AGE TECHNOLOGIES_2014 project briefs

1. The Lesedi PV plant_ and Letsatsi PV plants are two of the
three largest PV plants on the African continent.
 Age’s scope of supply included:
The proposed system consisting of the following elements were requested:
1. INFRARED DOMES in the access and at strategic points.
2. THERMAL CAMERAS in the perimeter and in the principal internal roads.
3. VIDEO MONITORS & VIDEO ANALYZER
5. Access Control with Biometric Readers
6. Control Centre in the O&M Building
7. IR Detector, in the inverters buildings and in the O&M buildings.
8. Guard Tour System.
9. Complete manual to operation and maintenance
Product used in the project
 Scope of work to be done
 Fiber Network
 Installation of fiber cable
 Installation of splice boxes
 Installation of patch leads
 Complete manual for operation and maintenance of the system
 Training
 Total value of the project upon
completion
 1.9 million
 Duration of the project
 3 months

2. Enclosure Built
8x Floor Standing PLC Enclosures
2x Network Enclosures for Control
and PLC room
13x Power Distribution Enclosures
23x Junction Boxes
33x Instrument Solenoid Bank Enclosures
PLC Inputs and Outputs
288x Analogue Inputs
224x Analogue Outputs
896x Digital Inputs
384x Digital Outputs
Drives Control Engineered
58x Variable Speed Drives
1x Direct Online Starter
2x Soft starters
Project Value
Supply and Engineering R4.2M
Completion
Hardware Supply Complete
Software Engineering Complete
Commissioning July 2014
Foskor is a proudly South African producer of phosphates
and phosphoric acid with international exposure. Foskor
unlocks shareholder value through the profitable,
responsible and sustainable beneficiation of phosphate
rock into either phosphoric acid or phosphate-based
granular fertilisers sold globally.
Founded in 1951, Foskor’s Mining Division in Phalaborwa
mines phosphate rock, from which Foskor’s Acid Division
in Richards Bay produces phosphoric acid and phosphate-
based granular fertilisers for local and international
markets. The opencast mine in Phalaborwa has the
capacity to produce 3 million tonnes per annum of
phosphate rock concentrate from 35 million tonnes of
ore mined per annum. Once crushed, milled,
concentrated and dried, most of the phosphate rock
concentrate is railed to Foskor’s processing plant in
Richards Bay, 800 km away on the KwaZulu-Natal coast.
The D Stream Flotation Plant Replacement (DSF) project
originates from the Foskor’s infrastructure replacement
strategy.
This project will ensure that the installed flotation
capacity remains at a level which makes it possible to
produce circa 3 million tons of concentrate per annum
(mtpa), therefore protecting the production strategy of
the Phalaborwa operations. The project consists of new
600 tph flotation plant.
AGE Technologies JHB was awarded the Supply,
Engineering and Commissioning of the complete PLC and
Scada Control System. The Control System consists of
Schneider’s Quantum PLC and Adroit Scada System
communicating through Hirschman switches. The project
also consisted of the supply and manufacture of the
Festo instrument solenoid bank enclosures.

3. As Tharisa Mine is the largest known single chrome resource deposit in the world,
the Group is well positioned to benefit from the projected growth in demand for
chrome, which is primarily used in stainless steel manufacturing.
MDM Engineering contracted AGE Technologies to supply in all the requirements
of the Tharisa Expansion
project.
 Age’s scope of supply included:
 Supply of all Siemens PLC hardware (S7-300 & S7-400)
 Supply of all Siemens SCADA software (WinCC)
 RIO Panel supply & manufacturing (34 panels)
 Ethernet & Profibus fiber network installation, splicing, testing, certification
and drawings (Est. 6000m fiber and 900 splices)
 Supply, installation, configuration and commissioning of 4x Wireless
Ethernet radios that links to 4x pump stations (4IPNET Radios)
 2x Commissioning engineers to assist with I/O testing & process
commissioning (I/O count 1546)
 General supply of cable, junction boxes & any other equipment needed
throughout the project
 Configuration of all networks running through OLM’s and the setup of the
OLM’s
 Product used in the project
 Multi core Instrument cable to the value of R400,000.00
 Siemens OLM
 Outdoor Fibre cable (total of 18.7kms)
 Network Switches (3 port & 6 port)
 All fiber equipment inc. adapters, connectors, pigtails & cable
 Scope of work to be done
 Fiber Network
 Installation of fiber cable.
 Installation of splice boxes.
 Installation of patch leads
 Supply IPDB’s
 Installation of a Profibus over fiber network
 Total value of the project upon completion
 5.9 million
 Duration of the project
 8 months

4. Solution provided to company
The physical structure was constructed by FAMAK in Poland and
shipped to Mozambique. The electrical design and construction
(wiring, cabling, PLC software and MCC cabinets) took place in South
Africa. It was assembled in Beira, and the electrical and
instrumentation installation commenced after. AGE Technologies did
PLC and SCADA software development and will be responsible for
commissioning.
 Products used in the project
PLC control system: Siemens S7-300 PLC with ET200S
Distributed IO
Motor control: Siemens SIMOCODE's and Siemens
Micromaster VSD's
Instruments: majority is supplied from Schneider but
includes Siemens, Rockwell and Weidmuller
All Cabling used on the Stacker predominantly from Jaycor
and Africa Cables
 Relevant information
MCC's were constructed by Raise and Lower
AGE provided 3 containers, operator cabin with all equipment inside,
all PLC and networking equipment, all electrical cables, equipment,
drives, relays, circuit breakers & switchgear
One 630 kVA, 6.6kV/400V transformer
People involved in the project
 Norman Jackson – Project Manager -
Design
 Paul van Rooyen – Project Manager -
Electrical Design and hardware
 Gabriel van der Merwe –
Project Technician - SCADA,
Instrumentation Design, Hardware
 Karlin Gomo- PLC Programming and
Functional Design Specification
Project Scope & Objectives
AGE Technologies was responsible for the
design manufacturer of the entire electrical
and instrumentation requirements of the
Stacker Machine that was installed at the new
coal terminal in Beira Harbour, Mozambique.
AGE Technologies provided the PLC and
electrical control systems.

5. AGE Technologies JHB (Ltd) together with Instrumentation &
Electrical Consultants had to supply King Shaka International
Airport with Equipment & Design of an Redundant Fibre Profibus
and Profinet Networks with Siemens S7-400 Hot Standby PLC in
SIL3 Safety and Standard I/O.
 Duration of the project
Started 1 May 2010 and ran for the duration of 5-7 months.
 The problem was
to provide Siemens Equipment that could be integrated into a
reliable fail-safe system for the Fuel Storage System at the
Airport.
 Solution Provided
We provided them with a Siemens S7-400 Hot Standby PLC with
Redundant networks and Dual Redundant WinCC SCADA.
 Products in the project
Siemens S7-400 Hot Standby PLC, SIL3 Safety ET 200 IO Stations,
Standard ET200 IO Stations, Redundant WinCC SCADA, Dual
Redundant Profibus Networks, Dual Redundant Profinet
Networks
 Scope of work
AGE was responsible for assisting with the design of the
PLC/SCADA system, to make sure that a working system was
offered to the end user, and to supply the actual PLC hardware
and SCADA software packages.
IEC did the actual system integration and wrote most of the
application software. Some software for leak-detection was
written in Germany.

6. Age Technologies JHB- a member of the Age of Africa Technologies
Group - were commissioned by ESKOM to come up with a simple
yet intelligent design for the ash conveyor protection system at
their Kendal Power Station in Mpumalanga.
 Design
Owing to the length of the ash handling conveyor, the
protection system had to incorporate enhanced fault finding
and accurate trip site location .
This unique design in long-line conveyor protection is a world
first. All of ESKOM's criteria were met and incorporated all
the other aspects of conveyor related alarms such as belt rip,
misalignment, and blocked chute detection, yet there are no
electronics in the field.
 Duration
The system, which took six months and comprised 66 man
months from conception to completion, is so efficient and
easy to maintain that AGE are pleased to report their client is
extremely pleased with the reliability of the plant.
 Scope
AGE's brief included the overall project management, PLC
engineering using a Siemens Su110 PLC, equipment supply,
installation and commissioning.
 The project, which was repeat business for AEG with ESKOM,
was completed on time and within budget.

7.  In line with their philosophy of client
relationship marketing, AGE Engineering
undertook this project at Fry's metals of
Wadeville during their annual end-of-year
shutdown. Although small in size the process
to be automated was quite sophisticated
from the point of view of all the different
processes that had to be brought together.
 Lead reclamation has it's own characteristics
and AGE Engineering had to firstly familiarise
themselves with the reclamation process.
Once that was done they had to write the
process software for the ingot pouring,
handling and stacking system.
 In addition to the InTouch SCADA package,
ControlWize made use of a Microsoft SQL
Server with an Access data base for the train
handling facility at the load-out station.
 The project included management, PLC
engineering, equipment supply, installation
and commissioning and took one man-month
to execute.
 Being a shutdown there was no margin for
error and the automation, using an Allen
Bradley S5 PLC, went off smoothly with no
technical hitches experienced at handover.

8.  ESKOM identified the need for the replacement
of the coal stacker/ reclaimer control system at
their dry cooled power station near Ellisras in the
Northern province.
 Overview
AEG's construction division were awarded the
project to design, supply and install such a
system to provide plant alarm status, monitoring
and reporting. This was repeat business for AEG
who also executed the station MV switchgear
project and the overland Ash Handling conveyor
systems.
The project was carried out during the transition
period from AEG to AGE Engineering and was
completed ahead of the prescribed contract
period.
 Duration of project
The 12-month contract, which comprised 64
man-months effort, included the full project
management, PLC engineering using a Modicon
'A' series PLC, full equipment supply, installation
and commissioning.
 Significant feature
of this project was the design, by one of AGE's
engineers, of unique connection terminals -
housed in the PLC cabinet - which comprised full
lightning protection on all inputs and outputs.
This type of terminal has now become a standard
in the electrical industry

9.  Zimplats was established by Delta Gold Limited (Delta) in 1998 to take over its
platinum interests. In May 1999 the company purchased BHP’s interests in the
Hartley Platinum and the Mhondoro Platinum Joint Ventures which included a
concentrator and smelter.
 AGE’s Scope of work to be done –
– Capturing of Plant wide process Data and Historizing for minimum period of twelve
months
– Alarm & Fault Logging which will detail the precise reason for Plant Stoppage to enable
the Technician to rectify the fault with minimum down time
– Up to date PLC and SCADA software
– New Plant Computers and Servers with web reports available for Plant Managers.
– The enhancement of the electrode slipping system enables it to measure the actual state
of the electrode slipping system. The new program functions just as the existing program
with the additional benefits:
– Shorter slipping times
– Any given movement, de-clamping, raising, clamping or lowering takes only as long as
required.
– Reliability of the electrode slipping system is improved. Error conditions are alarmed on
the SCADA
 Significant Features of the project –
AGE Technologies offered the following enhancements and benefits to their
current system
– Plant wide Server/Client topology which centralizes their Data for easier Alarming, Data
Retrieval and Reporting and Backup.
– First Up Alarming programmed into their PLCs, with clear Alarm and Fault messaging at
their SCADA Clients
– Fixed format Daily Reports for the Smelter Plant and the Concentrator Plant
– Device Status and Interlock Display Dash boards to assist operators.
– Upgraded two obsolete TSX17 PLCs to Modicon M340 under Unity Software.
– Conversion of Concept PLC programs to Unity by upgrading PLC firmware
– Removed redundant MB+ network that was no longer required.
– Auto-save Change Management Software, that automatically keeps all their PLCs and
SCADA software backed up and tracks any software changes that is being implemented.
– Archestra System Platform Software and Unity PLC Software Training for
Engineers/Technicians
– New latest Dell Computers (Severs and Work Stations) for their entire Plant Operations.
– Onsite System Commissioning
 Duration of the project –
 ± 8 months
 Budget –
 R 2 ,495 024.00

10. Set amongst the beautiful rolling hills and valleys
of the KwaZulu-Natal midlands, the largest
waterworks in KZ Natal and most modern in the
country, Umgeni Water's Midmar Dam
Waterworks, was successfully commissioned, on
schedule, in October 1996.
 Built on the site of the old Mill Falls
waterworks outside Howick, the first phase
of 250 Ml/day will be augmented to an
ultimate capacity of 1000 Ml/day by 2005,
when predicted water demand is expected
to be around 450 million cubic metres per
year.
 AEG were originally awarded the
subcontract to main contractor Aquazur but
owing to the disruptions within AEG at the
time, leading up to their ultimate sale, AGE
was contracted to complete the contract. In
order to minimise disruptions to the
contract AGE Engineering made use of all
the existing AEG personnel, some of whom
were sent for training in Germany in order
to commission the MCC's bus system.
 Duration
The multi-million rand project was 14
months in duration and comprised 130
man-months effort. AGE Engineering's
scope included Project management, PLC
engineering, equipment supply - including
the sophisticated Motor Control Centres,
installation and commissioning

11.  Background
The brewery has ten Cellars. Each cellar is
divided into different tanks, in which the
fermentation takes place. Glycine is passed
through tubes wound round the tanks to control
the temperature during the brewing process.
A solenoid valve is used to open and close flow
of glycine. Pt100 at the top and bottom of each
tank are used to monitor the temperature. The
temperature is either monitored using the Top/
Bottom PT100 or both PT100s. should any of the
PT100 fail the PLC will switch the control
completely to the healthy one.
Each of the tanks can be in one of the following
modes: Ready, Filling, Fermentation, Chill or
Cleaning in Progress (CIP)
 AGE’s Scope of work to be done –
The plant is divided into three Control systems,
i.e. Cellar 1&2, Cellar 3-8 and Cellar 9&10.
A SCADA (Supervisory Control And Data
Acquisition) system will provide a graphical
overview of the whole control system. An
Ethernet TCP/IP network will link the three
Systems and the SCADA.
 Significant Features of the project –
 HMI will provide the operator with status of each
Cellar and Tank
 SCADA system will provide a graphical overview
of the plant, with the status of each tank.
 A graph of all temperatures and operator
inputted information will be available.
 The fermentation manager will be able to change
the operating mode of a tank, and with a login
password he can also change the temperature
set points.
 A historical log will also be kept of all tank
batches that have been brewed
 Keeping data for each batch is important
for quality purposes.
 The Mode of operation of each tank will
be colour coded - determined by its
background Colour in the overview page.
 A Siren and alarm lamp will be installed at
each control system to warn the operator
of an alarm condition
 Products used –
 Modicon TSX Premium from Schneider
Electric
 PLC software - PL7 Pro for TSX Premium
PLC
 HMI - is an EZTOUCH, Modbus/TCP 8” Slim
panel
 SCADA System - Intouch version 9, with
1000 tag licence
 Spider, 5 port 10/100 Ethernet switches for
each Control system
 Duration of the project –
6 months
 Total Value –
R 605,906.34

12.  Background
Botswana Ash (Pty) Ltd began operating in April 1991. The mine is located at Sua Pan,
which is approximately 180 kilometres from Francistown in northern Botswana. The
Company produces Soda Ash and Salt. All the activities of the mine are undertaken at
Sua Pan – from production through to marketing and sales and administration. The
primary market for Soda Ash is South Africa, where most of the products are used in
the glass industry. They also produce fine and coarse salt. Like Soda Ash, the Salt
products are sold within the continent. Production capacity is 650 000 tonnes per
annum.
 AGE’s Scope of work to be done
To upgrade of old absolute TSX-17-20 Telemecanique
PLC’s to the newest Schneider M340 PLC with UnityPro Software for the Soda Ash
Stacker as well as the Salt Reclaimer. AGE Technologies also replaced all panels on
site. In the Salt Reclaimer the panels was replaced by stainless steel panels to help
prevent rust.
The upgrade included –
Supply of all Hardware
Software Engineering & Installation and Commissioning
 Products used
Schneider M340 PLC with UNITYPRO Software
CPU340‐20 MODBUS ETHERNET
Radio telemetry System
PLC, Termister Relays & Output Devices Supply Breakers
Emergency Bypass Keyswitch
New Panel Electrical Drawings plus Field
PLC Application Software Development according to the FDS documents
HMI Application Software development
PLC/HMI Onsite PLC software Commissioning
 Duration of the project
6 weeks
Total Value
Soda Ash Stacker – R 420 000
Salt Reclaimer – R 350 000

13. Xstrata are one of the world's largest global diversified natural resource
companies and a major producer and marketer of more than 90 commodities.
Their presence at each stage of the commodities chain provides us with superior market
insight and access to opportunities. They have a strong footprint in both established and
emerging regions for natural resources.
SCOPE OF WORK:
Product Included:
IMPALA PLANT - Supply and Install an Enermax plus Meter with Modem for remote metering outside 400v Substation in
Metering box.
 Supply 400V, 3 phase 4 wire 5Amp Enermax Plus meter with external memory.
 Supply cell modem for meter and sim card.
 Supply 3 x 1500/5 metering current transformers.
2. WONDERKOP PLANT - Supply and Install an Enermax Plus Meter with Modem for remote on 11KV Incomer panel.
 Supply 110V, 3 Phase 4 wire 5Amp Enermax Plus meter with external memory.
 Supply cell modem for meter and sim card.
 Supply 3 x 5/5 metering interposing current transformers
3. EPL PLANT - Supply and Install an Enermax Plus Meter with Modem for remote on 11kV Incomer panel.
 Supply 110V, 3 Phase 4 wire 5Amp Enermax Plus meter with external memory.
 Supply cell moden for meter and sim card.
 Supply 3 x 5/5 metering interposing current transformer.
K2.5 PLANT - Supply and install an Enermax Plus Meter with Modem for remote on 11kv Fdr panel.
 Supply 110V, 3 Phase 4 wire 5Amp Enermax Plus meter with external memory.
 Supply cell moden for meter and sim card.
 Supply 3 x 5/5 metering interposing current transformer.
5. K4 PLANT - Supply and install an Enermax Plus Meter with Modem for remote on 11kV panel.
 Supply 110V, 3 Phase 4 wire 5Amp Enermax Plus meter with external memory.
 Supply cell moden for meter and sim card.
 Supply 3 x 5/5 metering interposing current transformer.
6. WPL PLANT - Supply and Install an Enermax Plus Meter with Modem for remote on 11kV Incomer panel.
 Supply 110V, 3 Phase 4 wire 5Amp Enermax Plus meter with external memory.
 Supply cell modem for meter and sim card.
 Supply 3 x 5/5 metering interposing current transformer.
7. Remote data base for all remote meters
 Supply 1 x Meter reader that interface with modem, including software
Significant features of the project
 Remote access from anywhere in the country with cellular coverage to all metering data achieved. Software interface
gave the ability to generate electrical bill for energy consumption audit.
Duration of the project – 4 weeks
Total value of the project upon completion – R156,000.00

14.  AGE Technologies JHB (Pty) Ltd. secured the contract
to assist Arcelor Mittal’s planning department with
the design, project management and commissioning
of the automation system required at the
Vanderbijlpark works Continuous Casting plant.
 Scope of work to be done
Was the equipment supply and product training of
Modicon Quantum PLC's and FactoryLink SCADA.
However, the whole project was to be executed
during a planned shutdown period and required
careful planning in order to minimise disruption at
the changeover.
 Products used
The PLC was programmed in hot stand-by
configuration and it was decided to make use of
standard terminal cabling in order to facilitate a
smoother transition.
 Duration of the project
The project was five months in preparation and
comprised 3 man-months effort in execution.

15.  In one of the longest ongoing contracts on
AGE Engineering's order book, their contract
to provide automation packages to Pretoria
City Council
pump stations must rate as their longest.
 Started in mid 1995 - whilst still operating as
AEG Construction - their brief was to supply
an automation system to 5 pump stations
within the greater Pretoria metro pole.
 The first one completed was at the Fountains
station, followed by Garsfontein, Elardus
Park, Klapperkop and finally Mooikloof over a
period of four-and-a-half years.
 The project was run out of Pretoria's
department of water environment and
executed as five separate contracts.
 AGE's brief was to provide the project
management, PLC Engineering using Modicon
Compact and Micro PLC's, the equipment
supply, installation and commissioning. What
started out as first-time business for AGE
developed into a long-term relationship and
resulted in repeat business.

16.  Main contractor CHI Control appointed AGE
Engineering to carry out the PLC engineering,
equipment supply and commissioning of the
man riding and ore belts project at Randgold's
Lorraine Gold Mine in the Free State.
 This project, although only one month in
duration was very sophisticated in that it
called for an interface from the Modbus to
the Allen Bradley soft starters Scan Port.
 The Allen Bradley PLC interfaced to an AFE
SCADA data panel via Modbus an AFE data
panel interfaced to an existing SCADA via
Modbus