Optimal efficiency

November 2009 PLCs, DCSs & Controllers

Worsley Alumina improves productivity with Experion and advanced applications.

A world-class research and development laboratory, administration centre, maintenance workshops, warehouse and advanced alumina transport and storage facilities make it one of the world’s most modern and efficient refineries.

Operating proactively

Elevating production performance in an alumina refinery is a challenge because it hinges on an operator’s ability to be proactive and act on information appropriately. Worsley Alumina realised that one catalyst to improving performance was to use advanced automation to replace some of the operators’ current tasks, allowing them to focus on production goals.

“Following an extensive review of our process management, we knew we wanted to implement advanced applications and improve our production control,” said Angelo D’Agostino, senior process control engineer at Worsley Alumina. “Our operators were key to this transformation and seen as the biggest lever to improve production and quality, and to decrease costs.”

Part of the transformation included implementing a centralised control room and upgrading Worsley’s Honeywell TDC 2000 control system. It also included finding ways to make operators more proactive through advanced automation technology.

Solution implementation

Following an extensive study of its process management Worsley Alumina obtained approval for the advanced process management (APM) system; a project that put Worsley on the upgrade path to Experion.

The project also included upgrading the existing GUS and US operator stations to the Experion Station TPS (ES-T) to allow plant staff the benefit of using HMIWeb graphics while still maintaining the connection to the existing local control network. “Our operators are looking forward to using their leading-edge, new central control room utilising an Experion HMI to consolidate old and new control systems and monitor advanced process control,” said D’Agostino.

Upgrading from legacy Honeywell technology was easy with the support of Honeywell’s services team. With continuous evolution and backward compatibility, Worsley was able to migrate its TDC 2000 control system to the latest Experion platform without any problems.

“Honeywell makes advanced automation and control easy through its superior products, integration with existing infrastructure and advanced training methodologies. Our team felt in control and right at home with their Honeywell counterparts. Honeywell did a great job of knowledge transfer to our team and have helped us achieve a benchmark in advanced automation control,” D’Agostino said.

The benefits

In order to maintain its competitive advantage, Worsley needed to provide its operators with a more effective way to manage the various processes employed at the refinery. Worsley turned to Honeywell’s advanced applications based on the proven Experion Process Knowledge System (PKS) platform to achieve its objectives. As a result, the refinery experienced the following benefits:

* Higher production volumes.

* Increased energy savings.

* Quality improvements.

* Stable process operations.

* Reduction in manual interventions.

* Increased process capabilities.

* Protection of past automation investments

For more information contact Debbie Rae, Honeywell Southern Africa, +27 (0)11 695 8000, [email protected], www.honeywell.co.za

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