System Title

Automated Control System and Emergency Shutdown of the Second Process Line for Formaldehyde and Carbamide Formaldehyde Concentrate at FiKS Plant.

Purpose of System Development

Replacement of existing automation system with a new modern one during the upgrade of the unit.    

Description of Automation

The following equipment was to be automated:

• Storage tanks
• Switching device
• Chemisorber
• Absorbing tower
• Turbo blowers TB-80
• Alcohol evaporator
• Heat exchangers
• Mixers
• Pumps
• Batching devices

System Functions

• Collection, registration and storage of data transferred by primary sensors and devices
• Monitoring of process parameters and control of operation modes in order to support relevant parameters
• Light alarm (warning and emergency) when process parameters exceed preset limits, based in microcontroller MK-05 manufactured by SME TEC
• Data protection from unauthorized access
• Self diagnostics, issue of messages on failures
• Displaying process progress on mnemonic diagrams
• Displaying parameters in text or graphic format
• Displaying on work stations the extreme positions electrically actuated valves
• Pre emergency alarm based on warning parameters, identifying the explosion hazard on the facility
• Failure free transfer of the process equipment into safe state in all modes
• Automated emergency protection

Design

PCS system is based on electronic control and automation devices (screen registrators, program regulator, digital indicators by JUMO).ESD system is based on Modicon Compact by Schneider Electric. The upper level of the system is based on SCADA In Touch by Wonderware.