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Replicated ESD Systems Cut Commissioning Time

ControlGlobal.com
12/02/2009

By Andrew Bond, Industrial Automation Insider

HIMA Paul Hildebrandt has upgraded the existing HIMA ESD (Emergency Shutdown) system at Lanxess' hexane oxidation plant at the Krefeld-Uerdingen Chemical Park in North Rhine-Westphalia, Germany. In order to fit in with the very short period for which the plant was to be shut down before commissioning, a Factory Acceptance Test (FAT) on the expanded and modernized safety system was conducted using a 1:1 replica of the system at HIMA's Brühl facility. All of the expanded system's functions were tested during the FAT, which was conducted in collaboration with staff from Lanxess and TÜV Süd Chemieservice and HIMA. As a result commissioning time was reduced to a minimum.

The plant produces KA oil, a mixture of cyclohexanone and cyclohexanol and a key intermediate in the production of thermoplastic, which is produced by the oxidation of cyclohexane. The role of the ESD system is to monitor limit values and control valves and to deactivate the reaction and relax the process in the event of a dangerous condition developing.
The existing HIMA system had provided reliable and fault-free operation since 1999, and the new project involved the addition of two new module racks and I/Os and the extension of the communications with the Siemens basic process control system (BPCS) through the provision of a Prefabs-DP connection.

Engineering Tool

As well as the incorporation of new central modules with larger memories, the project involved upgrading the ELOP II engineering tool, providing Ethernet-based communication with the engineering PC. The new ESD system handles a total of 936 safety-related I/O and consists of an H51q safety controller with nine I/O Module Racks (IOMRs), housed in two switchgear cabinets. Lanxess uses HIMA's Planar F, HIQuad and HIMatrix systems in its 44 plants all over the world.