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Plant InformationLocation: Huizhou, Guangdong Province, ChinaOrder date:April 2006Completion:March 2008Bridgestone (Huizhou) Synthetic Rubber Co., Ltd.CENTUM CS 3000 and Exaquantum PIMS Improve Production Efficiency at Chinese Synthetic Rubber PlantExecutive SummaryIn 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 SolutionsImproved information displayAt 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. Operation data management and analysisWith 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 processes7Success Story CollectionChemical (Fine & Specialty Chemical, Biofuel)& Pharmaceutical

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