Introduction
Denca Controls is well experienced in the unique requirements of the
chemical and petrochemical sector having worked with several chemical
and petrochemical companies to provide integrated automated control systems.
Denca uses imaginative software engineering to provide automated and
interactive process control systems without incurring additional
production downtime. This is particularly relevant to the needs of the
chemical and petrochemical sector, as the following case study demonstrates:
Problem
Brunner Mond used a manually controlled system for loading heavy ash
into tankers for onward delivery. Maximum output was 56 loads per day
and bottlenecks often occurred. To speed the loading process, Brunner
Mond asked Denca Controls to investigate the feasibility of automating
the loading operation.
Solution
The initial study confirmed that it was feasible to automate the plant
and Denca Controls were commissioned to deliver a solution - but without
interrupting the daily loading operation!
Automation was therefore achieved by designing, manufacturing,
programming and installing a driver self-loading system which:
- provided each driver with a read/write data tag to regulate the
quantity of ash delivered into the tanker
- ensured that the tanker docked at the relevant chutes to maintain an
even distribution of the load
- interfaced with the driver via a touch pad and joystick to ensure
accurate positioning of the chutes and correct loading.
Benefits
The driver self-loading system delivered the following main benefits to
Brunner Mond:
- faster throughput of tankers removed any bottlenecks
- accuracy of loading avoided under and over delivery
- contamination of the loading area with spills was virtually eliminated
- automation allowed the re-allocation of staff to more critical
production areas
- work was completed without reducing the daily volume of ash loaded.
Technical
Denca Controls was initially engaged by Brunner Mond to undertake a
feasibility study and prepare an outline design proposal for automation
of the heavy ash loading mechanism at Winnington Works. We were then
subsequently contracted to:
- provide a detailed E&I design package
- software engineering - configure automation software for PLCs, HMI and data tag system
- manufacture control panels
- install and commission works.
The primary system consisted of the following elements:
- 2 x Allen Bradley SLC 500 PLC panels
- 2 x Allen Bradley touch-pad panel-view operator interfaces
- A read/write data tag system for the drivers
The contract also included the design and manufacture of the following
elements:
- several pneumatic solenoid panels
- an electrical control desk with joystick controls and a mimic fascia
- refurbishment of 20 starters within an existing MCC
- specification of all instrumentation
- instrument air supply system complete with dryer.
The above installation provided Brunner Mond with an automated system
which is faster, more accurate and cleaner than the previous system.
For further details, please contact John Talbot on 0151 257 9010
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