Automation Systems Improving Performance: A New Automation System Helps to Improve Production Capacity
Improving production capacity with minimum turnaround time: Honeywell Experion PKS replaced 25-year-old technology at Kribhco Ammonia Extension Plant in Hazira, India, in a record time of 25 days.
India-based urea, ammonia and fertilizer manufacturer Krishak Bharati was revamping its ammonia extension plant in Hazira, Surat, to increase availability of the control system during production. The facility was challenged by old technology that was holding back its performance. The plant was running on a 25-year-old system, and decided a key step in the ammonia expansion project, i.e., to replace the old technology with new controllers and an advanced process knowledge solution.
The company decided to implement the Honeywell Experion Process Knowledge System (PKS) with a C300 Process Controller using Process Manager Input / Output (I/O) module solutions and Safety Manager at the Hazira facility. Lack of reliability with the existing system caused frequent plant stoppages and affected productivity.
The Goal: Fast Automation Implementation with Minimal Turnover Time
A key goal that was met was the fast, efficient implementation of the Experion PKS solution with a minimal shutdown period of 25 days. Additional benefits included:
- Improved plant performance and production capacity
- Stable plant operations and reduction in plant idle time due to elimination of unwanted trips
- Reduction in spare part inventory requirement
- Lower maintenance costs
- Improved energy efficiency
- Eliminated ghost tripping.
Background of the Kribhco Plant
Headquartered in Noida, Krishak Bharati Cooperative (Kribhco) is an Indian cooperative society that manufactures urea, ammonia bio-fertilizers and other chemicals. It has a manufacturing complex in Hazira near Surat with three boilers, two steam generators, two ammonia plants, four urea plants and an ammonia extension project.