Knowledge Center: Plant Safety
Indian Chemical Plant Upgrades Safety and Controls
Indo Gulf Fertilizers of India manufactures and markets urea, a nitrogenous fertilizer. The company has been able to sustain its leadership position of through its focus on adding value to farmers as a total solution provider, helping them improve their yield at lower cost.
The first to introduce the principles of Six Sigma in the agricultural field, Indo Gulf has successfully enabled farmers to achieve higher yield, quality and profits. It is also the only fertilizer unit in India to adopt the world-renowned TPM (total productive maintenance) practices under the guidance of the Japan Institute of Plant Maintenance (JIPM).
After initially operating the Ammonia and Urea sections of its plant with third-party single loop and multi-loop controllers, in 2006, Indo Gulf decided to upgrade and revamp to the latest DCS based system.
The automation was introduced so that all operations could run in auto mode with a safe, proper and sequential shutdown system in case of emergency, thereby not endangering the plant.
Road to renewal
The revamp of the old system of third-party controllers posed a major challenge in terms of design and engineering with regards to matching the locations of new panels within the present control room layout.
The company selected Honeywell to upgrade its existing control system technology to Honeywell’s Experion Process Knowledge System (PKS), with the scope of the total project including the design, engineering, supply, installation, testing and commissioning of the complete DCS system – centered around Experion PKS C300 redundant controllers – for both the Ammonia & Urea plants, as well as the emergency shutdown system – comprising Honeywell’s TUV approved (TUV SIL3) Safety Manager – for the Ammonia plant.
Other features included optic fiber connectivity with gigabit interface between Ammonia and Urea control rooms; a HART Management System, Integration of third- party devices for temperature monitoring, vibration monitoring, gas chromatography analysis, etc; hardwired MIMIC panels with Mosaic for ESD operation; and an alarm paging system.
The implementation was required to be performed in a short shutdown duration in which major tasks such as removing approx 400 existing cables, tagging for termination, and installation of around 40 DCS panels needed to be done. The design, detailing, manufacture and supply of the system also had to be done within a short duration of four months.
Reaping rewards As a result of the control system upgrading, Indo Gulf was able to realize increased efficiency through the connectivity of the two separate control rooms (Ammonia and Urea), which enabled operations to be done from either of these locations.
Improved operator performance was achieved via an enhanced human machine interface (HMI), and increased process performance was achieved through more effective logging of events and generation of alarms.
In addition, the new system enables better business decision-making via the report generation facility, and increased security is provided by having multiple levels of access.
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For more information Please visit Honeywell website at www.honeywell.com/ps/sea
Indo Gulf Fertilizers of India manufactures and markets urea, a nitrogenous fertilizer. The company has been able to sustain its leadership position of through its focus on adding value to farmers as a total solution provider, helping them improve their yield at lower cost.
The first to introduce the principles of Six Sigma in the agricultural field, Indo Gulf has successfully enabled farmers to achieve higher yield, quality and profits. It is also the only fertilizer unit in India to adopt the world-renowned TPM (total productive maintenance) practices under the guidance of the Japan Institute of Plant Maintenance (JIPM).
After initially operating the Ammonia and Urea sections of its plant with third-party single loop and multi-loop controllers, in 2006, Indo Gulf decided to upgrade and revamp to the latest DCS based system.
The automation was introduced so that all operations could run in auto mode with a safe, proper and sequential shutdown system in case of emergency, thereby not endangering the plant.
Road to renewal
The revamp of the old system of third-party controllers posed a major challenge in terms of design and engineering with regards to matching the locations of new panels within the present control room layout.
The company selected Honeywell to upgrade its existing control system technology to Honeywell’s Experion Process Knowledge System (PKS), with the scope of the total project including the design, engineering, supply, installation, testing and commissioning of the complete DCS system – centered around Experion PKS C300 redundant controllers – for both the Ammonia & Urea plants, as well as the emergency shutdown system – comprising Honeywell’s TUV approved (TUV SIL3) Safety Manager – for the Ammonia plant.
Other features included optic fiber connectivity with gigabit interface between Ammonia and Urea control rooms; a HART Management System, Integration of third- party devices for temperature monitoring, vibration monitoring, gas chromatography analysis, etc; hardwired MIMIC panels with Mosaic for ESD operation; and an alarm paging system.
The implementation was required to be performed in a short shutdown duration in which major tasks such as removing approx 400 existing cables, tagging for termination, and installation of around 40 DCS panels needed to be done. The design, detailing, manufacture and supply of the system also had to be done within a short duration of four months.
Reaping rewards As a result of the control system upgrading, Indo Gulf was able to realize increased efficiency through the connectivity of the two separate control rooms (Ammonia and Urea), which enabled operations to be done from either of these locations.
Improved operator performance was achieved via an enhanced human machine interface (HMI), and increased process performance was achieved through more effective logging of events and generation of alarms.
In addition, the new system enables better business decision-making via the report generation facility, and increased security is provided by having multiple levels of access.
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For more information Please visit Honeywell website at www.honeywell.com/ps/sea
