|
BUTANEDIOL
SAFETY INTEGRITY SYSTEM
|
| Cost:
$390,000
|
| Control
Hardware: Tricon®
V9.2 Triple-Modular Redundant System
|
| Control
Language:
TriStation® 1131 Development
Software (475 Hard I/O points) |
| HMI:
Intellution® Fix-32 Industrial
Automation Software (3000 Soft I/O points) (89 HMI screens)
|
| Description:
TRIPLE-MODULAR
REDUNDENT EMERGENCY SHUTDOWN SYSTEM |
|
The GEMINOX® Butanediol
Plant was a world's first, grass roots chemical plant consisting
of the following sections:
| |
• |
Two
Maleic Anhydride Reactor Sections |
| |
• |
Hydrogen
Recycling Section |
| |
• |
Reactor
Depressurization Section |
| |
• |
Scrubber
Off-gas Burner Section |
| |
• |
Three
Large Compressor Sections. |
The
plant had limited intermediate storage facilities, making
the reliability of the instrumentation, control, and Safety
Integrity System of paramount importance. Demar Automation
delivered a fully integrated Safety Integrity System using
three triplicated TRICONEX™ Tricon Version 9.2 fault-tolerant
controllers. The System interfaces with Bentley Nevada equipment,
Woodward Governors, as well as the Delta-V Distributed Control
System (DCS). The system architecture consisted of two SCADA
Servers with four remote Clients, a Sequence of Events (SOE)
recorder, and a development workstation on a TCP/IP network.
The control program scheme took advantage of three of the
IEC-1131 standards for PLC programming, i.e., Function Blocks,
Structured Text and Ladder Logic. Operator interface to the
Emergency Shutdown System and DCS was managed by Intellution's
Fix-32 Industrial Automation HMI Software over a Modbus interface.
Demar's
scope of work included system design, procurement, programming,
panel fabrication, documentation and testing.
Back
to top |
COAL
BARGE UNLOADER
|
| Cost:
$350,000
|
| Control
Hardware: Opto
22® MISTIC®
Module 200 Controllers |
| Control
Language:
Opto 22® Cyrano®
200 Visual Control Language (150 hard I/O points) |
| HMI:
Opto 22® MISTIC®
MMI (400 soft I/O points) (13 HMI screen) |
| Description:
AUTOMATED BARGE UNLOADING
|
This
project was the first-of-a-kind, completely automated barge
unloader used for unloading petroleum coke. Its architecture
was made up of the following systems: |
| |
| |
• |
Barge
unloading |
| |
• |
Barge
haul |
| |
• |
Conveyor
control. |
|
| |
| The
improvements to the barge unloading system allowed 1250 tons
of coke to be unloaded per hour, compared to the old system,
which could handle only 312 tons of coke per hour.
Demar
Automation delivered a fully automated control system utilizing
a state-of-the-art programmable controller (Opto-22™
hardware and software) interfacing with flux vector drives.
Demar's scope of work included electrical engineering and
control system design, programming, procurement, panel fabrication,
installation, testing, and documentation.
|
|
UNDERGROUND
STORAGE FACILITY AND METER INTEGRATION
|
| Cost:
$803,000
|
| Control
Hardware:
Allen-Bradley Omni Flow Computers |
| Control
Language: RSLogix
(600 Hard I/O points) |
| HMI:
RSDisplay (2000 Soft I/O points) (4800 Soft I/O points from
metering) (60 HMI screens) |
| Description:
BULK STORGE FACILITIES |
The
storage facilities included many wells and numerous salt dome
cavities for storing many types of hydrocarbons. Demar Automation
provided a complete PLC control system for controlling all
aspects of the storage facility, including PLC system controlled
transfer pumps, valve alignment, and peripheral equipment
at the site. The system incorporated multiple Allen-Bradley
5/80 and 5/40 processors communicating over Allen-Bradley's
Data Highway Plus. Metering instruments and high voltage motor
protective devices were interfaced via serial communications
links to the PLC. Screen graphics for all meter runs and motor
controls were developed for the Honeywell DCS system.
Demar
Automation's scope of work included all electrical, instrument,
and control system design, programming, testing, and documentation.
Back
to top |
VITAMIN
E PURIFICATION UPGRADE
|
| Cost:
$425,000 |
| Control
Hardware: Allen-Bradley's
PLC-5/80 ControlNet® |
| Control
Language: Allen-Bradley's
RSLogix® (750 Hard I/O
points) |
| HMI:
Intellution® iFix Dynamics™
Automation Software (4000 Soft I/O points) (89 HMI screens)
|
| Description:
BATCH
PLANT OPERATIONS |
In
an effort to stay competitive, our client needed to improve
their refining process to produce a higher grade Vitamin E.
To this end, the refining system as well as the existing Control
System was upgraded. Demar Automation engineered a new control
system that subdivides the plant into two general areas, the
Reaction area and the Refinement/Utility area. The process
control program was written using Sequential Function Charts
to take advantage of the successive operation of the Reaction
System. The operator interface was managed by Intellution's
iFix Dynamics Automation Software. Demar Automation developed
Custom ActiveX controls for the HMI application to meet navigation
requirements specified by the customer.
Demar
Automation delivered a totally new and upgraded control system
using Allen-Bradley's ControlNet®
hardware and software. Demar's scope of work included system
design, specification, procurement, programming, panel fabrication,
documentation and testing.
Back
to top |
CERAMIC
EXTRUSION PLANT EXPANSION
|
| Cost:
$350,000 |
| Control
Hardware: Siemens
Simatic®-505 |
| Control
Language: Siemens
APT® software (1100 Hard
I/O points) |
| HMI:
National
Instruments' Lookout Process Control HMI Software (2200 Soft
I/O points) (15 HMI screen) |
| Description:
CERAMIC
EXTRUSION AND MATERIAL PROCESSING |
Two
new and completely automated Batching, Mixing and Extrusion
lines were installed at an existing client facility. The control
system architecture utilized the Advanced Siemens Simatic™-505
platform consisting of multiple distributed processor and devices
all communicating over a redundant Profibus™. Operator
interface was accomplished using National Instruments' Lookout
Process Control HMI Software. The control system strategy was
written using Siemens APT™ software and was distributed
among the following subsystems: |
| |
|
| |
• |
Recipe
Selection |
| |
• |
Minor,
Major, and Liquid Ingredient Batching |
| |
• |
Hopper
and Vacuum Conveying |
| |
• |
Product
Mixing |
| |
• |
Extruding |
| |
• |
Drying |
| |
• |
Super
Sacking/Tote Packaging. |
|
| |
|
| Demar
Automation delivered a fully automated control system, designed
for easy expandability and maintenance, which would allow
production of a variety of products (chemical mixtures). Demar
Automation's scope of work included electrical and control
system design, programming, procurement, panel fabrication,
installation, testing, and documentation.
Back
to top |
Air
Separation Plant Expansion
|
| Cost:
$250,000 |
| Control
Hardware: Moore
APACS DCS® |
| Control
Language: Moore
4-Mation® Configuration
Software (300 Hard I/O points) |
| HMI:
Moore
Vision (WonderWare™) HMI Automation Software (1000 Soft
I/O points) (26 HMI screens) |
| Description:
AIR
SEPARATION |
The
plant expansion consisted of installing one new Nitrogen Pipeline
Compressor (11,000 hp), two new Oxygen Pipeline Booster Compressors
(2500 hp each), modifications to three existing Nitrogen Pipeline
Compressors, and one new chiller. The new Moore APACS™
DCS-based system and HMIs automated the start-up, shutdown,
and pipeline pressure control processes for the compressors.
The scope
of work for Demar Automation included all electrical, instrument,
and DCS system design, specification, procurement, programming,
panel fabrication, documentation and testing. |
|
