Mackay Sugar
Boiler Control Formal Compliance Audit
- Mackay. QLD
- Marian Mill Boilers No. 1 & No. 3 88MW capacity
- I/O Count 1000
- Control System - Rockwell Control Logic 500 Fisher & Porter DCU 3200
Mackay Sugar engaged Mipac to undertake a formal control system and control elements compliance audit of both No. 1 & No. 3 boilers to ensure they met Australian Standards and best practice.
Mipac assembled a team of senior qualified engineers and a boiler expert that undertook an engineering review against standards and best practice, a formal CHAZOP (Control Systems Hazard and Operability review) and documented findings and recommendations.
Project scope
- Battery limits, fuel feeder system and steam stop valves of both boilers
- Due to the age of the control systems, direct integration of PLC and DCS logic/code and reverse engineering of SAMA diagrams was required
- Control System functional descriptions were developed to support the review
- Identify the relevant Australian and ISO Standards, Statutory Regulation and best practice
- Scoping of possible solutions, systems and infrastructure.
- Providing unbiased advice and recommendations of technology, tools and systems on the market
- Recommending, configuring and installing monitoring solutions
- Designing, implementing and procurement single unit or entire systems
- Facilitate a site CHAZOP and document
- Undertake a formal review, document and make actionable recommendations for Mackay Sugar to be compliant to all relevant Australian Standards
Project highlights
- The review was engaged and undertaken in 2018 after completion of the 2017/18 crushing season
- A Mipac CHAZOP and RPEQ certified engineer facilitated the site review. Participation included a broad cross-section of Mackay Sugar site engineering and operations and an independent qualified boiler expert
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