Bashkir soda company (Wonderware InTouch)

Scope / process Process optimization of production of the calcinated soda, cutting of costs for production of one ton of finished goods due to decrease in losses of principal components of raw materials in the course of their processing and increase in allocation efficiency of balance sheet loading of production^[1] .

Main objectives of a new system

• Automatic collecting, processing and information display from accounting points in a graphic and tabular style in real time;
• Manual entry of values from points on not automated metering stations;
• Control of the accuracy of the information arriving from sensors and systems;
• Registration and information storage about controlled parameters;
• The sound and visual alarm about technology and system violations;
• Submission of the current information to operation personnel and other users in the form of symbolic circuits, operational and reporting documents, diagrams, etc.;
• Automatic calculation and representation of raw balances (including instant) on each repartition;
• Operational regulation of balance sheet loading proizv (10-30 offers) odstvo;

System concept

At a stage of preproject inspection, after assessment of scale of a scope of necessary points of control, the decision to break project implementation into stages was made. The stage – "The crude and cleaned brine" became first of which. During preparation of the concept and structure of a system, specialists of "BSK", in close cooperation with Klinkmann company developed the specification of the project. Then, the development team was trained in the center of preparation "Klinkmann".

The simplified concept of creation of a server part, with the subsequent transition to technologies of virtualization was the basis for implementation of the first stage.

The technical advantages got in result of application of the new products Wonderware

As a result of project implementation specialists of JSC BSK got such advantages as:

• a common information space within all production;
• the model which is visually describing structure of all production;
• ease of integration of already existing automated systems of production;
• uniform multi-user object-oriented development environment, deployments and maintenances of a system;
• high-performance database of real time;
• client-server architecture of implementation of dispatching interfaces.

Having estimated simplicity of integration of third-party data into a system, at quite short terms, specialists of the company performed communication with all existing management systems and the dispatching systems of the enterprise.

The possibility of their analysis in a complex and applications of different techniques of assessment for receiving optional data became result of consolidation of all data. So, for example, data analysis about raw and product flows of distillation columns allowed to estimate with a high accuracy quality of the process proceeding in them which efficiency decreases because of accumulation of deposits in devices, in view of features of chemical reactions that in turn gave the chance to predict need of carrying out cleaning of devices and to plan these works.

The commercial advantages got in result of application of the new products Wonderware

Decrease in losses of raw materials in the course of processing due to the system of balances on each repartition High-quality distribution of finished goods by grade Reduction of quantity of abnormal stops due to forecasting of a MRO of the equipment Release of excessive number of operation and operational and repair personnel

Notes