Our client is one of the Country’s early chemical manufacturers. Since their establishment, they have achieved hundreds of chemical process innovations, consistently contributing to technological know-how advancement.

Requirement and Objective

• They approached Master Integrators to integrate a fully equipped automation system design besides the supply of PlantPAx for their multiple chemical manufacturing plants.
• We implemented the Control System Solution (Automation) to three significant areas at the plants:
  1. Control System Solution at Multiple Hazardous Reactors
  2. Control System Solution at Distillation and Agitated Thin Film Dryer (ATFD) Units
  3. Control System Solution at Falling Film Evaporator (FFE)

Solution:

• We understood the process requirements with detailed study of production and quality variations. Along with this, we created a new automation strategy with SOP towards the derivable for the automation solution.
• We installed PlantPAx solution with high performance HMI as per ISA 101 standards and safety management system as per 18.2 Standards.
• Alarm management solution as per the necessary standards and guidelines was also implemented.
• We provided training to the operators using emulators to ensure smooth operations.

Result:

• Project completion with minimum shutdown
• Faster response time
• Increased safety due to safety interlocks and alarm management based on ISA 18.2 standards
• Consistency in quality output
• Increase in production output by 7%
• High return on investment