RO Plant Integration for Magnetite Iron Ore Operation

The RO plant was originally delivered as a standalone package with its own local control and operator interface. It had limited integration into the main plant control system, limited visibility from the central SCADA environment, and incomplete alignment with the site’s process control standards. The site required the package to be brought into the main control network so operators could monitor and control the RO plant from the main plant SCADA system. VSD status and device information also needed to be made available to improve diagnostics, control visibility and maintainability.

• 01 Reverse engineered the standalone RO package control system
• 02 Reviewed the existing package operation and control interfaces
• 03 Developed process and electrical documentation
• 04 Marked up drawings and P&IDs
• 05 Worked with the process team to redesign and optimise the control region
• 06 Rebuilt the RO plant control logic to align with the main plant control standard
• 07 Integrated the RO plant into the main control network
• 08 Brought VSD status and communications into the control system
• 09 Integrated RO plant monitoring and control into the site SCADA environment
• 10 Removed reliance on the original standalone package HMI
• 11 Completed SAT and commissioning support
• 12 Updated control philosophy and drawings
• 13 Supported operational handover and maintainability improvements

VSD information was integrated into the main control system so operational status, control feedback and diagnostics could be used by PLC and SCADA systems. This improved operator visibility and reduced dependence on the original package interface.