Petrochemical complex reaps

Paul Boughton

The complex also manufactures 100percent of the country’s polyether, which is used mostly for plastic auto parts.
Because of the age of some of the facilities and the complexity of the processes, production must be continually monitored to ensure high-quality product. Before the new upgrade, all NKNH plants were controlled by a locally designed system.
“We had to have several very experienced technologists constantly watching over the process,” said Damir Gizatullin, chief instrumentation engineer.
However, Emerson’s PlantWeb digital plant architecture has already been installed and activated in two of the plants, resulting in improvements of 12percent in productivity and 5percent in yield. Overall plant reliability is better too.
“Since the installation of PlantWeb, we have much better control. Our technologists are able to start up the plant and walk away to perform other duties,” added Gizatullin.
PlantWeb enables NKNH to run plants with reduced supervision by delivering more complete and intelligent digital automation, using the latest technologies in field devices and easy-to-use operations and maintenance stations. The architecture continuously monitors the processes and the instruments themselves, providing alerts and guidance when and where needed to enable highest efficiency by those running the plant.
The polyether plant, which had previously experienced quality issues that resulted in a nearly five per cent rejection rate, has had no rejections or quality issues since installation of PlantWeb. Productivity at the styrene plant has improved by 12percent.
PlantWeb integrates intelligent digital field devices with modular hosts, including the RS3 distributed control system for the initial project, and the DeltaV digital automation system for current and future projects.
AMS Suite predictive maintenance software is included. The field-based architecture is connected by information rich HART or FOUNDATION fieldbus communication protocols, capturing and delivering critical operating information about the instrumentation, process equipment, and the process itself.
Over 95percent of all instrumentation was supplied by Emerson and includes Micro Motion Coriolis flowmeters, Rosemount pressure and temperature transmitters and Fisher FIELDVUE digital valve controllers (DVCs). The DVCs were fitted to existing control valves.
Productivity improvements have been made possible on the styrene plant due to the improved accuracy of the control; this was brought about through the use of the Emerson field equipment including Micro Motion flowmeters and FIELDVUE DVC digital valve controllers. The technologists now feel comfortable filling at a steady rate, knowing that the reactor will fill faster, that the ratio of raw ingredients will be correct and that the product will meet the required quality level. This has enabled a reduction in the time taken to produce a batch from 14-6hours to 12-14hours.
All of the field instrumentation communicates via HART digital communications protocol with Emerson’s AMS Suite: Intelligent Device Manager software. The AMS Device Manager software is being used by technicians to diagnose device faults within the field equipment, as well as to perform calibration and functional checks.
The intention is to expand the usage by carrying out further training for additional technicians; this will enable cost savings in maintenance by implementing predictive maintenance practices.
“We are pleased that our global organisation and local Russian engineering support, combined with our innovative technology, are already assisting NKNH with significant operational improvements, and we look forward to even more in the upcoming projects,” said John Berra, president of Emerson Process Management.
An upgrade to the polypropylene plant is the next planned project. PlantWeb architecture will use FOUNDATION fieldbus digital communications technology for the polypropylene plant upgrade, enabling expanded savings due to the even more robust predictive diagnostics in FOUNDATION fieldbus environment.
Additionally, fewer instrument drawings are required, less space is needed in the control room, less cabling is required, and commissioning takes less time. Additional projects have been identified and are currently going through the NKNH project approvals process.