Tanzania Breweries Limited (TBL) in Dar es Salaam successfully implemented an advanced flare control system to monitor and manage gas flaring operations. The project involved installing sensors, controllers, valves, and comprehensive instrumentation integrated with ST-300 PLC and Wonderware visualization. This sophisticated flare control system enhances environmental protection and operational safety while minimizing the ecological impact of brewing operations.
Project Objectives and Scope
The primary goal was to establish a robust system for effective gas flaring monitoring and control. Specifically, the project aimed to reduce environmental impact while maintaining high safety standards at TBL’s Dar es Salaam facility. The comprehensive solution addresses both routine operations and emergency scenarios through advanced automation and control technologies.
System Components and Integration
Control System Architecture
The flare control system integrates multiple components into a unified automation platform. The core system utilizes an ST-300 PLC for reliable process control and Wonderware InTouch for intuitive visualization. This combination provides operators with real-time monitoring and control capabilities.
Sensor and Instrumentation Network
We installed a comprehensive network of sensors and instrumentation throughout the flare system. These include pressure transmitters (31FTP04), temperature sensors (T1-100), and various monitoring devices. All instruments connect seamlessly to the control system for accurate data acquisition.
Valve Control Systems
The system manages multiple control valves for precise flare operation. These valves regulate gas flow, purge cycles, and emergency shutdown functions. Proper valve control ensures optimal combustion and environmental compliance.
Key System Functions
Operational Control Modes
The system provides multiple control modes including flare enable/disable functions. Operators can monitor purge status, running conditions, and start pressure achievement. The load tracker ensures efficient flare operation based on process demands.
Safety and Alarm Management
Comprehensive alarm systems monitor critical parameters including low temperature conditions and valve positions. The system triggers appropriate responses to abnormal conditions, preventing hazardous situations. All safety functions comply with industrial safety standards.
Parameter Monitoring
Key parameters monitored include pressure levels (1.00-1.50 mbar), temperature readings (1.60°C), and various process values. This detailed monitoring ensures optimal flare performance and environmental compliance.
Commissioning and Validation
System Testing Protocol
Following installation, we conducted extensive commissioning to validate system performance. We tested the system under various operational scenarios including normal and emergency conditions. All components demonstrated excellent performance and reliable operation.
Staff Training Program
We conducted comprehensive training sessions for TBL operational staff. These sessions equipped personnel with the knowledge and skills needed to operate and maintain the new system effectively. The training covered both routine operations and emergency response procedures.
Environmental and Safety Benefits
Reduced Environmental Impact
The flare control system minimizes gas flaring and associated emissions. This reduction supports TBL’s environmental responsibility goals and regulatory compliance. The system ensures efficient combustion, reducing the ecological footprint of brewing operations.
Enhanced Operational Safety
Advanced monitoring and control features significantly improve plant safety. The system prevents hazardous conditions through early detection and automatic response mechanisms. Safety interlocks and alarm systems protect both personnel and equipment.
Improved Process Efficiency
Optimized flare operation reduces energy consumption and operational costs. The automated system ensures precise control based on process requirements, minimizing waste and maximizing efficiency.
Technical Implementation Details
PLC Programming
We programmed the ST-300 PLC using advanced automation software to handle complex control logic. The programming includes safety interlocks, sequence control, and alarm management functions.
HMI Development
The Wonderware InTouch interface provides intuitive operator controls and visualization. Operators can monitor system status, acknowledge alarms, and adjust parameters as needed. The user-friendly design ensures efficient system operation.
Network Integration
All system components integrate through industrial communication networks. This integration enables seamless data exchange and coordinated control between different system elements.
Conclusion: Sustainable Operations Achieved
This successful flare control system implementation demonstrates TBL’s commitment to environmental stewardship and operational excellence. The project establishes new benchmarks for safety and sustainability in the food and beverage industry. Through this achievement, TBL Dar es Salaam now enjoys enhanced environmental compliance, improved safety, and optimized operations. The project highlights IAES’s capability in delivering advanced automation solutions that balance operational needs with environmental responsibility.
