In petrochemical manufacturing it''s very important to monitor the temperature and pressure of the air separation tower, compressor, heat exchange, rectification tower, and the vapor pipeline for the control room. When a petrochemical facility wanted to upgrade to a more reliable and efficient monitoring system, combining Advantech''s IPC-610 and ADAM-5000/485 modules proved to be the right solution to solve all of the company''s critical requirements.
System Requirements
For over 6 years, the customer had been using an out-of-date on-site monitoring system, which had the following issues:
- The system was inefficient, requiring a large number of employees to check the on-site data manually.
- The system was becoming unstable, and increasingly unsafe for employees to work with.
- The system was becoming unreliable, and experiencing increasing system failures.
- The facility was no longer satisfying production requirements, and maintenance costs were rising.
- The system had minimal communication ability, and required a synchronized database via the Internet.
System Diagram
System Description
The new monitoring system includes Advantech''s ADAM-5000/485, IPC-610, and KingView software from the system integrator. It monitors and records temperature and pressure in the air separation tower, based on RS-485 distributed ports. The ADAM-5000/485 contains two ADAM-5017 8-channel Analog Input Modules to detect pressure signals, and two ADAM-5013 3-channel RTD Input Modules to detect temperatures. The ADAM-4015 6-channel RTD Modules collect temperature signals below -200°C from field equipment. The ADAM-5000/485 collects all data from I/O modules and converts to the IPC-610 data server via the RS-232 communication port. This new system allows operators to monitor the data through a simple graphic display in the KingView software.
Conclusion
The purpose of air separation equipment is to separate nitrogen and oxygen for internal use. If it fails, an accident will occur; therefore, the monitoring system becomes very important to protect operations.
Compared to a PLC system, using ADAM-5000/485 with ADAM data acquisition modules is cost-effective. Operators can read field data in the central control room via the monitoring system without manually checking the data themselves. This reduces the time to review data, reduces labor costs, and lowers the risk of danger. Additionally, work efficiency is increased relatively.
Furthermore, all handwritten data records are replaced with digital data storage; now all data is stored in a data server, so that operators can retrieve it anytime from the new system.
Specifics of Project Implementation:
- ADAM-5000/485: 4-slot Distributed DA & C System for RS-485 Networks
- ADAM-5017: 8-channel Analog Input Module
- ADAM-5013: 3-channel RTD Input Module
- ADAM-4015: 6-channel RTD Module with Modbus
- IPC-610: 4U 14-slot Rackmount Chassis with ATX Motherboard Option
- KingView software from System Integrator