Hot water air cooling unit in a first zone of the LDPE reactor

Development: September 2022 – November 2022
Implementation: June 2023

Facility description:
A hot water air cooling unit control system for a first zone of the ethylene polymerization reactor. Integration into the existing APCS.

Works performed:

• Inspection of the facility, collection of initial data
• Development of design and detail design documentation for the APCS according to the requirements specifications
• Development of application software for PLC and SCADA
• Installation, start-up and adjustment
• Personnel training on the system operation
• Putting into trial operation
• Elimination of identified deficiencies
• Putting into commercial operation

Hardware and software main specifications:

• Upper level: SCADA system WinCC
• Lower level: ABAK-K2 and SIMATIC S7-417H controllers.
• Industrial Ethernet field bus.
• Data exchange with a local control system via Modbus RTU protocol.

Project features:

— Works at a hazardous production facility were performed while the existing equipment was in operation.
— Integration of the existing APCS based on the SIEMENS controllers with a new air cooling unit control subsystem.
— Precise process control with the use of frequency converters.
— Data transmission to the enterprise’s MES.