Corporate Brochure v0.2 lower res

CHEMICAL FOOD AND
BEVERAGE
WATER & WASTE
WATER
POWER PULP & PAPER
OIL & GAS MINING FERROUS & BASE
METALS
PETROCHEMICAL
Industrial Automation
and Optimization
Matrikon Moore
Company Overview

Matrikon Moore | 2 Matrikon Moore | 3
• Our services
• Conceptual architecture overview
• The main industries we serve
• Where we operate and deliver
• The project delivery journey
• Delivery successes
Matrikon Moore was founded in 1984 and is a privately held company, registered in South
Africa. Our head office is in Johannesburg, with regional offices in South Africa (Secunda
and Vanderbijlpark), Houston and London.
We provide a comprehensive set of services ranging from control-system design input to
front-endengineeringdesign(FEED)studies,rightthroughtoturnkeyprocess-automation
projects. Service scope also includes optimization and longterm maintenance services for
offshore installations.
Sector focus in on offshore and onshore oil and gas production, with special emphasis on
FPSO integrated control and safety systems (ICSS), subsea master control stations (MCS),
and refining.
In addition to oil and gas we have significant installed systems in mining, ferrous and base
metals, petrochemical, chemical, food and beverage, waster and waste water, power,
and pulp and paper facilities.
Our customer base is global, including several of the oil majors, leading EPC providers,
and blue-chip mining houses.
We have a long-standing reputation for engineering and service excellence, underpinned
by our ISO 9001 and OHSAS 18001 certifications, and IEC61508 and 61511 recognition.
CONTENTS OUR SERVICES
Each of the services listed can be delivered on a
turnkey basis, as standalone solutions on existing
installations, or as equipment supply only.
Process instrumentation
The full spectrum of process instrumentation is
supported, including measurement of pressure,
temperature, flow, level, acoustics and motion.
Additional areas of supply include positioners,
standalone process controllers, process recorders,
wireless HART products, and instrument-related
communication software and peripherals.
Equipment cubicles
Equipment cubicles and control-room furniture are
designed in 3-D using the latest E-Plan software and
techniques. The approach makes optimal use of
space, while ensuring easy and convenient access
for maintenance personnel. Cubicles range from
indoor use, through to use in extreme outdoor
conditions, such as on offshore marine installations.
Ex-rated cubicles can be supplied to bespoke project
specifications.
Control systems (PLC and DCS)
We offer comprehensive PLC and DCS solutions
ranging from a few hundred I/O, right up to large-
scale solutions encompassing integration of disparate
plants with several thousand I/O geographically
dispersed across large campuses or sites. Solutions
can be for standalone control, or can include
historians, integration with peripheral systems, and
secure provision of information to off-site systems
such as ERPs or production-monitoring systems.
System migration
Systems that are end-of-life or that need upgrading
are systematically migrated to modern systems using
automated tools and techniques to minimize plant
downtime, and ensure preservation of intellectual-
capital investment in existing systems.
Safety systems
On safety-critical plants we offer solutions using
safety-rated PLCs/DCSs, integrated with the main
control system. Our expertise also includes safety
compliance of peripheral equipment such as
instrumentation and cubicles required on IS or Ex
-rated plant areas. Our engineers are IEC 61508
and IEC 61511 certified, and the systems we deliver
typically comply with standards from IEC, API, and
NFPA, etc.
Control system and plant optimization
Our multi-loop and multi-variable analytical software
ensures plants are optimally tuned across a broad
range of plant operating conditions. We predict
equipment failure well in advance, thereby avoiding
unnecessary shutdowns. Real-world analysis
also reduces the need for unnecessary routine
maintenance. Advanced alarm-management analysis
takes into account the big picture of plant alarms,
and ensures safer operations by eliminating nuisance
alarms.
Compressor control and protection
With more that 27 years experience in advanced
single-stage and multi-stage compressor control we
offer protection and control solutions across a vast
range of installations including air, polyethylene,
polypropylene, nitrogen, and oxygen, etc. We
minimize energy consumption by safely reducing
unnecessary blow-off, and optimizing compressors
configured for parallel operation.
Operator training simulators
Comprehensive operator training is imperative
for safe operation on safety-critical plants. These
simulators can be very costly. In our approach the
costs of plant training simulators are reduced by
reusing existing PLC/DCS code and HMI interfaces,
along with fully integrated thermodynamic models
to give operators a solid grounding in safe plant
operation of hazardous plants.
Longterm maintenance
Longterm healthcare on systems, including annual
interventions, ensure systems are maintained
optimally. 24x7 telephone support, with next-
business-day on-site support is available where
required. System upgrades ensure control systems
are kept current and protected from external
cyber threats. This approach prevent systems from
becoming obsolete over time.

Matrikon Moore | 4
Operator Stations Instrument Management Historians
Data Links and
Remote Reports
Engineering
Workstations
Work Station and Control Rooms
Alarm
Management
Production
Management
Control Loop
Optimization
Predictive
Maintenance
OPC
OPC
ProcessLAN
SafetyLAN
TurboLAN
SafetyBus
TurbineandCompressorSkids
I/OBus
Spreadsheets Reports Trends Charts
OPC
ServerClusters
PatchPanels
I/OPanels
Power
Management
Training Simulators
Subsea Control
BATCH Control
SCADA Control
Turbine and
Compressor Control
Safety ControlDCS / PLC Control
Field Instrumentation Touch Panels Telemetry
CONCEPTUAL ARCHITECTURE OVERVIEW TO DEMONSTRATE THE BREADTH OF OUR SYSTEMS CAPABILITIES
Safety Instrumentation

THE MAIN INDUSTRIES WE SERVE
OIL & GAS: FPSO
We specialize in process automation
and safety shutdown systems on
FPSOs, Oil Platforms, FSOs, and
Jack-ups. We also provide a number
of ancillary services to protect
these valuable assets and reduce
operational risks inherent in control
and automation systems. Coupled
with optimization of the process and
field instrumentation we are a global
provider of oil and gas solutions.
Our global reach means we can
deploy commissioning teams in most
geographies, while taking advantage
of reduced labor costs in our central
engineering offices.
OIL & GAS: SUBSEA
Our key focus is the process
automation and control of the
Master Control System that controls
the subsea systems (SMU and
SCM). Since we provide automation
solutions for topside production
we are in a unique position to offer
robust systems, integrated across the
end-to-end production processes. In
addition we provide plant-specific
operator training simulators that
mirror typical plant operating
conditions. After-project healthcare
service contracts are available to
ensure you maximize the return on
your investment in control systems.
FERROUS & BASE METALS
We specialize in the automation
and control of electric arc furnaces,
electrodecontrol,equipmentcooling,
raw-material-handling systems,
transformer monitoring and control,
primary off-gas cleaning plants, gas
distribution plants, secondary off-
gas cleaning plants, and peripheral
plants such as boilers, etc. Solutions
encompass the full spectrum of your
automation requirements, including
safety-rated systems on critical plant
areas, advanced control strategies,
specialized equipment housings, and
fit-for-propose instrumentation.
CHEMICALS
Batch and continuous process
solutions are available across a
broad range of control strategies. We
provide design consultancy services
and commissioning assistance to
ensure clients realize completion of
their global projects in record time.
Experience covers a broad spectrum,
including organic and inorganic
chemicals. Our migration service
migrates legacy systems to modern
systems, thus maximizing clients’
return on investment in plant control
to meet the high demands in the
market for their products.
FOOD & BEVERAGE
We specialize in the process
automation and control of CIP plants,
batch-mixing plants, brew houses,
raw-material-handling systems,
water-purification plants, cookers,
and process transfers. Solutions
range from small standalone
systems, through to full plant process
automation, with interfaces to MES
and ERP systems. Our solution suite
enables easy integration of various
package solutions with the main
control strategies to give a total
perspective on plant operation.
Plant data is collated in customized
management reports.
MINING
Matrikon Moore provides advanced
process control solutions that
automate and protect your
investment in mining equipment
and production processes.
Solutions are typically engineered
in accordance with S88 principles,
and range from the mining coalface
through to concentrators, refineries
and smelters. Our experience
and mining process knowledge
has enabled our clients to realize
increased plant availability and
improved production yields, while
operating assets in accordance with
strict safety requirements.
PETROCHEMICAL
A dedicated team of engineers with
an average 15 to 20 years experience
in petrochemical processes provides
critical services to South Africa’s
largest refineries. The team has full
responsibility for developing and
maintaining control and protection
systems for compressors and
turbines across several refining
complexes. Skills are world class
in safety-instrumented systems
and safe plant operation in order
to ensure uninterrupted and safe
operation in critical plant areas.
Predictive maintenance means
refining assets maximize uptime.
PULP & PAPER
Moore’s pulp and paper solutions
encompass all facets of plant
operation,includingchippreparation,
chemical processing, pulp handling,
and machine controls in the finishing
house. We also provide solutions
for the control of peripheral plants
such as water treatment, boilers, air
compressors,etc.Outsideofthemain
control systems we provide process
instrumentation, plant optimization,
and support services. In advanced
solutions we consolidate production
reports centrally, for example at the
headoffice,toprovideaconsolidated
view of collective plant production.
WATER & WASTE WATER
Matrikon Moore delivers solutions
that protect our environment by
providing control strategies to purify
water to a high quality level for
use in process industries, and for
domestic consumption. In South
Africa we assist local-government
organizations to achieve their Blue
Drop certification by implementing
high-availability control systems
that monitor and deliver continuous
adherence to statutory regulations.
Our architectures allow collection of
geographically dispersed data into
a central repository for analysis and
process optimization.
POWER
Power solutions cover the full
spectrum of plant operation,
including boiler automation and
control, interfacing with dedicated
turbine-control systems, and control
of peripheral plants such as water
treatment, plant air compressors,
etc. Plant control and plant safety
systems are tightly integrated.
Outside of the main control systems
we provide robust solutions to plant-
specificchallengessuchasmeasuring
bunker levels in coal silos, measuring
bulk-fuel-oil flows, and accurately
measuring water flows using non-
invasive clamp-on flow meters.
Matrikon Moore | 7Matrikon Moore | 6

WE OPERATE AND DELIVER GLOBALLY
HQ: Johannesburg, RSA
Secunda Office
Vanderbijlpark Office
Houston Office
London Office
Project Location
Office Locations
1
2
3
4
3
4
1
2

FULL-SPECTRUM SERVICE CAPABILITY
We offer the full spectrum of supply and engineering
services, ranging from supply of field instruments only,
right through to full system design and commissioning
on a turnkey basis.
Our scope of supply typically includes interfaces
with peripheral systems and packages to provide
comprehensive control of plants.
ISO 9001: 2008 CERTIFIED
All of our audited processes are documented and
executed using automated process flows. This rigorous
approach eliminates errors, and ensures we follow
robust, repeatable processes for project execution.
3-D CUBICLE DESIGN
In order to match conceptual architectures with the
real world we use 3-D designs to ensure equipment
fits into the cubicles allocated. This approach allows
engineers and clients to satisfy themselves that there
is adequate space to install equipment, and that there
is sufficient space for maintenance personnel to access
systems once installed on site.
COMPREHENSIVE TESTING
Three levels of testing are available for projects:
• Internal factory acceptance testing (FAT)
• Client-witnessed FATs
• External FATs
All tests follow documented procedures, in line with
our ISO 9001 processes. Results are published to the
client, and resolution of issues is tracked closely.
GLOBAL REACH
Once tested, the systems are deployed on site,
where our commissioning teams ensure they are
commissioned in line with documented procedures,
and in line with the plant process-control philosophies.
Changes are rigorously managed to ensure
modifications are documented and approved by the
client.
On-site discipline in change management means that
plant documentation is up to date, and reflects the
“as-built” status of the control system and wiring.
THE END-TO-END PROJECT LIFE-CYCLE
FEED Study
&
Proof of Concept
• Solutions based on extensive system deployment experience.
• Accurate pricing based on robust architecting and solutioning.
• Rapid prototyping and proof-of-concept demonstration of integrated components.
Tendering
• Precise pricing based on accurate bills of materials derived from solution designs.
• Integrated solution design and pricing models ensure that solution changes are rapidly and
accurately reflected in updated pricing and tender schedules.
Design
• Solutions based on customers’ corporate engineering standards.
• Vendor-recommended best practice – we are recognized experts in the systems we supply.
• Our 3-D cubicle design tools ensure optimal equipment location and placement, and ensure
convenient maintenance access.
Configuration
• Accurate interpretation of control philosophies by experienced engineers.
• Accelerated development through use of extensive standard libraries.
• Automated error checking to trap anomalies, and rapidly align to process design changes.
• Streamlined approach to change management.
Assembly
&
Testing
• Audited fabrication, assembly and wiring of cubicles.
• Extensive hardware and software FATs minimize on-site commissioning time lines.
• End-to-end testing of all control philosophies ensure accurate plant operation.
Commissioning
• Experienced staff ensure safe and expedient commissioning.
• Our ISO 9001 approach delivers high-quality documentation.
• Training courses are provided for operators and technical staff.
• Operating training simulators can be developed for critical plant applications.
Long-term
Operational
Support
• On call 24/7 for critical applications.
• Upgrades to systems bring them in line with the latest technology standards.
• Migration of systems using automated techniques – minimizing the need for plant downtime.
Optimization
• Optimization tools tune loops and maximize plant production.
• Predictive tools anticipate and prevent plant trips.
• Alarm management methods facilitate safe plant operation.
OUR PROJECT DELIVERY APPROACH

THE PROJECT DELIVERY JOURNEY
ISO 9001 Work Flows
Automated Tools and Processes
Client Project
Changes Requests
Client User
Requirements:
• Narratives
• I/O counts
• P&IDs
• Other docs
Reference
Architecture
Our custom-developed automation tools import data directly from client source
documents to eliminate coding errors, and accelerate system development.
Our structured and disciplined delivery approach means fewer coding errors, less on-site
rework, and ultimately safer plant operation.
Automated
Preliminary DCS/
PLC Configuration
Automated
Preliminary
Graphics
Configuration
Error-free Bill of
Materials
Automated
Cause-and-effect
Configuration
Example 3-D cubicle design layouts
3-D Cubicle
Designs

SELECTED DELIVERY SUCCESSES
OIL & GAS
FPSO N’Goma (Offshore Angola)
Topside and Subsea Control and Safety Systems
Size: 6,500 wired I/O, 3,500 OPC I/O, and 45,000 soft I/O
Project locations:
• Engineering: Johannesburg, South Africa
• Installation: Keppel Shipyard, Singapore
• Final commissioning: Offshore Angola
Project duration: 1.5 years shipyard; 6 months on location
The project on this FPSO was to supply the integrated control and safety system
(ICSS), and subsea master control station (MCS).
Work was executed in full compliance with IEC 61511, considering the full IEC life
cycle. The accelerated schedule of works was completed in ten months, ahead
of the exhaustive factory acceptance test (FAT). Hardware consisted of multiple
redundant servers, clients, redundant CPU’s and I/O. Extensive interfacing to
various 3rd
party vendors across multiple platforms was required.
The MCS entailed extensive interfacing with dedicated subsea control systems to
provide control from the central control room. On deck remote I/O were used to
provide control of the fire and gas, marine, topsides and turret systems.
Moore deployed an experienced construction and commissioning team to the
shipyard, to ensure the control system was ready for when the vessel sailed. The
customer’s stringent quality requirements and demanding schedule were all met
on time, and on budget.
All work was completed in compliance with our IS0 9001 quality system, with
documented work flows, policies and procedures to ensure that all deliverables
had undergone mandated quality checks.
PETROCHEMICAL
Wet Sulphuric-acid Plant
Control and Safety Shutdown System
Size: 610 hardwired I/O with 41 PROFIBUS devices
Project locations:
• Installation: Secunda Complex, South Africa
Project duration: 24 months
The wet sulphuric-acid plant converts 3,5% H2
S in off gas from the Rectisol and
Phenosolvan plants into sulphuric acid by combustion and catalytic conversion of
SO2
to SO3
, thus reducing sulphur emissions by 16,000 tonnes per annum.
Matrikon Moore was responsible for the end-to-end design and supply of the
DCS and emergency shutdown (ESD) system. The Siemens APACS system was
chosen for the DCS, with the Siemens SIL3-rated Quadlog for the ESD. These were
controlled through Siemens PCS7 operator stations (OS).
The graphics on the OS were designed in accordance with the abnormal situation
management (ASM) consortium guidelines for effective operator display design.
All control loops were engineered, coded and commissioned in line with the
client’s stringent safety requirements.
OPTIMIZATION
FPSO Okha (Offshore Australia)
Control-loop Optimization
Scope: All FPSO topside compressor and turbine control loops
Project locations:
• Remote diagnostics: Johannesburg, South Africa
• Final commissioning: Offshore Australia
Compressor and turbine control loops on the FPSO were oscillating despite
numerous attempts at optimizing tuning parameters. This was in part due to the
complex interaction of various process control loops on the plant.
Matrikon Moore was provided with a remote connection to the vessel, allowing
experts to work on the system at any time of the day, without being constrained
by time-zone issues or lack of on-the-ground local support.
The optimization team deployed a control-loop monitoring and advanced loop-
tuning system to identify and provide tuning parameters for the compressor and
turbine control loops. Systematic remote analyses rapidly identified the root
causes of the instabilities, which were then solved through inputting optimized
tuning parameters into the relevant controllers.
MINING
Copper and Cobalt Mine
Plant-wide DCS
Size: 3,100 hardwired I/O, with 650 PROFIBUS drives
Project locations:
• Installation: Kolwezi, Democratic Republic of Congo (DRC)
Project duration: 3 phases spread over 24 months
This remotely located greenfield copper and cobalt mine consists of crushing,
milling, leaching, thickeners and electro-winning. The DCS had to be expanded
significantly as part of planned plant expansion to increase capacity by 200,000
tonnes per annum.
Software engineering was completed in Johannesburg, and an extensive FAT
was conducted to verify compliance with the control narratives supplied by the
EPC. A large part of control narratives had to be developed by Matrikon Moore,
in compliance with S88. These were based on EPC-supplied process narratives,
which we used to develop the DCS control strategies that were ultimately
deployed on site.
On this collaborative project the control system hardware was free-issued to
Matrikon Moore for local assembly and integration. Cubicles were supplied by a
3rd
party, and dispatched directly to site.
Our engineers went to the mine to install the final FAT version of the DCS
configuration software tested in Johannesburg. The system was then fully
commissioned, with our oversight including loop testing, hot commissioning of all
DCS I/O and PROFIBUS MCCs, operator training, and assurance of system go-live.
FERROUS & BASE METALS
Ferro-manganese Plant (South Africa)
Electric Arc Furnace DCS
Size: 4,000 hardwired I/O
Project locations:
• Installation: Meyerton, South Africa
The Meyerton campus comprises of four electric arc furnaces ranging from 50
to 80 megawatts each, and a 50 megawatt turbo-generator power plant utilizing
waste gas from the smelting processes. All of these plants were automated by
Matrikon Moore between 1997 and 2013.
This particular project comprises of an 80 megawatt electric-arc furnace for the
production of 120 000 tonnes of high-carbon ferro-manganese per annum.
The standard Siemens Advanced Process Library (APL) was used for this project,
which ensures that the library will be maintained and expanded with future
Siemens software updates. The APL also provides exceptionally rich functionality
to operators, and incorporates customized reports for operations staff.
The control system consists of eight Siemens AS417 CPUs with remote ET200M
I/O. Two redundant H-systems CPUs are used for the Gas Cleaning and Distribution
Plants. These are connected to a redundant server pair, providing live data to six
client stations, and one OpenPCS7 connection for the 3rd
-party site historian.
The entire new PCS7 control system was live and ready for hot commissioning
within time-line expectations, and was successfully commissioned within the
available budget.
COMPRESSORS
Rectisol Compressors
Control and Safety System Replacement
Size: Eight compressors with 120 control and safety I/O each
Project locations:
• Installation: Secunda Complex, South Africa
Project duration: 36-month phased roll out
Provision of anti-surge control system and failsafe shutdown system for propylene
compressors and vacuum blowers.
This project was the first to implement anti-surge control on the Siemens S7
controllers for the client. The solution was deployed on a fully integrated control
system comprising of a series of redundant Siemens S7 processors and I/O racks.
An abnormal situation management (ASM) library was developed and used for
graphical user interface to ensure safe and reliable plant operation.
The complete compressor-control packages for all eight compressors including
anti-surge, ESD, and oil systems were delivered during routine plant shutdowns,
on time, and to client specification.

Key Clients: Contact us:
info@moore.co.za
South Africa Head Office (Johannesburg)
Tel: +27 (11) 466 1673
South Africa (Vanderbijlpark)
Tel: +27 (16) 932 4471
South Africa (Secunda)
Tel: +27 (17) 631 2744
USA (Houston)
Tel: +1 832 631 6349
Europe (London)
Tel: +44 777 265 1605
www.moore.co.za
Copyright
Moore Process Controls Pty (Ltd)
Moore is an equal-opportunities employer.
We are ISO 9001:2008 and OHSAS 18001:2007 accredited, and IEC 61508 and IEC
61511 certified.
Legal notice: The logos, trademarks and
references used in this brochure are
acknowledged as belonging to their respective
owner. These organizations have not consented
to their use by Moore Process Controls, nor
are they affiliated to Moore Process Controls.
Their use is not an endorsement of Moore
Process Control’s services or products.

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