approach makes optimal use of space, while ensuring easy and convenient access for maintenance personnel. Cubicles range from indoor use, through to use in extreme outdoor conditions, such as on offshore marine installations. Ex-rated cubicles can be supplied to bespoke project specifications.

Control systems (PLC and DCS)We offer comprehensive PLC and DCS solutions ranging from a few hundred I/O, right up to large-scale solutions encompassing integration of disparate plants with several thousand I/O geographically dispersed across large campuses or sites. Solutions can be for standalone control, or can include historians, integration with peripheral systems, and secure provision of information to off-site systems such as ERPs or production-monitoring systems.

System migrationSystems that are end-of-life or that need upgrading are systematically migrated to modern systems using automated tools and techniques to minimize plant downtime, and ensure preservation of intellectual-capital investment in existing systems.

Safety systemsOn safety-critical plants we offer solutions using safety-rated PLCs/DCSs, integrated with the main control system. Our expertise also includes safety compliance of peripheral equipment such as

instrumentation and cubicles required on IS or Ex -rated plant areas. Our engineers are IEC 61508 and IEC 61511 certified, and the systems we deliver typically comply with standards from IEC, API, and

NFPA, etc.

Control system and plant optimizationOur multi-loop and multi-variable analytical software ensures plants are optimally tuned across a broad range of plant operating conditions. We predict equipment failure well in advance, thereby avoiding unnecessary shutdowns. Real-world analysis also reduces the need for unnecessary routine maintenance. Advanced alarm-management analysis takes into account the big picture of plant alarms, and ensures safer operations by eliminating nuisance alarms.

Compressor control and protectionWith more that 27 years experience in advanced single-stage and multi-stage compressor control we offer protection and control solutions across a vast range of installations including air, polyethylene, polypropylene, nitrogen, and oxygen, etc. We minimize energy consumption by safely reducing unnecessary blow-off, and optimizing compressors

configured for parallel operation.

Operator training simulatorsComprehensive operator training is imperative for safe operation on safety-critical plants. These simulators can be very costly. In our approach the costs of plant training simulators are reduced by reusing existing PLC/DCS code and HMI interfaces, along with fully integrated thermodynamic models to give operators a solid grounding in safe plant operation of hazardous plants.

Longterm maintenanceLongterm healthcare on systems, including annual interventions, ensure systems are maintained optimally. 24x7 telephone support, with next-business-day on-site support is available where required. System upgrades ensure control systems are kept current and protected from external cyber threats. This approach prevent systems from becoming obsolete over time.

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Operator Stations Instrument Management HistoriansData Links and

Remote Reports

Engineering Workstations

Work Station and Control Rooms

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Safety ControlDCS / PLC Control

Field Instrumentation Touch Panels Telemetry


CONCEPTUAL ARCHITECTURE OVERVIEW TO DEMONSTRATE THE BREADTH OF OUR SYSTEMS CAPABILITIES

Safety Instrumentation

THE MAIN INDUSTRIES WE SERVE

OIL & GAS: FPSOWe specialize in process automation and safety shutdown systems on FPSOs, Oil Platforms, FSOs, and Jack-ups. We also provide a number of ancillary services to protect these valuable assets and reduce operational risks inherent in control and automation systems. Coupled with optimization of the process and field instrumentation we are a global provider of oil and gas solutions. Our global reach means we can deploy commissioning teams in most geographies, while taking advantage of reduced labor costs in our central engineering offices.

OIL & GAS: SUBSEAOur key focus is the process automation and control of the Master Control System that controls the subsea systems (SMU and SCM). Since we provide automation solutions for topside production we are in a unique position to offer robust systems, integrated across the end-to-end production processes. In addition we provide plant-specific operator training simulators that mirror typical plant operating conditions. After-project healthcare service contracts are available to ensure you maximize the return on your investment in control systems.

FERROUS & BASE METALSWe specialize in the automation and control of electric arc furnaces, electrode control, equipment cooling, raw-material-handling systems, transformer monitoring and control, primary off-gas cleaning plants, gas distribution plants, secondary off-gas cleaning plants, and peripheral plants such as boilers, etc. Solutions encompass the full spectrum of your automation requirements, including safety-rated systems on critical plant areas, advanced control strategies, specialized equipment housings, and fit-for-propose instrumentation.

CHEMICALSBatch and continuous process solutions are available across a broad range of control strategies. We provide design consultancy services and commissioning assistance to ensure clients realize completion of their global projects in record time. Experience covers a broad spectrum, including organic and inorganic chemicals. Our migration service migrates legacy systems to modern systems, thus maximizing clients’ return on investment in plant control to meet the high demands in the market for their products.

FOOD & BEVERAGEWe specialize in the process automation and control of CIP plants, batch-mixing plants, brew houses, raw-material-handling systems, water-purification plants, cookers, and process transfers. Solutions range from small standalone systems, through to full plant process automation, with interfaces to MES and ERP systems. Our solution suite enables easy integration of various package solutions with the main control strategies to give a total perspective on plant operation. Plant data is collated in customized management reports.

MININGMatrikon Moore provides advanced process control solutions that automate and protect your investment in mining equipment and production processes. Solutions are typically engineered in accordance with S88 principles, and range from the mining coalface through to concentrators, refineries and smelters. Our experience and mining process knowledge has enabled our clients to realize increased plant availability and improved production yields, while operating assets in accordance with strict safety requirements.

PETROCHEMICALA dedicated team of engineers with an average 15 to 20 years experience in petrochemical processes provides critical services to South Africa’s largest refineries. The team has full responsibility for developing and maintaining control and protection systems for compressors and turbines across several refining complexes. Skills are world class in safety-instrumented systems and safe plant operation in order to ensure uninterrupted and safe operation in critical plant areas. Predictive maintenance means refining assets maximize uptime.

PULP & PAPERMoore’s pulp and paper solutions encompass all facets of plant operation, including chip preparation, chemical processing, pulp handling, and machine controls in the finishing house. We also provide solutions for the control of peripheral plants such as water treatment, boilers, air compressors, etc. Outside of the main control systems we provide process instrumentation, plant optimization, and support services. In advanced solutions we consolidate production reports centrally, for example at the head office, to provide a consolidated view of collective plant production.

WATER & WASTE WATERMatrikon Moore delivers solutions that protect our environment by providing control strategies to purify water to a high quality level for use in process industries, and for domestic consumption. In South Africa we assist local-government organizations to achieve their Blue Drop certification by implementing high-availability control systems that monitor and deliver continuous adherence to statutory regulations. Our architectures allow collection of geographically dispersed data into a central repository for analysis and process optimization.

POWERPower solutions cover the full spectrum of plant operation, including boiler automation and control, interfacing with dedicated turbine-control systems, and control of peripheral plants such as water treatment, plant air compressors, etc. Plant control and plant safety systems are tightly integrated. Outside of the main control systems we provide robust solutions to plant-specific challenges such as measuring bunker levels in coal silos, measuring bulk-fuel-oil flows, and accurately measuring water flows using non-invasive clamp-on flow meters.

Matrikon Moore | 7Matrikon Moore | 6

WE OPERATE AND DELIVER GLOBALLY

HQ: Johannesburg, RSA

Secunda Office

Vanderbijlpark Office

Houston Office

London Office

Project Location

Office Locations

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FULL-SPECTRUM SERVICE CAPABILITYWe offer the full spectrum of supply and engineering services, ranging from supply of field instruments only, right through to full system design and commissioning on a turnkey basis.

Our scope of supply typically includes interfaces with peripheral systems and packages to provide comprehensive control of plants.

ISO 9001: 2008 CERTIFIEDAll of our audited processes are documented and executed using automated process flows. This rigorous approach eliminates errors, and ensures we follow robust, repeatable processes for project execution.

3-D CUBICLE DESIGNIn order to match conceptual architectures with the real world we use 3-D designs to ensure equipment fits into the cubicles allocated. This approach allows engineers and clients to satisfy themselves that there is adequate space to install equipment, and that there is sufficient space for maintenance personnel to access systems once installed on site.

COMPREHENSIVE TESTINGThree levels of testing are available for projects:• Internal factory acceptance testing (FAT)• Client-witnessed FATs• External FATsAll tests follow documented procedures, in line with our ISO 9001 processes. Results are published to the client, and resolution of issues is tracked closely.

GLOBAL REACHOnce tested, the systems are deployed on site, where our commissioning teams ensure they are commissioned in line with documented procedures, and in line with the plant process-control philosophies.

Changes are rigorously managed to ensure modifications are documented and approved by the client.

On-site discipline in change management means that plant documentation is up to date, and reflects the “as-built” status of the control system and wiring.

THE END-TO-END PROJECT LIFE-CYCLE

FEED Study&

Proof of Concept

• Solutions based on extensive system deployment experience.• Accurate pricing based on robust architecting and solutioning.• Rapid prototyping and proof-of-concept demonstration of integrated components.

Tendering• Precise pricing based on accurate bills of materials derived from solution designs.• Integrated solution design and pricing models ensure that solution changes are rapidly and

accurately reflected in updated pricing and tender schedules.

Design

• Solutions based on customers’ corporate engineering standards.• Vendor-recommended best practice – we are recognized experts in the systems we supply.• Our 3-D cubicle design tools ensure optimal equipment location and placement, and ensure

convenient maintenance access.

Configuration

• Accurate interpretation of control philosophies by experienced engineers.• Accelerated development through use of extensive standard libraries.• Automated error checking to trap anomalies, and rapidly align to process design changes. • Streamlined approach to change management.

Assembly&

Testing

• Audited fabrication, assembly and wiring of cubicles.• Extensive hardware and software FATs minimize on-site commissioning time lines.• End-to-end testing of all control philosophies ensure accurate plant operation.

Commissioning

• Experienced staff ensure safe and expedient commissioning.• Our ISO 9001 approach delivers high-quality documentation.• Training courses are provided for operators and technical staff.• Operating training simulators can be developed for critical plant applications.

Long-term Operational

Support

• On call 24/7 for critical applications.• Upgrades to systems bring them in line with the latest technology standards.• Migration of systems using automated techniques – minimizing the need for plant downtime.

Optimization• Optimization tools tune loops and maximize plant production.• Predictive tools anticipate and prevent plant trips.• Alarm management methods facilitate safe plant operation.

OUR PROJECT DELIVERY APPROACH


THE PROJECT DELIVERY JOURNEY

ISO 9001 Work Flows

Automated Tools and Processes

Client Project Changes Requests

Client User Requirements:

• Narratives• I/O counts• P&IDs• Other docs

Reference Architecture

Our custom-developed automation tools import data directly from client source documents to eliminate coding errors, and accelerate system development.

Our structured and disciplined delivery approach means fewer coding errors, less on-site rework, and ultimately safer plant operation.

Automated Preliminary DCS/PLC Configuration

Automated Preliminary

Graphics Configuration

Error-free Bill of Materials

Automated Cause-and-effect

Configuration

Example 3-D cubicle design layouts

3-D Cubicle Designs


SELECTED DELIVERY SUCCESSES

OIL & GASFPSO N’Goma (Offshore Angola)Topside and Subsea Control and Safety Systems

Size: 6,500 wired I/O, 3,500 OPC I/O, and 45,000 soft I/OProject locations:• Engineering: Johannesburg, South Africa• Installation: Keppel Shipyard, Singapore• Final commissioning: Offshore Angola

Project duration: 1.5 years shipyard; 6 months on location

The project on this FPSO was to supply the integrated control and safety system (ICSS), and subsea master control station (MCS).

Work was executed in full compliance with IEC 61511, considering the full IEC life cycle. The accelerated schedule of works was completed in ten months, ahead of the exhaustive factory acceptance test (FAT). Hardware consisted of multiple redundant servers, clients, redundant CPU’s and I/O. Extensive interfacing to various 3rd party vendors across multiple platforms was required.

The MCS entailed extensive interfacing with dedicated subsea control systems to provide control from the central control room. On deck remote I/O were used to provide control of the fire and gas, marine, topsides and turret systems.

Moore deployed an experienced construction and commissioning team to the shipyard, to ensure the control system was ready for when the vessel sailed. The customer’s stringent quality requirements and demanding schedule were all met on time, and on budget.

All work was completed in compliance with our IS0 9001 quality system, with documented work flows, policies and procedures to ensure that all deliverables had undergone mandated quality checks.

PETROCHEMICALWet Sulphuric-acid PlantControl and Safety Shutdown System

Size: 610 hardwired I/O with 41 PROFIBUS devicesProject locations:• Engineering: Johannesburg, South Africa• Installation: Secunda Complex, South Africa

Project duration: 24 months

The wet sulphuric-acid plant converts 3,5% H2S in off gas from the Rectisol and Phenosolvan plants into sulphuric acid by combustion and catalytic conversion of SO2 to SO3, thus reducing sulphur emissions by 16,000 tonnes per annum.

Matrikon Moore was responsible for the end-to-end design and supply of the DCS and emergency shutdown (ESD) system. The Siemens APACS system was chosen for the DCS, with the Siemens SIL3-rated Quadlog for the ESD. These were controlled through Siemens PCS7 operator stations (OS).

The graphics on the OS were designed in accordance with the abnormal situation management (ASM) consortium guidelines for effective operator display design. All control loops were engineered, coded and commissioned in line with the client’s stringent safety requirements.

OPTIMIZATION FPSO Okha (Offshore Australia)Control-loop Optimization

Scope: All FPSO topside compressor and turbine control loopsProject locations:• Remote diagnostics: Johannesburg, South Africa• Final commissioning: Offshore Australia


Compressor and turbine control loops on the FPSO were oscillating despite numerous attempts at optimizing tuning parameters. This was in part due to the complex interaction of various process control loops on the plant.

Matrikon Moore was provided with a remote connection to the vessel, allowing experts to work on the system at any time of the day, without being constrained by time-zone issues or lack of on-the-ground local support.

The optimization team deployed a control-loop monitoring and advanced loop-tuning system to identify and provide tuning parameters for the compressor and turbine control loops. Systematic remote analyses rapidly identified the root causes of the instabilities, which were then solved through inputting optimized tuning parameters into the relevant controllers.

MININGCopper and Cobalt MinePlant-wide DCS

Size: 3,100 hardwired I/O, with 650 PROFIBUS drivesProject locations:• Engineering: Johannesburg, South Africa• Installation: Kolwezi, Democratic Republic of Congo (DRC)

Project duration: 3 phases spread over 24 months

This remotely located greenfield copper and cobalt mine consists of crushing, milling, leaching, thickeners and electro-winning. The DCS had to be expanded significantly as part of planned plant expansion to increase capacity by 200,000 tonnes per annum.

Software engineering was completed in Johannesburg, and an extensive FAT was conducted to verify compliance with the control narratives supplied by the EPC. A large part of control narratives had to be developed by Matrikon Moore, in compliance with S88. These were based on EPC-supplied process narratives, which we used to develop the DCS control strategies that were ultimately deployed on site.

On this collaborative project the control system hardware was free-issued to Matrikon Moore for local assembly and integration. Cubicles were supplied by a 3rd party, and dispatched directly to site.

Our engineers went to the mine to install the final FAT version of the DCS configuration software tested in Johannesburg. The system was then fully commissioned, with our oversight including loop testing, hot commissioning of all DCS I/O and PROFIBUS MCCs, operator training, and assurance of system go-live.

FERROUS & BASE METALSFerro-manganese Plant (South Africa)Electric Arc Furnace DCS

Size: 4,000 hardwired I/OProject locations:• Engineering: Johannesburg, South Africa• Installation: Meyerton, South Africa


The Meyerton campus comprises of four electric arc furnaces ranging from 50 to 80 megawatts each, and a 50 megawatt turbo-generator power plant utilizing waste gas from the smelting processes. All of these plants were automated by Matrikon Moore between 1997 and 2013.

This particular project comprises of an 80 megawatt electric-arc furnace for the production of 120 000 tonnes of high-carbon ferro-manganese per annum.

The standard Siemens Advanced Process Library (APL) was used for this project, which ensures that the library will be maintained and expanded with future Siemens software updates. The APL also provides exceptionally rich functionality to operators, and incorporates customized reports for operations staff.

The control system consists of eight Siemens AS417 CPUs with remote ET200M I/O. Two redundant H-systems CPUs are used for the Gas Cleaning and Distribution Plants. These are connected to a redundant server pair, providing live data to six client stations, and one OpenPCS7 connection for the 3rd-party site historian.

The entire new PCS7 control system was live and ready for hot commissioning within time-line expectations, and was successfully commissioned within the available budget.

COMPRESSORSRectisol Compressors Control and Safety System Replacement

Size: Eight compressors with 120 control and safety I/O eachProject locations:• Engineering: Johannesburg, South Africa• Installation: Secunda Complex, South Africa

Project duration: 36-month phased roll out

Provision of anti-surge control system and failsafe shutdown system for propylene compressors and vacuum blowers.

This project was the first to implement anti-surge control on the Siemens S7 controllers for the client. The solution was deployed on a fully integrated control system comprising of a series of redundant Siemens S7 processors and I/O racks.

An abnormal situation management (ASM) library was developed and used for graphical user interface to ensure safe and reliable plant operation.

The complete compressor-control packages for all eight compressors including anti-surge, ESD, and oil systems were delivered during routine plant shutdowns, on time, and to client specification.

Key Clients: Contact us:

[email protected]

South Africa Head Office (Johannesburg)Tel: +27 (11) 466 1673

South Africa (Vanderbijlpark)Tel: +27 (16) 932 4471

South Africa (Secunda)Tel: +27 (17) 631 2744

USA (Houston)Tel: +1 832 631 6349

Europe (London)Tel: +44 777 265 1605

www.moore.co.za

Copyright Moore Process Controls Pty (Ltd)

Moore is an equal-opportunities employer.We are ISO 9001:2008 and OHSAS 18001:2007 accredited, and IEC 61508 and IEC

61511 certified.

Legal notice: The logos, trademarks and references used in this brochure are acknowledged as belonging to their respective owner. These organizations have not consented to their use by Moore Process Controls, nor are they affiliated to Moore Process Controls. Their use is not an endorsement of Moore Process Control’s services or products.

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