The operations at Eti Bakir are spread over a wide area, with some of the factory facilities several km away from the central control room. Due to the distances involved and the complexity of the customer requirements, a fully IP-based system was the only practical solution

handling data traffic from any networked source device, such as sensors, image processors, CCTV cameras or data stores, synchronizing and sharing content instantly across any number of locations with minimal latency. Although connected on a single physical

The Eti Bakır Mazıdagı plant in Turkey boasts a huge video wall in its main control room, with further LCDs in smaller control rooms. A complex project, the high volume of data is networked, managed and shared using Mitsubishi Electric’s S-SF suite

˘ C auxiliary units, the Eti Bakır Mazıdag

overing 1.58 million square meters and incorporating five factories and 12 !ı

fertiliser and metal recovery plant in Mardin, Turkey is a huge installation. At its heart, a Mitsubishi Electric video wall keeps a watchful eye over operations. Agriculture is a vitally important part of

the Turkish economy, and it is one of the few countries in the world to remain self- sufficient in food production. Among many other products, it is the world’s leading exporter of hazelnuts and raisins, and the fourth largest producer of fresh vegetables. For many years, high demand for mineral fertilisers had outstripped domestic production, which meant relying on imports. In 2011, the Mazıdag

!ı came

under the ownership of Cengiz Insaat. Following major investment and a rapid modernisation programme, Eti Bakir was transformed in just three years into a facility that now produces 20% of Turkey’s mineral fertiliser needs. With multiple operations based on the

site, it was decided to centralise all the process control functions into a purpose- built tower. The main control room facility is located on the eighth floor of the tower, with other smaller control rooms for the individual factories and supporting functions, such as power and steam generation plants, located across a further six floors. At the centre of the main control room facility is a Mitsubishi Electric video wall consisting of 40 72WE120 72” DLP cubes. The control rooms on the other six floors are equipped with LCD video walls comprised of Mitsubishi Electric LM55 55” displays in a 3 x 2 configuration. In total there are

IP network, each of the individual factories and systems such as CCTV are isolated from each other via independent VLANs (virtual large area networks) for security purposes. However these sub-VLANs remain accessible to the main control room display VLAN, enabling it to have complete oversight over the entire system. Operators in the main control room are able to drill-down to access detailed data and content from any of the sub-systems under its overall control. Interfacing the individual VLANs proved

a technical challenge for Mitsubishi Electric’s engineers, but the versatility of the S-SF system ensured the commissioning proceeded smoothly and was completed on time. Moreover, the ability for operators to remotely access and manage every asset via the S-SF network has proved useful. For example, video walls in management areas which are not required outside of office hours are turned off automatically to improve energy efficency and screen longevity. Eti Bakır Mazıdag

!ı came fully online in

nearly 100 individual video wall displays throughout the facility, all of which need to be centrally managed. While the LCD video walls monitor specific aspects of the plant’s operations, the main control room screen needs to provide oversight of the entire operation. Managing the huge volume of live data and CCTV camera feeds was a technically demanding challenge requiring the use of the very latest screen control technologies. Mitsubishi Electric’s S-SF suite has

provided the solution to the challenges of this complex project. The five components of the suite, Display Agent, Multicast Converter, Application Server, S-SF Control and S-SF Master, work together to create a native IP-based system capable of

A benefit of the S-SF system is its inherent versatility and scalability, enabling it to cope easily with any future enhancements which may be required

The S-SF system hardware is based on standard, widely-available network components, removing the need to develop and debug proprietary hardware or operating systems. The result is a more reliable, cost-efficient system

the final quarter of 2018, and has made an impact on both the national and local economies. The facility has provided direct employment for 1,250 local people and indirect employment for a further 5,000. O

"mer Mafa, CEO of owners Cengiz, said:

“When fully operational, the plant will meet $350m of fertiliser needs annually, while at the same time producing $270m of cobalt, zinc and copper annually.” Designed for native IP network-based

command and control display architectures, the S-SF software suite enables network- based display systems to operate efficiently and with greater scalability. Using the S-SF architecture, control

room video walls no longer require a dedicated display wall processor. Fault tolerance is assured due to the multiple redundancies inherent in the distributed network architecture. If one network node develops a fault, its role is instantly assigned to another node to achieve seamless fail-safe response and guaranteed 24/7, zero-downtime performance. The S-SF system hardware is based on standard network components, so there’s no need to develop and debug proprietary hardware or operating systems.

Mitsubishi Electric


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