Solvay selects DCS with flexible I/O
Electronic marshalling with Emerson’s DeltaV I/O characterization modules increases project flexibility with lower installation costs.
International chemical and plastics maker Solvay, headquartered in Brussels, Belgium, has selected Emerson Process Management’s DeltaV digital automation system Version 11 with electronic marshalling and characterization modules (CHARMs) to improve control of its PVC polymerization process at its plant in Tavaux, France. The selection follows Solvay’s earlier deployments of DeltaV in other facilities.
“Based on our recent positive experience with the DeltaV system’s electronic marshalling, we know we can rely on Emerson to deploy this game-changing functionality on our PVC project,” said Franck Jouault, system manager for Solvay Tavaux. “This technology will streamline our project implementation, minimize I/O footprint, and reduce downtime.”
The Tavaux plant, which is Solvay’s largest, faces the task of managing a diverse and aging collection of installed control systems from multiple suppliers. This includes conventional DCSs, PLCs, relay-based systems, pneumatic systems, and legacy emergency shutdown systems (ESD). Modernizing and integrating the plant’s 45,000 I/O points as part of the expansion projects is an ongoing and costly challenge.
Emerson says it has completely redesigned hardware architecture of the DeltaV system Version 11 in a way that streamlines these kinds of lifecycle challenges. The electronic marshalling offered in Version 11 eliminates the need for terminal blocks and much of the additional wiring and cabinet space associated with conventional DCSs. Startup time also improves due to the reduced hardware content and workload.
Selection of DeltaV technology for the PVC polymerization process followed a previous Solvay test program to verify that the new I/O system would be compatible with existing field devices and wiring requirements. Solvay had also successfully implemented the DeltaV system with electronic marshalling on two other projects of increasing size and complexity.
“The new project will automate 2,600 I/O points,” said Frederic Puissegur, system project manager for PVC at the Tavaux plant. “In addition to the DeltaV system with intrinsically safe CHARM I/O, it will include a redundant batch server, batch campaign manager, audit trail software, a DeltaV SIS process safety system, AMS Suite predictive maintenance software, engineering services, and on-site training.”
Solvay personnel noted that the platform simplifies project engineering and execution, particularly the electrical and wiring studies, compared to a DCS with its traditional I/O cards. Solvay has been able to eliminate the marshalling cabinet and the associated wiring and design—a huge benefit, given the plant’s space constraints. This reduced engineering effort also means faster project execution, so that the process can come back online sooner.
The new system also helps reduce project cost and schedule risks. In past projects, Solvay reckons that it had to add 5% to any project time and cost estimates because of change orders, incorrect estimates, and other problems. With CHARMs, I/O definition and late changes are easier to deal with during project implementation. Solvay now has the flexibility to assign any I/O point to any controller for optimum use of controller and processing resources.
Solvay Tavaux also anticipates that the DeltaV system will provide higher availability while avoiding unplanned downtime, because problems can be isolated to a single I/O channel – minimizing impact on the system.
Edited by Peter Welander, pwelander(at)cfemedia.com
Visit the Control Engineering Process Control Channel.
Case Study Database
Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.
These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.
Click here to visit the Case Study Database and upload your case study.
2012 Salary Survey
In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.
Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.