Control System for Chemical Storage and Distribution – Denmark
This exciting project saw Delta Rock design, build, and commission a bespoke control software system and associated panel for a client’s manufacturing facility in Denmark. The system manages caustic chemical product transfer to and from the operational plant.
The client is a global player and a leading specialist in the decarbonisation technologies. With extensive expertise they are perfecting solutions to enable the transition towards the use of renewable energy resources.
The Project – Design, Manufacture and Commission
The control system was based on the Siemens S7-1500F PLC, with integrated safety functionality for the management and operation of failsafe circuits (emergency stops, and overfill prevention), as well as for the whole storage and distribution facility. To interface with Siemens CPU, Delta Rock used a Siemens HMI panel designed for outdoor use and developed software to provide a graphical display of the operating system elements. This was based on the system P&IDs and included tanks, pumps, pipes, valves and instruments etc.
This real-time display provides live system information (alarms, status, trends etc.), to enable the team to monitor the system performance at all times. Typically for this type of system, alarms and password protection was incorporated for enhance security.
Once Delta Rock had completed the operating software system design, panels were manufactured at our in-house workshop and delivered to site, in Denmark. Under the guidance and support of Delta Rock, a local contractor was responsible for the installation.
On-Site Commissioning: A Multi-Stage Process
Once installation was completed our Technical Manager was required to travel to site to undertake the full on-site commissioning, of the control panel and system.
Staged Commissioning 1, 2 and 3
Stage 1: Signal Verification The initial stage involved testing all instrument signals to verify the electrical installation was executed correctly and that all expected signals and controls performed as required and in the correct locations.
Stage 2: Functional Testing Once the first stage was proven, the second stage focused on functional testing to ensure the system logic was executing correctly.
Stage 3: Product Testing The final commissioning stage involved testing the system with the actual product. Product was delivered to the site with the use of a cistern and pumped into storage tanks. Upon request from the process plant systems, chemicals were then transferred to local buffer tanks or directly to process lines controlled by other systems. This ensured the process worked efficiently as design.
On-Site Commissioning: A Multi-Stage Process
A Successful Project, from Start to Finish
The successful transfers marked the completion of the project on site, followed with the submission of an updated as built documentation.
All software and panel designed and produced by Delta Rock successfully performed and delivered efficient operational services, in accordance with the project brief and customer objectives.
Driving operational efficiencies with control panel system design and manufacture
Delta Rock continues to be at the forefront of the automation development, supporting a diverse range of industries, from Food and Beverage to Chemical Plants.
With our extensive in-house expertise and experience, including hazardous areas, we are driving forward innovation, efficiencies and quality to ensure businesses remains competitive and safe.
If your business is keen and need to update or redevelop your control systems, or you require additional technical automation design resource, our team are on hand to discuss your requirements to help you streamline your operations.
Contact our team of experts: Supporting continuous improvement
T: +44 (0) 1244 536 444 | E: enquiries@deltarock.co.uk | W: deltarock.co.uk
