Reinstrumentation Project at HDPE Plant to Replace Legacy Pneumatic Instruments and PLCs with Integrated CENTUM CS 3000 PCS and ProSafe-RS SIS

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Executive Summary

IRPC-HDPE, Rayong, Thailand
Reinstrumentation Project at HDPE Plant
to Replace Legacy Pneumatic Instruments
and PLCs with Integrated CENTUM CS 3000
PCS and ProSafe-RS SIS

Integrated Refinery and Petrochemical Complex Public Co., Ltd. (IRPC) in Rayong, Thailand has a refinery (215,000 B/D) as well as several petrochemical plants that produce chemicals such as olefins (360,000 t/y) and aromatics that are used as feedstock at various types of plastics plants. One of these facilities, a 152,000 t/y high density polyethylene (HDPE) plant, relied principally on legacy pneumatic instruments and a PLC based safety system. (Some of the pneumatic instruments had been replaced with single loop controllers.) Due to high maintenance costs and the need for higher efficiency and productivity, IRPC decided to revamp its plants by installing new control systems and instrumentation based on the latest technologies.

Through the course of this project, Yokogawa Thailand successfully installed a fully integrated CENTUM CS 3000 production control system (PCS) and ProSafe-RS safety instrumented system (SIS) together with a plant information management system (PIMS) and an asset management system (PRM).

Customer Satisfaction

Phadet Prarom, PD11 Division Manager, said, "We are now very comfortable operating the HDPE plant and are experiencing no major problems with Yokogawa's systems. Yokogawa's systems and products are highly reliable." He went on to say, "We actually reduced the number of operators after introducing the PCS. The integrated production control system is functioning well. We are proud of our new control room, the brain of a VigilantPlant."

About HDPE

Marketed under the POLENE trademark, this polymer resin features properties such as high density, high stiffness, high impact strength, opacity, and good chemical resistance. HDPE is used in a variety of applications including consumer packaging, beverage bottles, pipes, and ropes.

The Challenges and the Solutions

The biggest challenge was applying the latest digital technology. Digital and pneumatic systems are fundamentally different in design and function.

It took about five months to do a detailed study of all the control loops and configure the production control system, and another month to do all cabling/wiring and systems installation. In addition to the wiring of about 5,000 I/O points for the new systems, some field equipment was replaced.

At the same time, operators underwent training in the new PCS at Yokogawa's Rayong office and engineers and maintenance personnel went to Yokogawa's Bangkok office for training in system configuration using feedback and sequence control functions. Yokogawa Thailand provided customer support from start to finish of this reinstrumentation project.

To improve safety, the ProSafe-RS SIS was installed to give the polymerization process an emergency shutdown capability, and the SIS was integrated with the PCS. With this system, every point in the SIS can be monitored from the human machine interface (HMI) in the same manner as the PCS. In addition, all PCS and SIS HART field devices can be monitored from the central control room with the Plant Resource Manager (PRM) package, enabling a more predictive and proactive maintenance approach that reduces total cost of ownership (TCO). Also, all process data can be handled in an integrated manner by the Exaquantum PIMS for improved product quality and system operation.

Through solutions such as these, Yokogawa Thailand is working with its customers to help them achieve a VigilantPlant.

Then (pneumatic panel) and Now (PCS/DCS)

Related Products & Solutions

안전 계장 시스템 ProSafe-RS (SIL3)

ProSafe-RS는 IEC 61508에 명시된 SIL3 (Safety Integrity Level)를 충족하기 위해 독일 인증 기관 (TÜV)에서 인증받은 안전 계장 시스템입니다. 대규모 통합 공정 자동화 프로젝트뿐만 아니라 독립 구성 솔루션에 이르기까지 2,400개 이상의 프로젝트를 수행하였습니다.

분산 제어 시스템 (DCS)

Yokogawa는 프로세스 자동화를 위해서 중요한 운영 인프라를 제공합니다. 분산제어시스템(DCS)은 플랜트 또는 산업 공정의 자동화 된 제어 및 운영을 위한 플랫폼입니다. 10,000개 이상의 플랜트에서 고객의 생산 목표 달성하기 위해서 Yokogawa DCS가 적용되었습니다.

안전 계장 시스템 (SIS)

안전 계장 시스템(SIS)은 사람, 환경 및 자산을 보호합니다. Yokogawa의 SIS 및 관련 안전 솔루션은 비상 정지, 화재 및 가스, 버너 관리 및 HIPPS의 애플리케이션에 널리 적용할 수 있습니다.

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