Product category:
Process Control and Monitoring Systems
News Release from: ABB Automation Tech (Instrumentation + Automation) | Subject: ProduceIT
Edited by the Processingtalk Editorial
Team on 28 April 2005
ABB control system helps Kodak achieve
top quality
An ABB process and recipe control system has helped Kodak achieve 100% product quality for seven consecutive months at its synthetic chemicals plant in Kirkby, Liverpool
An ABB control system has helped Kodak achieve 100% product quality for seven consecutive months at its synthetic chemicals plant in Kirkby, Liverpool Kodak Kirkby Factory Manager Tony Field says: 'This sustained level of quality is an incredible achievement, particularly so soon after the installation of a system as large and complex as this.' The system, secured against competitive bids, replaced an earlier Taylor control system, bringing the latest ABB controllers and software to manage a fully integrated plant producing specialist chemicals for the photographic industry
This article was originally published on Processingtalk on 17 Jul 2008 at 8.00am (UK)
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It controls logic, recipes and key process control variables such as temperature, pressure and flow rates across the entire plant process system, consisting of 12 reactor vessels.
The system incorporates OperateIT, the Web-enabled unified operator interface, together with ProduceIT electronic batch management, InformIT enterprise-wide data historian systems and connectivity services for integration with plant-wide systems.
The hardware elements include client/server operator stations, AC 460 industrial process controllers and a variety of hard-wired relay/pneumatic panels to handle the system 1,750 I/O, both S800 and S890 I/O modules from the ControlIT product suite.
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Says Field: 'The major benefit the system brings us is the batch control provided by ProduceIT, giving us the ability to manage and control recipes for each of our products and maintain consistent quality.
The interface with the operators is also more graphical and being Windows based is easy to understand.
We now have better control of the plant, as the control system lets operators know if something is not going to plan.' The system is also integrated with the Kodak management system.
Data is fed from the control system to the management system analysis tool, providing the company with automatic diagnostic reports and much better data on downtime and other key process variables.
Implementation of the system took place in November 2003 during a two week shutdown period, followed by an extensive commissioning period.
Says Field: 'A successful installation was critical: we were abandoning the old system and putting our faith in the new one and if it had not worked we would have been left without a factory.
But installation and commissioning went extremely well and we started up the plant making good product exactly on schedule.
I was very impressed with the dedication ABB showed in resolving any issues we had.
Overall I was very pleased with the way the project developed.'.
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