ITS & Honeywell’s TDC 3000 Improve Efficiency and Safety for a Chemical Manufacturer
Industrial Technology Systems Ltd (ITS) has worked with a chemical manufacturer to write the application code for a Honeywell TDC system to control their calciner and improve on-site safety standards.
The startup/shutdown of the calciner and startup/shutdown/changeover of the primary fans was automated by ITS’ engineers using a Honeywell TDC 3000 Distributed Control System. The functionality of the existing system was expanded to include the new automation software, which included database I/O, Interlock Logic, Process Calculations, Operator Graphics (GUS), and Sequence Code (BPO Format).
In addition a Honeywell TDC Fail Safe Controller (FSC) was included to handle the safety critical operations associated with startup, shutdown and normal running of the calciner. This now communicates with the sequence code and interlock logic to enable these to be changed to a safe state if the FSC detects a fault condition.
The new software has provided the operators with greater control. They are now capable of starting and stopping the calciner from the central control room. The calciner startup and shutdown has been automated using CL code in BPO format, enabling the operator to initiate startup and shutdown with a control sequence.
Air and steam purge sequences are now automatically set at the appropriate times, preventing the build up of potentially explosive mixtures in the calciner and keeping the fuel lines free of materials other than the main burner fuel.
Process graphics provide the operator with a dynamic graphical representation of the calciner for monitoring and control purposes, and safety critical operations are now controlled and monitored using approved hardware and logic.
Sequences are written in a standard format making the software easy to
understand for plant based technicians and engineers. Any additions or modifications needed at a later date can be implemented quickly and easily.
ITS’ project objectives were to:
- Provide the operator with the facility to start/stop the calciner from the central control room
- Develop an automated startup and shutdown of the calciner with suitable air purge and ignition sequences
- Design a facility to enable the operator to select gas or oil as the fuel for the calciner burner
- Enable the operator to select a primary fan prior to the calciner startup and initiate the primary fan automatic change over during normal running
- Interface to an approved fail safe control system for safety critical operations and monitoring
- Achieve successful communication between the Honeywell TDC 3000 and the Fail Safe Controller
Due to the functionality required and the size of the Honeywell TDC 3000 system, ITS developed a specific BPO message handler to include all of the operator messages required by the client.
ITS was involved in meeting the changing functional requirements of the client. The new change control procedure enabled the changes to be considered more thoroughly and configuration, testing and implementation carried out in a controlled manner, thereby keeping project costs and time scales to a minimum.
The project was completed within the time scales and budget. Commissioning was carried out without any problems with the software provided, due to the careful and thorough testing of the software using PICS simulation software prior to installation on the site system.
The customer is extremely satisfied with the solution and the service provided by the ITS' personnel. They also requested that ITS install and commission the software for the next calciner when a suitable shutdown window is identified.
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