Client Challenge
A pharmaceutical manufacturer needed to upgrade their ammonia system to improve operational efficiency and ensure compliance with their process logic description (PLD). The upgrades needed to be completed while the plant remained in operation to minimize production disruption and downtime. The goal of the upgrade was to provide supervisory control, real-time data monitoring, fault detection and alarm notifications.
The project was centered on commissioning a hot water vaporizer (HX-2063) and implementing precise control of tank T-400’s level. Additionally, ten pressure transmitters needed to be installed to replace Interlock Protection Function (IPF) alarms previously provided by flow meters.
Our Solution
Our team executed a comprehensive upgrade plan tailored to the client’s needs. Key activities included:
- Development of Control Logic Description (CLD): A detailed CLD was developed based on our client’s template to define the system’s operation clearly.
- PLC Control Logic Programming: Using RSLogix 5000 v20, our team programmed the control logic in the PAP 201 Allen-Bradley controller. Standard function blocks and user-defined types were employed to streamline development and ensure modularity.
- Advanced PID Loop Design: A PID loop was configured to manage tank T-400’s level, incorporating logic to override basic PID functionality and coordinate related valve controls for optimal performance.
- HMI Overhaul: Updates were made to the iFIX/Proficy HMI to provide operators with enhanced supervisory control, equipment status displays, fault and alarm alerts, and real-time data logging. Standard dynamos and tag templates were utilized to ensure consistency and efficiency.
- Onsite Startup and Commissioning: The system was started up and commissioned online without interrupting plant operations. The team worked closely with plant operators to coordinate workflows and minimize production impact.
- Thorough Documentation: All code and configuration updates were meticulously documented to facilitate future maintenance and scalability.
The Results
The ammonia system upgrade delivered significant benefits for the pharmaceutical client:
- Enhanced Process Control: The PID loop and supporting logic provided precise control of tank T-400’s level, ensuring optimal performance and reliability.
- Improved Alarm Management: Replacing flow meter IPF alarms with pressure transmitters enhanced system reliability while retaining flow meters for monitoring purposes.
- Operational Efficiency: HMI modifications improved operator oversight, enabling faster response times to alarms and better visibility into system status.
- Seamless Integration: By completing the upgrade while the plant was operational, DSI Innovations avoided production downtime, preserving the client’s productivity.
- Robust Documentation: The provided documentation ensured that the client’s team could maintain and expand the system with ease.
This successful project underscored DSI Innovations’ ability to deliver complex system upgrades with minimal disruption, enabling clients to meet operational goals with enhanced reliability and control.
