A total of 50 assets are operated in the process and two full production management clients. The System 800xA Batch Management complies with ISA S88 and allows the standardization of production control according to the requirements of customer orders.
Information Management Server
For the reporting process, Automatización implemented an Information Management Server that generates specific reports for raw materials, electrical consumption, steam and water utilization, batch production, process variables, alarms and events.
A redundant connectivity server was installed, guaranteeing the availability of the system. The license of this system covers 600 redundant tags.
Operator Workplace and Engineering Workplace at Control Room
The control room has two operator workplaces with Batch functionalities: one with four monitors for operating the processes, and another for monitoring batch processes (i.e., PFC), editing recipes, accessing data, including making online changes to the recipe.
The second workstation also features the engineering workplace where the operator can make adjustments, changes and enhancements in the control system.
The system has three AC 800M controllers: two in redundant configuration, for process control, and one for auxiliary plant equipment which connects the plant meters via a Modbus RTU network. This setup prevents the process controllers from being overloaded with data traffic tasks that could affect the performance of the CPUs.
Fieldbus and I/O Modules
The system has a control rack for the controllers and DP/PA converters; and four distributed control racks that have remote I/O modules connected by Profibus DP. The I/O modules for hazardous areas are S890. Each reactor has a Profibus DP master module to which the variable-speed drives and I/O modules are connected via remote DP/PA converters. For this project, Profibus PA instruments such as Series 266 pressure transmitters, temperature transmitters and Coriolis mass flowmeters were also supplied.