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

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