ABB, NJC complete major METAL plant automation upgrade

A combined compressor house (CCH) control system replacement project, undertaken by NJCSI (Pty) Ltd. (NJC), an ABB Authorised Value Provider (AVP), has won high praise from client ArcelorMittal. “The professionalism, dedication, and attention to detail have not only met but exceeded our expectations,” says Erich Blaschczok, Senior Electrical Engineer, Information Management, at ArcelorMittal.

The project was critical as CCH supplies all instrumentation air, blast air for the blast furnaces, and other air requirements for the Vanderbijlpark facility. Complicating the project was the fact that a major shutdown could not be initiated due to the CCH being integral to the entire operation, explains NJC CEO Sarane Richard-Coombes. “The project required meticulous planning, clear communication, and unwavering support.”

The rewired panels involved a staggering 12 000 I/O points, highlights Sebastian Lopes Pereira, DCS Engineer at NJC. ArcelorMittal entrusted the production-critical project to NJC since they have had a longstanding business relationship for over a decade. “What gave us the edge in securing this project is that competitors insisted on a shutdown, which was a non-negotiable for the client,” adds Pereira.

NJC continued to further develop their reference of successful project implementation as the latest was one of three projects it has carried out at AcerlorMittal over the years. The six-month project was completed successfully and handed over in December. Sagren Govender, Business Development Manager at NJC, adds that the support received from ABB was exceptional, with stock available at all times of key components, including expert assistance and support.

NJC has been an AVP for ABB Control Technologies since 2016, embarking on their first joint project in 2006. Since then, NJC has completed many projects featuring ABB systems across Southern Africa. It is skilled in ABB Ability™ System 800xA and Manufacturing Execution Systems (MES) for industry segments from food and beverage to pharmaceutical, pulp and paper, and mining and metals.

“NJC is an incredibly valuable partner for us in the southern Africa region. They are a great example of a best-in-class system integrator who is well positioned in several key growth segments on the continent,” says Kristian Olsson, Global Head of Partner and OEM Sales, ABB Control Technologies.

The company is a professional engineering service provider of process control, automation, and information systems. It designs and installs control systems and management systems that meet customer specifications for performance and reliability, having established a name for itself in the local automation industry since its inception in 1997.

“Global leaders such as ABB have selected us as their channel partners for the design and implementation of their products. Based on a solid engineering background and diverse resource base of experienced professionals, we provide a complete service to both industrial and corporate companies.

“Our mission to deliver excellence in industrial IT and control systems to facilitate world-class production environments. We aim to be a provider of choice due to our reputation for providing quality, innovative solutions represent outstanding value to our clients,” explains Richard-Coombes.

NJC’s engineering services allow clients to optimise their production processes and to form a clear picture of how to manage them. Its experienced automation specialists cover all areas within automation engineering and industrial IT, including management information systems, S88 compliant batch system integration, process control and optimisation, electrical and instrumentation engineering, turnkey industrial automation projects, PLC/SCADA systems, distributed control systems, advanced batch handling and MES integration solutions, automation engineering consulting, and safety systems compliance.

ABB’s control technologies, particularly ABB Ability™ System 800xA and MES, offer significant advantages for the metals industry by enhancing productivity, quality, and sustainability. The former goes beyond traditional distributed control systems by integrating process control, electrical control, safety systems, and asset management into a unified platform.

This integration allows real-time monitoring and optimisation of metallurgical processes such as steelmaking and rolling mills. By maintaining precise control over operations, it helps reduce defects, ensuring consistency in metal properties while also optimising energy consumption in energy-intensive processes like electric arc furnaces and reheating furnaces. Its seamless compatibility with existing systems, including ERP and third-party solutions, provides complete operational visibility, leading to more efficient decision-making and higher overall efficiency. 

MES complements this by bridging the gap between business planning and plant operations. With real-time production tracking, MES solutions monitor work-in-progress, yield, and quality deviations, helping to optimise output while minimising material waste. They also improve inventory management by ensuring the efficient use of raw materials, reducing costs and preventing production slowdowns.

Predictive maintenance capabilities further enhance uptime by identifying potential equipment failures before they occur, ensuring continuous and reliable operations. Additionally, MES solutions support regulatory compliance by automating the tracking of emissions, energy usage, and production parameters, making it easier to meet environmental and industry standards.

More info, please visit: www.abb.com