Chemical Equipment Update
The low-risk strategy of starting small allowed the Siemens and Syngenta teams to work in partnership to clearly define what was required, without the enormous combined pressures of trying to replace all four process control systems simultaneously. Liaising closely, the teams took a number of weeks to
define the processes required by the new plant control, such as validating the necessary actions and sequences used in the production cycle. Investment was also made in writing the software for the new system and the collaborative approach involved testing schedules with Syngenta’s on-site control team travelling to Siemens’ Manchester base to trial the new system. Such hands-on training was integral to the longer-term strategy of operator buy-in and gave the Syngenta team the knowledge and expertise on a first-hand basis which would be required to support the new control system when it went live on day one. .
Switchover With more than 15 years since the last major control system replacement at Huddersfield, the Syngenta team was a little nervous when the first phase switchover took place. However, the meticulous planning and potential problem-solving work undertaken by the two teams beforehand paid dividends, and the first control system was implemented on time during shutdown and, crucially, without any production downtime on site. Having successfully managed the first phase of the overall
programme, thoughts turned to phase two. This involved the replacement of a 15 year old plant computer on the site’s Reglone process plant. The team approach from phase one was continued and the efficiencies and learnings from the first smaller-scale project helped determine, underpin and drive forward the actions for the second phase. Subsequent phases, that have seen the final two legacy process control systems replaced, followed the planning, testing
and implementation template created at the first stage. This approach has proven to provide Syngenta with cumulative and significant time and cost savings across such a substantial four year project. Mick Pearson sums up the project from Syngenta’s point
of view: “The sense of achievement is fantastic. The four new control systems have been replaced and are operating superbly, bringing the business operational efficiencies, production stability we wanted and removing future system support issues. All production quotas have been delivered and the product quality maintained. We have worked alongside Siemens who brought with them the significant project expertise we required, backed by the PCS7 process control solution that meets the flexible and scalable control needs we will need into the future. We now have plant control systems that are more reliable, are cheaper to run and give us more opportunity to both analyse the processes better and then to optimise them. The proof of the success is in the performance, and we have not experienced any production breakdowns in the four years since the inception of the switchover programme.”
Process improvements Going forward, and in keeping with the site’s strategic approach and the investment made in ensuring the Syngenta operators were fully behind the new systems, the process control team are continually seeking process improvements and cost efficiencies. Indeed, software changes implemented in-house are now
routine and frequent, allowing the production process to react to the changing needs of the business. The ability now to carry out software changes and introduce new I/O online is contributing to reducing any unnecessary downtime. ❒
For more information, visit
www.automation.siemens.co.uk
Metering pumps for aggressive media can be flexibly matched to any site conditions
P
rocess metering pumps are used in all applications where corrosive, toxic and flammable liquids are metered under very high pressures and extreme temperatures. They are, for example, used in the chemical industry, petrochemical industry, refineries as well as oil and gas production or as special metering pumps in the process industry.
High-power process metering pump series complete the metering pump portfolio of ProMinent in the high-end segment. The hydraulics, diaphragm and plunger process metering pumps of ProMinent with their robust design guarantee reliable operation, even under the most demanding conditions. Thanks to their modular design, the metering pumps can be flexibly matched to any conditions at the site. Depending on the demands, the pumps can be used at extremely high
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Fig. 1. The process diaphragm TriPower MF according to API 674 offers high performance with smallest footprint. It delivers up to 38 m3
pressures of more than 3000 bar and product temperatures ranging between -40°C and 400°C. Furthermore, a metering of high- to highest-viscosity liquids is possible. Because of their compression-rigid characteristic, a very precise metering is possible. The requirements pursuant to API 675 on oscillating displacement pumps with adjustable stroke volume can be absolutely complied with. The long service life of the diaphragm and the plunger guarantees a maintenance- and trouble-free operation. Hermetically sealed metering units and adequately resistant materials provide for a problem-free delivery of aggressive media. ❒
/h at pressures of up to
400 bar. Thanks to its compact design, the pump has a considerably smaller footprint than conventionally designed pumps.
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ProMinent Dosiertechnik GmbH is based in Heidelberg, Germany.
www.prominent.de
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