Advanced automation for ammonia refrigeration plant in the petrochemical industry
Integrated solution for the safe, reliable and efficient operation of a compressor and condenser system in an explosion hazardous environment
Righi designed and realised an integrated automation solution for an ammonia refrigeration plant for a major petrochemical company in Iran. The project involved the realisation of the control panels for the compressor and condenser skids, the development of the plant management and automation software, the design of an intuitive operator interface (HMI) and the implementation of a Modbus communication system for integration with the plant DCS.
In addition, a dedicated SCADA system was developed for supervision and continuous recording of process data, ensuring complete monitoring and optimised plant management.
Challenge
- Operating in a Zone 1 classified area: Need to install ATEX-compliant equipment to ensure safety in hazardous environments.
- Integration of heterogeneous systems: Coordinate and automate different components such as compressors and condensers within a single control architecture.
- Reliability and availability: Ensure plant continuity through a redundant control system.
- Effective communication: Ensure smooth and reliable communication between the automation system and the plant’s DCS.
- Increased reliability: The redundant architecture guarantees the operational continuity of the system, even in the event of a breakdown.
- Guaranteed safety: The use of certified switchboards for hazardous areas ensures compliance with regulations and the protection of personnel and equipment.
- Efficient integration: Smooth communication with the plant’s DCS improves supervision and process control.
- Reduced cabling costs: Installing the UCP switchboard directly in Zone 1 avoided laying long cables to safe areas, optimising costs and simplifying the infrastructure.
