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Batch process automation for lube oil blending plant with integration of field devices on ASI bus technology

Batch process automation for lube oil blending plant with integration of field devices on ASI bus technology

A Multi-national Lube Oil manufacturer sets up green field facility near Mumbai for manufacturing of Lube Oils with Best in class technology for Batch Automation & Field integration with ASI bus technology resulting in faster time to market manufacturing large product variants.

Challenge

  • Existing plant was fully manual so no exposure to automation
  • New Plant expected to be best in class for technology & automation for competing with Global MNCs.
  • Faster time to market & highly flexible recipe management to take care of large product variants (500+ recipes)
  • Due to wide geographical spread of the plant it was expected to use latest network technology up-to device level to optimize Field installation and cabling cost
  • This being high volume low profit business plant operation expected to be at peak levels throughout (365 X 24 X 7)

Solution

  • Rockwell Process Automation system with Ethernet DLR as Network back-bone connected to various ASI Master modules located in field for field device integration
  • Field mounted Rockwell make IP-67 VFD's installed near the motors
  • High end flexible Recipe management system based on specialized package for Blending plants – Auto-Blend
  • Special Software features to reduce the batch cycle time and increase the through-put to maintain peak level production maximizing the plant asset utilization.

Result

  • Integration of Field devices & VFD's on network resulting in reduction of overall installation time & cost of cabling & erection resulting in faster commissioning & reduction in overall project cost
  • Proven & time tested recipe & batch management system – Auto Blend enabled faster & error free production start up leading to faster time to market
  • Quick & fastest product changeover achieved due to the flexible recipe management system
  • Accurate charging resulting in almost zero amendments
  • Accurate Batch records & reports of Batch tracking

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