Automation upgrades drive plant expansions

Paul Boughton
All sectors in the process industry are investing heavily in new plant management technologies, particularly to drive plant expansions.

Honeywell has announced two new contracts in the paper sector. In the first, it has been selected by Casa Editorial El Tiempo to upgrade its current Printa press automation system as the company seeks to take full advantage of the growth of the thriving South American newspaper industry. As a result of the upgrade, the main newspaper publisher in Colombia and the owner of El Tiempo, the largest circulation newspaper in the country, expects to increase its production capacity and substantially reduce costs at its printing facilities in Bogotá and Caloto.

Automation systems

In contrast to Europe and North America, South America is experiencing increases in newspaper circulation advertising revenue, driving growth for printers and publishers and increasing demand for quality automation systems and process control upgrades to manage the expansion.

Honeywell Process Solutions (HPS) will upgrade El Tiempo's Printa press control systems to the latest Profibus technology as well as update the existing controllers on El Tiempo's Goss Newsliner and Universal press lines. In addition, HPS will modernise the Printa systems' control desks and HMIs with Windows 7 operating system support, upgrade the Printa production management system and extend the Goss Universal press with ink pre-setting. These solutions will help Casa Editorial El Tiempo more easily and efficiently control the printing process, reduce waste and increase quality in every print run.

"Honeywell has enabled a smooth upgrade in what is a highly complex and strategic undertaking for our business. By minimising disturbances to the production process, they have allowed us to improve our current system with little impact on our daily operations," said Ubaldo Vidal, operations manager, El Tiempo. "We've had great success using Honeywell technology in the past, which is why we chose them to undertake the new upgrade as it means a gradual implementation, allowing delivery to be extended over four years, which has a beneficial effect upon our cash flow."

"The modifications we are making to El Tiempo's production process will ultimately allow it to get more papers into people's hands with greater efficiency and with less cost," said Marko Jämsén, leader of HPS's pulp, paper and printing business. "In the current economic climate it's of extreme importance that facilities improve the utilisation of their resources. Advanced process control technology such as the Printa system can help drive down costs and improve the bottom line."

Meanwhile HPS has also been selected by Kahramanmaras Kagit Sanayi ve Ticaret (KMKPAPER) a leading Turkish paper manufacturer, to deploy its Experion MX quality control system (QCS) and Experion Process Knowledge Control System (PKS) at a new paper mill based in Kütahya, Turkey.

The facility, which is due to be completed in May 2012, will produce de-inked newsprint, as well as printing and writing paper. The Experion PKS system will support trouble-free start-up and maintenance, while the Experion MX QCS will be used to monitor consistent paper quality using constant measurement of all critical variables to meet the high standards demanded by the customers.

HPS has been chosen due to its expertise, knowledge and experience in developing accurate, high speed measurement and robust quality control systems. Together, this helps Kahramanmaras Paper reduce the amount of downtime and scrappage, allowing the company to provide customers with consistently high quality products.

Muhammet Ciger, vice president, Kahramanmaras Kagit Sanayi ve Ticaret, commented: "With investment budgets tight and demand for quality steep, we needed to deploy a solution with the ability to provide us with the latest technology and state-of-the-art control in one integrated system and at an acceptable price. Honeywell was able to give us that as well as provide strong local service."

Honeywell's Experion systems help Kahramanmaras Paper produce high quality paper grades using only recycled stock without the need to add virgin pulp. The integrated control system also allows the pulping and papermaking processes to operate at maximum efficiency, optimising energy and raw material usage.

"Kahramanmaras is the latest in a line of manufacturers realising the overwhelming benefits and potential that integrated control systems can bring to their facilities." said Orhan Genis, vice president sales, EMEA for HPS. "This will allow them to produce high value-added paper grades with recycled pulp using less energy and raw materials and positioning this new facility to be more efficient and profitable," he concluded.[Page Break]

Number one in HMIs

Invensys Operations Management has achieved the number one market share position as a global provider of human machine interface (HMI) software and services in a recent ARC Advisory Group market study.

The report affirms the market share-leading position of the company's Wonderware InTouch and ArchestrA system platform software products for use in HMI, supervisory and Scada applications.

"We are thrilled to see the results of our accelerated focus on the HMI market, and we sincerely appreciate the recognition we have received from the ARC report. As a primary source of market data and analysis, their findings greatly validate the customer acceptance we are gaining," said Rashesh Mody, senior vice president of software and advanced applications for Invensys Operations Management.

He added, "Our active installed base for HMI is approaching 700 000 licenses, and for more than two decades, many of our customers have upgraded and migrated their applications to take advantage of new capabilities with just a few simple mouse clicks. We are proud that our offerings continue to address three key efficiencies - engineering, IT and operations - that help our customers empower their people and achieve real-time operational excellence."

According to Craig Resnick, research director for ARC Advisory Group and author of the recent study, "Invensys Operations Management has a multi-faceted strategy to enhance its market position, as well as to further its InFusion enterprise control system concept.

The company continues to update its Wonderware InTouch and ArchestrA system platform product lines and is placing strategic emphasis on the Scada and geo-Scada arena, which is reflected in the functionality delivered by the latest release of its software products."

Resnick added, "By being object-oriented, ArchestrA System Platform enables end users to pilot applications, and due to the scalability of its architecture, they can grow these pilots into large-scale implementations with minimal re-engineering.

Managing standards and change is also inherent to the architecture, so an HMI software application, or even just an element of the application, can be changed once and rolled out to multiple end users, helping end users achieve real-time business optimisation."[Page Break]

Oil platform

Finally, the Azerbaijan International Operating Company, operated by BP, has awarded Emerson Process Management a multi-million-dollar contract to automate a new offshore oil platform in the Azerbaijan sector of the Caspian Sea.

The Chirag Oil Project, to be completed in 2013 and operated by BP Azerbaijan, will enable additional oil to be recovered from the Azeri-Chirag-Guneshli field.

"We welcome the opportunity to work with BP Azerbaijan on this important project," said Steve Sonnenberg, president, Emerson Process Management. "We look forward to applying our automation technology, our experience managing offshore projects, and our local support capabilities to help make the Chirag Oil Project a success."

Digital plant architecture

Emerson is the main automation contractor for the project and will deliver a variety of technologies and services. The company's PlantWeb digital plant architecture - including Foundation fieldbus communications, digital automation systems, asset management software, and intelligent field devices - will provide process control and access to management information.

Its network of intelligent transmitters and valve positioners will deliver continuous process and equipment health information to identify potential problems before they affect operations.

Emerson also will provide project-management services to ensure the equipment is properly installed and integrated to meet technical, budget, and schedule requirements. Support for the Chirag Oil Project will be provided by Emerson Process Management's Azerbaijan office in Baku.

Development of the Azeri-Chirag-Guneshli field is managed by the Azerbaijan International Operating Company, a BP-operated consortium of nine oil companies.

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