Situation
A client from the city of Querétaro, Mexico, built a new building for the formulation of chemical products. He looked for an integrator who had extensive experience and certifications such as SINCI, for which we set about the task of designing a Layer Automation system that complied with industry standards and ATEX Zones.
Problems and Needs
The need of the project in technological terms was to find the elements, equipment, instruments that comply with the ATEX classified area.
In addition to the above, the system would have the ability to guide operators in an agile and intuitive way in the formulation of the products. The operators are oriented to take the process step by step or by stages manually and locally.
Reasons
Because the process area where the chemical formulation is prepared has a high reaction, the solution was oriented to have a SCADA system, where users are allowed to monitor the information generated during the reactions that are carried out on the product. end inside each Reactor
Some stages and/or systems were manually operated, however, information should be taken as evidence that the reaction was operating correctly, as well as alarm and record variables that were out of range for further analysis in the application.
Have a means of visualization in the event of any equipment failure that may occur.
Given the above, the following points were established:
Reports
Formulation
Technical requirements
A satisfactory solution
The technical requirements provided by the client were reviewed and evaluated. The SINCI programming team proposed a state-of-the-art technology that complies with EX, IA, Namur for the conditioning of the field signals.
- A PLC was used in the main control system.
- Network architectures for Ethernet DRL communications between the PLCs and the I/O were implemented
- For the HMI, software licenses were used for the development of the SCADA application, on a Workstation-type PC with essential characteristics for the type of application.
- The design of the application at the mimic level was developed to the SINCI standard under the 3D model that allows the operator to become familiar with their current processes.
Results
At the end of the implementation, training and monitoring of the system with the plant team, we highlight the following benefits:
- The formulation system operates and allows flexibility to operate each reactor or a sequence of reactors according to the production plan.
- The operator from the control room monitors the stages and responses of chemical reactions in real time.
- The parameters and variables of interest on the formulation and production by the system are recorded.
- With the implementation of the proposed hardware and the redundant configuration, the client guarantees the continuous operation of the project.
- With an editable template in the SCADA application, the customer can modify, delete or create new recipes as required in terms of production.
We meet the requirements and specifications established by the client and we value the joint work to deliver to satisfaction.
How can you achieve proper automation and chemical formulation?
Contact one of our engineers now so you can see all the benefits of automating your plant. The first step is to carry out a technical survey of the current situation of your factory.