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A fully integrated process control system gives full batch traceability and scheduling – globally

Our client has more than 300 production sites worldwide. Running as a truly global organisation, orders are taken centrally and then scheduled in the plant best suited to fulfil the client requirement. The automatic scheduling takes into account factors including raw materials available, capacity, current and future loading, etc. One of the sites, making Polyurethane Resins had an old, bespoke and unsupportable control system which could not be connected to the global corporate system.

​Overview

Our client has more than 300 production sites worldwide. Running as a truly global organisation, orders are taken centrally and then scheduled in the plant best suited to fulfil the client requirement. The automatic scheduling takes into account factors including raw materials available, capacity, current and future loading, etc. One of the sites, making Polyurethane Resins had an old, bespoke and unsupportable control system which could not be connected to the global corporate system.

The Brief

The URS from the client included requirements for system resilience based on Siemens hardware and linked via middleware to SAP/R3 with a phased changeover to enable production to continue during the upgrade.

System Architecture

Scope of Supply

  • System Design
  • Functional Design Specification
  • PLC & Scada supply and programming
  • Control Panel Design & Build
  • System Testing including SAP/R3 link
  • Electrical Installation
  • System Commissioning
  • System Support

Scope of Services

  • Principal Contractor
  • Project Management
  • Site Survey & Drawing Verification

Key Features

  • Siemens S7-400H PLC with each processor housed in a separate room for increased resilience
  • Two independent WinCC Scada systems
  • Siemens OP45 Touch screens at each workstation for operator interaction
  • Ingredient verification via barcode scanning and loadcells
  • Whole system backed up by 8 hour UPS system
  • Redundant Profibus throughout
  • Resilient fibre ring Ethernet with Scalance managed switches
  • Seamless integration with existing plant
  • Process safety achieved via PLC

Value Added by Boulting

  • Extensive system simulation
  • Low risk upgrade philosophy
  • Whole scope ownership
  • Ongoing support

Download as a PDF here

 

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