The system upgrade at Hoghiz was successfully implemented within the very short shutdown allowed by the high production demands at the plant. This was achieved despite the fact the ABB 800xA 6.1 had to be migrated to a fully operation plant.
“Thanks to great collaboration among Hoghiz’s automation team and ABB engineers, an intensive SW FAT and painstaking preparation, the commissioning of the CM3 with the new Minerals Process Control Library could be finished on time and without any major disruption for the running plant,” commented Marending.
The switch was also assisted by immediate buy-in by the Hoghiz operators, who were embedded in the commissioning project in order to optimize training. Despite being a significant change from the previous system, it has proved easy to master with only limited training required. The system’s intuitive displays tell operators what is happening; the operators just needed to adapt to the new symbols and layout.
“It all comes together in a very nice package that makes the operator’s life easier, makes fault tracing easier, and tells the operator who to send where in the field, before anything wrong happens with the process,” said Razvan Cocea, Head of Electrical and Automation for CRH South East Europe. “I am proud that I pushed for this to be the first plant in the world to use VisualControl. Now I know this is one of the best decisions that I have made in my life.”
The new system will now be rolled out to the rest of the plant in two more steps. The first will be undertaken this Winter and will cover all cement grinding lines and the raw mill. This will be followed next year by the kiln, petcoke and dispatch areas.