More efficient batch-process control


Dynea UK Ltd. (Mold, Flintshire), a leading producer of industrial adhesives, has purchased ABB 's System 800xA Extended Automation to update its existing system for its urea-formaldehyde (UF) resins and adhesives process. The overall process control system, including the phenol-formaldehyde (PF) segment, has over 1,000 I/O signals, with operator access via four operator stations for the UF plant and three for the PF plant.

Rick Hirons, plant engineer for Dynea, says, "One of the major benefits of the ABB system is that it includes batch management software, allowing Dynea to produce a more consistent product based on the ability to call up stored recipes. The chosen system will allow Dynea to meet all forthcoming legislative requirements."

Dynea chose the new system based partly on its strong relationship with ABB and previously Alfa Laval, which supplied the site's original SattCon system. Says Hirons: "We worked with Alfa Laval for 10 years and in all that time we never had a problem—we always got the best service from them. In fact, we have not pursued a formal service contract as they were always there when we needed them. Because ABB is using the same engineers, we were happy to award them the contract to also update the SattCon system."

System-800xA solution hardware includes two AC800M controllers and S890 I/O modules. I/O modules are ATEX certified, and the modules used for both plants provide commonality of spare parts and also feature integral, intrinsically safe area-barriers, reducing panel space requirements.

System software enables collection of production data, allowing production staff to identify and remove bottlenecks for future improvements. System 800xA reportedly allows software written for one part of the control system to be easily copied and re-used. Any changes or amendments made to the original software are updated in the copies and a change log maintained, thereby reducing software maintenance.

Future benefits will be achieved through the system's ability to configure HART devices remotely over the fieldbus, centralizing maintenance and cutting costs.

Hardware and software for the project have been jointly engineered by Dynea and ABB personnel. Dynea engineers worked on the graphics as well as the functional design & test specifications.

System 800xA Extended Automation was chosen by Control Engineering magazine to receive an Editors' Choice Award as one of the best products introduced in 2004.

— Richard Phelps, senior editor, Control Engineering

No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Choosing controllers: PLCs, PACs, IPCs, DCS? What's best for your application?; Wireless trends; Design, integration; Manufacturing Day; Product Exclusive
Variable speed drives: Smooth, efficient, electrically quite motion control; Process control upgrades; Mobile intelligence; Product finalists: Vote now; Product Exclusives
Machine design tips: Pneumatic or electric; Software upgrades; Ethernet advantages; Additive manufacturing; Engineering Leaders; Product exclusives: PLC, HMI, IO
This article collection contains the 5 most referenced articles on improving the use of PID.
Learn how Industry 4.0 adds supply chain efficiency, optimizes pricing, improves quality, and more.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Pipeline vulnerabilities? Securing hydrocarbon transit; Predictive analytics hit the mainstream; Dirty pipelines decrease flow, production—pig your line; Ensuring pipeline physical and cyber security