Helping to ensure that this migration took place with minimal risk and within the deadline therefore required specific and diverse skills. This is where Rockwell Automation Global Solutions came in. Its specific knowledge of boiler management and experience in risk management were indispensable in this situation. The Rockwell Automation Global Solutions team carried out a retrospective analysis of the legacy system and defined a migration solution that was able to provide optimal boiler operation with minimal risk.
This solution centres round the PlantPAx process automation system, based on three redundant Allen-Bradley® ControlLogix® PACs and completely integrated into the factory's overall system. The boiler management specialists from Rockwell Automation adjusted the settings and sequential automation processes that were necessary for control and command of the combustion.
At the end of August 2009, just before the campaign was to start, the factory conducted a week-long "dry run", during which teams from the sugar factory and the Rockwell Automation team carried out adjustments and tested the loads. The final adjustments of the system could be made only at production start-up, and there was no room for error.
The first day of the campaign went without a hitch, and the increase in power was as predicted. Michel Hennebique, Manager of Electricity - Automation at the Boiry sugar factory gave his confirmation: "The start-up and commissioning of the boiler under Rockwell Automation went very well; in under two days all the adjustments had been made. And there wasn't a single stoppage throughout the entire campaign."
With two sugar campaigns now completed, Tereos is in a position to benefit from the improvements generated by the Rockwell Automation solution. And the Rockwell Automation Global Solutions team with PlantPAx system has proved its ability to replace the conventional DCS solution as well as its competitiveness as a solution of this type.
"Boiler control has been improved, in particular in terms of monitoring reheating; boiler output now reaches 96%. Boiler operation is also much more reliable than before. With the Rockwell Automation solution, it has also been possible to link the boilers together, and power matching is now carried out automatically by the PlantPAx system. The skill and unfailing support from the Rockwell Automation team throughout the project made all the difference", states the Boiry Manager of Electricity & Automation.