ABB’s recently launched enhanced automation system – System 800xA– has been purchased by the world's leading producer and refiner of cobalt and the world’s fifth largest producer of nickel, for its Manchester UK facility.
OM Group Inc produces metal organics for use in various end use industries particularly paints, printing, tyres, petrochemicals, etc. When installed and commissioned, later this year, the ABB 800xA system will be used for batch management of a range of speciality chemicals including cobalt. It will control the reactors on the facility’s main production unit as well as controlling the sequencing of the various stages of the process.
The new 800xA features 880 I/O points and replaces a 20 year old Kent P4000 system. “The ability to take OMG’s existing P4000 and apply our Industrial IT solution directly, saved the company having to re-write specifications, thereby saving costs,” explains ABB’s Ernie Sidebotham.
Key to this batch control application is ABB’s redundant batch management solution. This is a comprehensive recipe management, batch and procedural control software package for flexible production management, is fully integrated with the 800xA system through to the production management displays and batch reporting facilities. It provides manufacturers with the flexibility, speed, and control they need to respond to increasing production demands while reducing life cycle costs and production downtime.
OMG’s Rey Duckworth says: “ABB made a survey of our process and recommended the 800xA as the most suitable system. We were very happy to stay with ABB as we have had good service out of the current system. With the addition of the batch package, the ABB 800xA is a good fit for our requirements. Continuity is good and the 800xA can be installed as a direct replacement for the P4000 system.”
System 800xA uses the ABB aspect object technology to provide personalised graphics and documentation such as SOP’s to the users of the system. OMG’s 800xA system consists of two operator stations, along with one engineering station. The system also comprises three AC800M controllers and S800 I/O.
The ability to capture all documentation on-line was a key attraction of the ABB solution. For example, quality control personnel have the ability to automatically update figures into a spreadsheet, for each batch, directly to their local PC.
Such remote terminals mean that plant personnel can see precise plant operational data from their local PC by simply calling up the relevant screens whenever needed. The plant teams can quickly feed back data into the system, saving time and thereby increasing production rates.
A whole raft of new reporting and additional management information is opened up such as product reports, product yield and analysis of this information.
Says Duckworth: “The increased amount of management information that the system gives us will greatly improve our efficiency. Batch records will let us make batch to batch comparisons, allowing the production department to fine tune the process in order to achieve the ultimate goal of the ideal batch.”