Migrating the Automation System of a Textiles Chemicals Plant

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CHT’s process sequences are much easier to analyze with Aprol. TrendViewer and AuditTrail now permit analysis of processes that could not be observed with previous solutions. The Aprol process control system stands out CHT formed a team of experts to perform an in-depth evaluation of three different process control systems, as well as control and HMI solutions from two bidders, based on an exhaustive matrix of specific criteria. In the end, B&R came out on top.

For Schätzle, the arguments supporting this decision were clear. “One of the decisive factors was that B&R’s Aprol—in contrast to the other very well known, widely used systems we evaluated—provides optimum support for stepwise migration. Aprol allowed us to move our production stations successively to the new process control system while keeping the old systems running in parallel.”

The CHT experts especially valued the newfound independence from Windows. B&R’s process control and HMI technology is based on Linux and the structure of the process control system is remarkably clear and intuitive. B&R’s finely graduated selection of control and HMI products has allowed CHT to match the performance of each system’s PLC to its requirements, as well as equip each system with a unique lineup of I/O modules and its own HMI unit. It was this flexibility that led the chemical producer to rely on B&R for control and HMI in addition to the process control system.

One Controller for Each Station

“The advantage is that we can mirror the actual system structure directly in the control and HMI technology, which helps us implement the stepwise migration perfectly from a hardware perspective,” explains Schätzle. He continues, “Another argument in favor of a single source solution is the lack of problems with interfaces and communication.”

Schätzle concedes that a solution from a large German control supplier would have also allowed CHT to equip each of its stations with a separate controller. “Yet this would have been possible only in a roundabout way or with the aid of a soft PLC, both of which were out of the question for us,” he explains.

The CHT manager sees very few disadvantages to switching suppliers for its process control system and control technology. “We would have had to rewrite a significant portion of our software anyway since 50 per cent of the code we have accumulated over the years is now unused, which would make reusing the software virtually impossible.”

A Cost-Competitive Approach

From a cost perspective, Schätzle sees little difference between the solutions evaluated. “There were some considerable differences in the offers we received from systems integrators,” says Schätzle, “yet the price estimates for the respective process control solutions varied by no more than 20 per cent.” This is owing to the strong decentralized structure of the production stations, which can be represented ideally by the distributed structure selected for the process control system. “Aprol allows us to monitor and document our processes, giving us clearer insight into the complex interrelationships,” says Schätzle.

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