Transforming a Hazardous Agro-Chemical Plant with Advanced DCS System
About the Client
A respected producer of high-quality chemical intermediates serving both domesticand
international markets. The company is recognized among 40 Indian firms awardedthe
Responsible Care logo for their commitment to safety and environmental responsibility.
Requirements
The client was setting up a
Greenfield hazardous chemical plant and needed a complete
control system for:
• Hazardous reactors,
including hydrogenation reactors
• Multi-effect evaporators
• Tank farms
• Integrated iMCC and
package units for boilers and spray dryers
They were focused on
improving safety and enabling plant-wide SMART monitoring.
- Delivering a complete DCS solution with seamless connectivity to the iMCC
- Ensuring the system was scalable to support a common programming platform for all package units
- Improve operator efficiency and visibility
- Understanding chemical-industry processes well enough to build and deliver the solution accurately and on time
- Participating in the HAZOP study to create safety loops and alarm management within the control system for hydrogenation and other hazardous operations
The Challenge
The project required addressing several critical challenges:
The Solution
- MIPL team designed, engineered and implemented integrated architecture PlantPAx system.
- i. 2600 remote I/Os in zone-2 area with high speed and high available Ethernet network.
- ii. iMCCs with 450+ feeders (Relays, Soft Starters, and AC Drive)
- Delivered SMART operating stations for operational & maintenance solution.
Key Outcomes
Real-Time Visibility
The integrated architecture and high-speed Ethernet network provided plant-wide monitoring and improved transparency.
Enhanced Safety
Strong safety features were built into hydrogen reactors and other hazardouso perations.
Faster Decisions
Centralized data helped operators make informed choices quickly.
Improved Quality
The DCS system supported consistent batch quality and optimized the use of plantassets and utilities.
Why the Client Chose MIPL
Proven Experience
Over 30 years
of experience in automation and control systems with a strong track record of
successful projects.
Industry Knowledge
Deep understanding of the chemical industry helps us build and deliver solutions thatwork right the first time.
Safety & Precision
Specialized expertise in safety studies and alarm management for hydrogen reactorsand other hazardous processes.
Delivering Results
Consistent track record of improving efficiency, quality, and delivering projects on time.