How a Chemical Plant Increased Output by 7% with a Complete Automation Upgrade
About the Client
The client is a well-known Indian chemical manufacturer, recognized for developing indigenous technologies and strong waste water management practices.
Requirements
The client needed to automate a complex facility that included multiple reactors,distillation units, ATFD, FFE, and tank farms. Because the plant handled toxic and hazardous chemicals, the automation system had to be designed with great care,ensuring safety at every step.
They also needed:
They also needed:
• Safe operation planning through HAZOP studies
• Proper alarm management to handle the risk of runaway reactions
• Accurate control of temperature, pressure, charging, and batching
• Correct selection of instruments suitable for harsh chemical environments
• A smooth installation plan with minimum plant downtime
• A network structure that could support future plant-wide and ERP connectivity
The Solution
- MIPL began by understanding the plant’s process needs and studying the variations inproduction and quality. Based on this, the team designed a clear and structured automation strategy along with updated SOPs to support smooth implementation.
- They then installed a PlantPAx system with high-performance HMI displays aligne dwith ISA-101 standards to make plant monitoring easier and more intuitive foroperators.
- To strengthen safety, MIPL also implemented an alarm management setup following ISA-18.2 guidelines, helping the plant respond to issues more quickly and effectively.
- Finally, the operations team received hands-on training to ensure they could run the upgraded system confidently and maintain consistent performance day-to-day.
Key Outcomes
7% Increase in Output
With improved control and smoother operations, the plant achieved a noticeable rise in production output, helping them meet demand faster.
Higher Safety Standards
Safety interlocks and structured alarm management reduced operational risks and improved the working environment.
Better Quality, Every Time
Consistent process control helped the plant achieve “first-time-right” quality more reliably.
Minimal Shutdown
The entire upgrade was completed within a short shutdown window of less than 15days, avoiding production loss.
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Why the Client Chose MIPL
Strong Safety Understanding
Experience in handling HAZOP studies and integrating the right safety features forhazardous environments.
End-to-End Expertise
From instrumentation and control systems to installation and commissioning,everything is managed under one roof.
Built for Tough Conditions
Deep knowledge of handling processes involving toxic chemicals, high temperatures,and highly congested plant layouts.