Automation of Monomer Production Facility

In 2005, our company was contacted by a local manufacturer of coatings used on both consumer and industrial products. Their need was to improve the efficiency of the existing equipment through implementing a new automation system.

After several scope reviews and meetings with the client, it was determined that the automation system would need to achieve the following requirements.
1. Installation of instrumentation onto some of the existing equipment included adding new instrumentation ports to the equipment. This included new pipe nozzle openings on some ASME Code tanks.
2. All instrumentation and automation components would be working in a hazardous class 1, division 1 location. Therefore all components of the system needed to meet the hazardous code requirements of the NEC and OSHA.
3. The system needed continuous monitoring of multiple mix tanks as a short temperature rise and/or fall could ruin the product and/or cause a possible explosive environment within the tanks.
4. Reporting and data acquisition needed to be printed and stored for each batch of manufactured product within the system. Redundant backup of the data was also required.
5. The software programs used within the automation system needed parameters that were flexible and easy to change as multiple coating products were to be manufactured within the same existing equipment.
6. Manual override of all automated equipment was also needed.

Our company’s automation specialist went to work and adapted our in house E.A.S.Y Treat automation system to meet the client’s needs. As the software running our system is programmed in house, it was easy to adapt it to include the needed flexibility the client required.

As our company is certified to manufacture, alter and/or repair ASME Code tanks, we also installed the new nozzle openings needed in the client’s existing ASME Code tanks.

Upon our completion of building the necessary hardware and software needed for the automation system, our company went to the client’s site and installed the automation system. This work included the installation of instrumentation, automated valves, PLC, SCADA, and computer based software at the client’s site.

Since 2005, the system has been in operation with no major issues. Since that time, the client has added an additional automation system to another part of their facility. While this additional system was not designed, manufactured, or installed by us, we have had the opportunity to help the client with a number of changes they needed made to the system’s software.

“It was a pleasure to work with TankFab on this project. They communicated well and were sensitive to our needs while on site.”

Bob Worfel, Project Manager, Great Southern Wood

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