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Bianchini Oil Extraction

Control system for soybean Oil Extraction Plant

Altus was entrusted with the development and implementation of the control and supervision system for the soybean oil extraction process at the company’s facility.

Modernization of the plant’s control system

The system deployed at the production unit in Rio Grande, RS, includes 10 automation panels with a total of 12 columns (PNs), along with over 70 CCM columns responsible for controlling the soybean oil extraction process..

Managing more than 3,000 I/O points, the solution oversees the entire oil extraction system, from soybean drying and preparation for oil extraction to oil extraction, meal production, and product storage and distribution.

In addition to the NX Series programmable controllers, the complete system includes more than 90 soft starter devices and PROFIBUS networked frequency inverters.

Remote supervision and control

The solution enables remote supervision and operation of the plant, minimizing operational risks for the workforce

Enhanced security

Swift detection of system faults and incidents, thanks to the implementation of precise, actionable diagnostics

Multiprotocol Capability

An open architecture system, utilizing widely recognized communication protocols (Profibus-DP, HART, and Modbus TCP)

Quick decision making

The PLC’s seamless communication with field devices enhances decision-making speed for the management team

Comprehensive PROFIBUS control with full connectivity

The developed application uses three Profibus networks: one redundant network with remote I/O units from the NX Series, and a simple network for controlling inverters and soft starters. While the redundant network has 13 redundant remote units, the other controls the inverters and soft starters with 99 items, including 27 inverters and 72 soft starters.

The entire project encompasses 10 automation panels with a total of 13 columns (PNs). The scope of the project also included commissioning, startup, assisted operation, and training for both maintenance and operational teams.

Remote supervision and operation with BluePlant HMI/SCADA

The system relies on BluePlant HMI/SCADA software to supervise key processes such as Warehouses 2 and 3, Laminators 1 and 2, Screeners, Preparation, Flow Scales 1 and 2, Dryer, and Pier Towers.

With 83 monitoring screens, the SCADA system manages over 150 motors that drive product and raw material movement within the plant and during ship loading operations at the pier.

The software provides plant managers and operators with remote access to the system, allowing them to collaborate in real-time with field technicians, streamlining overall plant management.

High-availability with Nexto redundancy architecture

The developed application utilizes the NX Series programmable controllers as the central component of the unit's control system. The high technological potential of Nexto products qualifies them to operate large numbers of remote points and racks, as well as to control projects such as water treatment in a distributed and redundant manner.

The system features a redundancy setup with two NX3030 CPUs — one primary (active), responsible for real-time control, and a standby backup unit that continuously monitors the performance of the primary CPU.

Caso alguma falha venha a ocorrer e a CPU principal fique indisponível, o equipamento em stand-by assume o controle do processo de maneira automática, sem a necessidade de qualquer ação do operador e sem causar perdas à operação da planta. Essa troca de função entre os equipamentos é conhecida como switch-over.