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Fibre optic backbone
for fertiliser production control system
Kemira,
the global chemicals company, has used ABB's IndustrialIT extensively
for new production control systems at its major fertiliser plant
in Denmark. The Fredericia, Jutland facility produces around 650,000
tonnes of complex fertilisers, acids and speciality products annually.
Fully integrated
production control systems were required in the speciality products
sector (SPS), which produces dicalcium phosphate and potassium nitrate.
The SPS comprises five decentralised plants, originally equipped
with three different distributed control systems, two PLC systems
and many single instruments in old mimic panels.
Centralised
monitoring
The existing
mixture of systems did not provide the required centralised monitoring
and control of all aspects of the production process. The upgrade
aimed to integrate the control systems, establish a common control
room and to renovate process and production equipment wherever possible.
Key criteria
for the new system were the ability for the company to do its own
programming, easy integration into the existing process, and the
ability to modify, update and improve the system as required. Kemira
Danmark chose a system based on IndustrialIT, comprising OperateIT
operator workstations and ControlIT PLCs connected by a redundant
fibre optic cable, providing the flexibility and efficiency needed
to control the intricate SPS production.
The first phase
of the project encompassed installation and implementation of the
new control system in the ion exchange, the vacuum dehydration and
the calcium chloride plants. Systems for further plants, and renovation
of production equipment, are covered within a further two phases.
Implementation of all three phases will deliver a common control
room with four OperateIT operator workstations, three local control
rooms, each with one OperateIT workstation, an engineering room
with an OperateIT workstation and Control Builder, as well as six
ControlIT AC 800M controllers distributed throughout the plant.
The system includes more than 3,600 I/O and a 1,000m fibre optic
plant network. A similar control network connected to two parallel
Aspect and Connectivity servers will provide redundancy.
ABB carried
out a complete re-cabling of the three Kemira plants in just three
days, while full installation and implementation was conducted with
a total plant downtime of only eight days - a result regarded by
Kemira as impressive, considering the huge logistical challenges
and complexity of the plant. Within two days of running in, the
plant had already resumed 80% of normal production.
ABB
h107@industrialnetworking.co.uk
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