Case Studies

1) Pemex Safety and Control Solutions (pdf)

Pemex is improving control and safety systems in all its plants and continues to build new facilities. It has support from ABB in all areas of control, safety, instrumentation and power, in each of its subsidiaries. ABB's Analytics, Instrumentation and Services solutions are also utilized by Pemex.

2) ProcessLogix Ensures Super-efficiency at Alphaolefins Plant (pdf)

The main problem with the legacy control system was that it had no feedback nor any human machine interface (HMI) monitoring system. Since annunciator panels did not always work, operators were not notified when problems arose.

With the pneumatic system, even charging a reactor was an adventure. The operator would open the necessary valves from the control room, then go out into the plant with a hammer or a crowbar. After checking to see if all the valve indicators were in the proper position, the operator used the crowbar to open sticky valves all the way and check levels in the reactor vessels with a sight glass.

A chart on the control room wall listed optimum values for charge time, oxidation times, and fill rates, but the operators had no way of monitoring these parameters. " On our best days, we operated at about 75% of capacity," says the alphaolefins plant site engineer. " With a rework rate of about 30%." Sometimes the bad batch could be reused but, in many cases, the reactor vessel had to be shut down.

3) Prompt Support Reduces Development and Start-up Time or Gas Authority of India Limited (pdf)

To further enhance its competitive edge, GAIL wanted to introduce two new production technologies at a new mega plant designed to augment production of its principle products, HDPE and LLDPE. Both are downstream petrochemicals used in the production of various plastic end products.

Market attraction would be augmented by the new plant's location, the first located outside the western part of the country, making it especially convenient for polymer consumers in Northern and Central India.

The plant would become a world-class gas cracker facility with a capacity to produce upwards of 500,000 tons per annum of ethylene, which would translate into 100,000 downstream units of HDPE and 160,000 units of LLDPE/HDPE annually.

4) Conoco Phillips Petroleum Saves Capital Costs and Energy with Medium Voltage Drive Solution (pdf)

Flexibility was key in choosing the station operating mode. Because the crude oil either originates out of tankage into the existing pipeline or is blended into the crude oil flowing upstream, the station pumps a wide range of crude oil types at various flow rates, viscosity and density. There were five different pumping scenarios to be considered. It was important to Conoco to reduce the number of pumps and motors necessary and not have excessive throttling. All these items would affect initial capital costs, energy efficiency and the corresponding long-term costs. Time constraints were also a big challenge, as the station had to be complete and fully running within 12 months.

To provide the right solution, Conoco turned to Rockwell Automation. The Rockwell Automation team worked to find a motor and control solution that was both economical and flexible.

5) PowerFlex 7000 Drives Oil Pipeline (pdf)

The challenge to increase oil volumes in the pipeline includedlarger pumps and therefore the installation of higher horsepower drives, all to be completed in a bare minimum shutdown time.

While the expansion is estimated to save the customer $5 million (Cdn) annually in transportation expenses, the cost of shutting down the pipeline was approximately $750,000 (Cdn) per day at full capacity. An efficient and economic installation required leading edge technology and experience, while keeping the pipeline in production.

6) Nuclear Scientist choose PSS programmable safety system (pdf)

A new Australian Nuclear Science and Technology Organisation (ANSTO) experimental facility uses five Pilz PSS programmable safety systems to protect scientists working in five separate safety zones. The overall system provides a high level of safety and conforms to the necessary standards, yet it performs its task unobtrusively.