Client Challenge
When a chemical plant sought to automate its Reactor Train, its operations turned to DSI Innovations. The plant’s existing reactors operated manually and transitioning to a fully automated Batch Control System was an essential part of their overall strategy to reduce cycle time, improve quality, reduce waste, and increase “first time right.” Our goal was to establish a streamlined, user-friendly automated control system adhering to ISA S88 batch control standards, minimizing human error, and enabling operability by staff with little prior experience in automated systems.
This comprehensive project required P&ID design, network infrastructure design, hardware specification, supplying field devices, panel fabrication, programming and configuration, installation support, Factory Acceptance Testing (FAT), commissioning services, and startup support.
Our Solution
We approached the project with a robust plan to upgrade the process equipment, which included:
- Ten monomer raw material tanks
- A new batch reactor
- Two pre-mix tanks
- Three raw material/catalyst mix tanks
- Manual addition scales
We also specified a new control room equipped with remote touchscreen interfaces, providing operators with streamlined, centralized control of the new system along with wireless tablets for remote access to the system from any location in the plant. To house the plant’s electrical equipment, we designed a custom-built Conex pre-installed with the necessary server rack and control panels.
As a Rockwell and Ignition partner, we implemented the latest Rockwell Automation hardware and software tailored to the client’s needs. The integrated Rockwell applications included FactoryTalk, Thin Manager/Client, and FactoryTalk Batch software, all of which significantly boosted operational efficiency for chemical production.
The new fault-tolerant, virtualized server-based batch process control and reporting system used Ignition software to provide insights into the process, display dynamic trend graphs, and generate reports on cycle times and material consumption
During the design phase, DSI provided the S88 batch design and a detailed Functional Specification for the system. We developed several procedures and created numerous recipes using the Standard Operating Procedures (SOPs) previously utilized by the client. Our detailed functional specifications were based on Process & Instrumentation Diagram (P&ID) and supported by our extensive knowledge of the Emulsion Polymer Production Process, ensuring the most efficient batch production of the client’s end product.
System commissioning began with validating field devices, testing safety interlocks, and testing process control sequence logic. After successful water batching over the course of 5 weeks, we then transitioned to testing raw materials. Throughout this period, we offered on-site support, made necessary adjustments, and resolved issues as needed. Effective communication played a key role in our project’s success. After handing over the new system to our client, we provided ongoing remote support to ensure optimal performance.
The Results
The successful system commissioning demonstrated the seamless integration of the new automated system into the existing infrastructure. Our commitment to project execution and design fulfillment ensured the system met the client’s standards and adhered to the final Process & Instrumentation Diagram (P&ID).
- Efficient Batch Production: Within five weeks of commissioning, we achieved efficient material production, validating the effectiveness of the new system.
- Operational Handover and Support: Our ongoing support ensured continuous access to expert assistance while plant staff familiarized themselves with the new system.
This project represents a significant advancement in the client’s automated batch processing, attributed to meticulous planning, cutting-edge technology, and a phased approach that ensured thorough testing and efficient implementation.
