CENTUM CS 3000 and Exaquantum PIMS Improve Production Efficiency at Chinese Synthetic Rubber Plant

Bridgestone (Huizhou) Synthetic Rubber Co.,Ltd. logo
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Executive Summary

Bridgestone (Huizou) Synthetic Rubber Co.,Ltd., China
Bridgestone (Huizhou) Synthetic Rubber Co.,Ltd., China

In response to growing global demand for synthetic rubber, the Bridgestone Corporation has built a synthetic rubber plant at the Daya Bay Petrochemical Industrial Park in Huizhou, China. The new plant is operated by the Bridgestone (Huizhou) Synthetic Rubber Co., Ltd. (BSRC), and the high-quality synthetic rubber produced there is mainly used in top-of-the-line automobile tires.

At this plant, which has raw material (butadiene and styrene) storage tanks and other facilities, synthetic rubber is produced through continuous and batch processes that include the adjustment of additives, polymerization, styrene recovery, blending, and drying.

The batch processes are controlled by a production control system (PCS) that normally receives certain parameters from a production computer system, but is designed with the capability to control all production operations in an emergency.

To control operations at this plant, Yokogawa installed its CENTUM CS 3000 and an emergency shutdown system based on the STARDOM network-based control system. The company also installed an Exaquantum plant information management system (PIMS) for the collection and analysis of process data and a simulator that is used to train plant operators.

The Challenges and the Solutions

1. Improved information display
At first, operators at this new plant had to scan three different human interface station (HIS) screens, but it was found that they sometimes missed important alarms when multiple alarms were issued. The decision was made to install one large screen in front of the HIS terminals, allowing operators to see at a glance important alarms and trigger an interlock sequence in a timely fashion. On this screen, four windows display process alarms, operator guidance messages, important annunciators, and important interlocks.

During plant commissioning/Today

2. Operation data management and analysis
With continuous processes, it is important to have up-to-date information. To improve the collection of process data, Yokogawa installed the Exaquantum PIMS. To improve access to that information so that production decisions can be made more quickly, it also placed client terminals at multiple locations around the plant and connected them via a local area network. This PIMS accomplishes the following:

  • Reduces operator workload by automatically generating daily reports
  • Facilitates troubleshooting and quality improvement activities by outputting trend   data when a malfunction occurs
  • Makes possible a more proactive maintenance approach by generating data on   operation time and number of batch campaign
  • Provides data on long-term trends needed to make improvements to plant processes

3. Training system
A Yokogawa plant simulator was installed to give operators the training needed to ensure a quick and smooth plant startup. The training system features the same functions, database, and graphic displays as a standard CENTUM control system, and is used to bring new operators up to speed on plant operating procedures as well as provide periodic refresher training to veteran operators. This system is also used to carry out simulations to verify software modifications.

4. Sustainable manufacturing
Many kinds of environment-related data have to be carefully monitored using the CENTUM CS 3000's alarm and trend functions. The data is strictly managed and monthly reports are submitted to the local government. In compliance with government regulations, power consumption data from a motor control center as well as data on steam consumption and industrial water usage are monitored to reduce energy consumption and implement sustainable production processes.

Customer Satisfaction

"Thanks to Yokogawa's highly reliable CENTUM CS 3000 production control system, we have complete confidence in our ability to operate this plant."

"By having clear access to all kinds of process data, our plant operators now have an up-to-the-minute understanding of what is going on with a process and can take quick and decisive action."

"We are always looking to make improvements in production processes and product quality, and seek to improve production efficiency using the data from both the system and laboratory data. We plan to repeat the PDCA activity cycle based on Yokogawa's platform."

行业

  • 化工

    化工厂依靠连续和批量的生产过程,每个生产过程对控制系统都有不同的要求。连续的过程需要一个强大而稳定的控制系统,该系统不能因为自身失效而导致生产线关闭;批量过程的重点在于拥有一个可以灵活调整公式程序的控制系统。两种系统都需要在产品质量记录中进行管理,并且能够执行非常规操作。横河电机凭借广泛的产品组合、经验丰富的系统工程师、遍及全球的销售和服务网络,为每个工厂流程提供解决方案。

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  • 特种和精细化工

    横河电机长期以来一直为特种和精细化工的客户提供服务。我们拥有可为您提供卓越可靠性和灵活性的批量解决方案,同时我们还有在设计批量解决方案时可应对各种复杂要求的行业专家。我们承诺与横河电机的合作伙伴关系期间,确保您能够在保证安全和遵从法规的前提下,生产满足客户需求的产品。

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相关产品&解决方案

  • 数据记录系统(Exaquantum)

    Exaquantum可以从过程工业的各个方面获取过程数据,并转换为易用、高价值、广泛发布的信息。Exaquantum是横河电机大多数OES的基础。

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