Digital automation systems improve control,consistency and maintenance at Cognis Hythe.

Plant operators are also seeing improved asset management. There are two major multi-functional monomers production units at Hythe, MMU2 and MMU3. The former was controlled by stand-alone controllers, while MMU3 is run by an early Rosemount System 3 distributed control system (DCS) from Emerson. With components on the MMU2 controllers becoming difficult to source, as well as problems around engineering support, there were concerns about plant availability. Then when the site control rooms had to be moved, the sheer cost of hard wiring old kit meant it was time to change. "To address the MMU2 issues we decided to install a DeltaV digital automation system," says Pepita Monk, site project engineer. "It was the most economic solution, and we could use the existing site LAN to enable the engineering and operator stations within the new control room to communicate with the controllers. "The system also prepares our plant to use the benefits of Foundation fieldbus [digital plant communications] technology and PlantWeb for future expansions." There are several useful points to note. First, when Emerson installed the new system, it was able to use the existing field wiring and termination panels. Second, by using DeltaV Simulate, the company was able to configure a training demonstration. Third, with the comms provided by Emerson for the MMU3 RS3 control system, the raw material inventory data on that unit can be shared with the MMU2 Delta V system. And fourth, the site is currently trialling an AMS (asset management system) suite with some 60 intelligent field devices connected to Emerson's Device Manager software and passing diagnostic data to technicians. The verdict: not only does this deliver the immediate benefits of digital technology, but it prepares the plant for future expansion and further digital technology in terms of plant operations and maintenance.