CET Group | Dulux Merrifield

Engineer, Engineering, Geelong, CET Group, Innovation, Compliance INDUSTRIES. CET Group provides value to many industries through our wide range of skills and experience. SERVICES. CET Group can work on specific tasks or run the whole job for you. Check out the services we can offer. PROJECTS. CET Group has worked on varied projects in both scale and product. Click to see our most recent projects. Innovation. Finding innovative solutions to problems is what puts CET Group above the rest. Engineering. Providing precise and calculated results based on experience, evidence and engineering principals. Compliance. Following national, regional and company standards to achieve safe and efficient outcomes.

Engineer, Engineering, Geelong, CET Group, Innovation, Compliance

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Dulux Merrifield

On the 17 March 2015 Dulux announced the construction of a new state-of-the-art $165M paint factory in Melbourne to supply Australia with water-based decorative paints.

CET Group was chosen as the process/mechanical consultant for this highly automated DULUX paint facility situated at Merrifield.

CET Group’s involvement began with concept development and costing inputs prior to project approval, through detailed design, technical construction assistance, joining the commissioning team, and validation assistance during initial production and during production output ramp-up.

It has been a long journey from developing the factory footprint and layout, to process throughput modelling, designing plants/units, producing ISO’s, specifying software and bench testing the code prior to site release. Commissioning brought together the physical plant with the automation of SAP, MES, Batch and Process Control in a seamless manner.

Process Control, reducing manual interventions, consistency and robustness were key success factors and a number of new ideas were introduced as well as some innovation that was devised, trialled and successfully implemented.

CET Group is proud and grateful to play a role in this team orientated project.

Scope

Process

Dispersion, Addition Systems, Mixing, Filtration, Base Storage, Transfers and Pigging

Services

Bulk Powders, Thickener, Bulk Liquids, Minor Liquids Transfers, Process Water, Compressed Air, Dust Extraction, Fume Extraction, Cooling Water, Chilled Water, Effluent

Pilot Plant

Services, and Process

Blend and Tint plant

Reviewer and Technical Management

Automation

Concept design, tagging and set-up based on S88 and a modular approach. Selection of platform, integrators, writing Functional Descriptions for all processes, services, SAP, and MES integration, detailed bench testing and on site commissioning.

Tasks as follows:

Process Model, using recipes for all products to determine the size and number of process units;
Site layout, Factory footprint, traffic movements;
Equipment Layouts, raw material, product, people, traffic and waste flows;
Process Flow Diagrams (PFD’s), Piping and Instrument Diagrams (P&ID’s);
Functional Descriptions and all automation specifications;
Equipment Specifications, Data Sheets and Lists (Valve, Equipment, Instruments);
Piping, Equipment and Support installation drawings;
3D modelling and isometrics for all piping
Co-ordination of all disciplines and information in project site 3D model;
Software and Major Equipment Bench/FAT testing;
Technical Site Assistance/Supervision
Commissioning, Validation for initial product manufacture, onsite scale-up assistance to full production, training and handover as built.

Client

Dulux Group

Date

2014 – 2018

Dulux Merrifield