Production boost with PlantWeb architecture

PlantWeb digital architecture at the Alexandria Carbon Black Company in Egypt reduced engineering and installation costs, improved product consistency, and lowered maintenance costs

Emerson Process Management has recently completed the installation and start-up of PlantWeb digital plant architecture with Foundation fieldbus technology on a fourth production line at the Alexandria Carbon Black Company (ACBC), in a USD1.2Million contract.

The company, Egypt's only manufacturer of carbon black, installed the new line to meet increased demand for carbon black products which are used in the manufacture of tyres, rubber products, plastics, inks, dyes and paints.

The Alexandria Carbon Black Company is the fastest growing carbon black producer in the world with over 90% of production being exported to companies that include Goodyear, Michelin, Bridgestone, Pirelli, Dunlop and Continental Tyre.

The new installation follows the similarly successful automation at the third production line at the plant.

PlantWeb has enabled reduced engineering and installation costs, improved product consistency, and lower maintenance costs.

PlantWeb Services from Emerson included engineering, installation, project management and start-up.

The PlantWeb solution includes five DeltaV digital automation workstations that use Foundation fieldbus digital communications protocol to communicate with intelligent field devices from Emerson, including Rosemount 3051 Smart pressure transmitters and Model 848T temperature products, Micro Motion Coriolis flow meters and Fisher valves with Fisher Fieldvue digital valve controllers.

Emerson AMS Suite: Intelligent Device Manager software is used to enable configuration and calibration of field devices, and to access the predictive intelligence of the digital devices.

Continuous on-line diagnostics in the field devices provide status of process and instrument health, enabling operations and maintenance personnel to recognise changes in status levels and take action to prevent issues before they occur.

The use of Foundation fieldbus simplified installation and commissioning, enabling Emerson to complete the project very quickly.

For example, the systems and marshalling cabinets were designed ordered, wired and tested in just seven weeks.

Following on from the success of the PlantWeb and DeltaV-based installations on production lines 3 and 4, ACBC is already working on a fifth production line to meet the ever increasing demand for its products.

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