Improving Performance: A New Automation System Helps to Improve Production Capacity

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The Challenge: Replacing an Ineffective Automation System

The Kribhco ammonia extension plant was running a 25- year-old system with hardwired logics. The technology was outdated and the system was missing key functionality. There were also no soft records for events such as alarm management or storage facility history. “Our control system was very outdated, and finding expertise to troubleshoot issues was very difficult,” said B.R. Patel, General Manager at the Hazira plant.

“Spares were very costly, so we were spending more money on maintaining an inventory. The technology was old, and when we made attempts to update the system, it was very difficult to implement modifications,” added Patel.

Seamless Integration of New Automation Systems

Solution offered by Honeywell Kribhco chose to team up with Honeywell Automation India for the challenging project of the complete replacement of the existing legacy system and hardwired cause and effect circuit. The choice was to install Honeywell Experion PKS with C300 Controllers and SIL3 TUV certified Safety Manager as an ESD system.

The entire system of approximately 5,000 I/Os was ripped out and replaced with 3500 I/Os of the DCS and a 1500 I/O safety system in a record time of 25 days using a “First Time Right Approach” in all aspects. The seamless integration of the Experion DCS with the ESD helped in significantly reducing I/O requirement.

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