The Challenge

To create a cohesive and comprehensive centralized control system for a greenfield plastics recycling facility comprised of 11 different independent skids, auxiliary systems, and the balance of plant (BoP) components.

 

The Solution

Drawing on our decades of experience, we employed an innovative approach to configure a Siemens’ SIMATIC PCS 7 DCS, enabling seamless communication with the 11 skids and various plant floor devices, each utilizing different communication protocols.

 

The Project 

Plastic recycling is a complex process due to the wide variety of polymers, additives, and contaminants in plastics. Currently, less than 10 percent of the 350 million tons of plastic produced annually is recycled. A new innovative plastic recycling company is on a mission to change this by using a cutting-edge advanced circular recycling process that allows for the vast majority of plastics to be recycled and reused, reducing waste and enhancing sustainability.

Partnering with a globally established engineering, procurement, and construction (EPC) firm, this new plastics recycling company set out to build its first state-of-the-art facility. Since this new recycling approach uses pyrolysis, a thermochemical process, the EPC firm knew the facility would need an advanced distributed control system (DCS) that could safely manage the different parts of this complex process.

Having selected Siemens’ SIMATIC PCS 7 DCS to serve as the centralized control system, the EPC firm faced the significant challenge of integrating this DCS with 11 independent skids and multiple auxiliary systems. To tackle this challenge, they sought a highly experienced partner capable of configuring and integrating the system in a way that would ensure cohesive and efficient plant operations.

As a Siemens Solutions Partner with extensive experience in configuring Siemens-based control systems, we were the perfect fit for this project. During the vendor selection process, we highlighted our expertise by identifying cost-saving opportunities for the end user through alternative design considerations and de-scoping options. For example, we demonstrated how a thorough test of the system could be accomplished with existing Siemens tools and how individual factory acceptance tests (FATs) for each independent skid was a redundant and unnecessary cost for little benefit.

Our comprehensive bid addressed all technical requirements for the control system while proposing several optimizations to help meet budget and efficiency goals. As a result, we were selected to serve as the main automation contractor (MAC) for this project. As the MAC, our key responsibilities included creating the master plan for the various vendors to follow when developing their control systems, coordinating the design and development of all the panels, and facilitating testing, startup, and commissioning.

 

Navigating Numerous Challenges to Effectively Manage Multiple Communication Protocols 

As we designed the network architecture for this control system, we faced multiple challenges with performing simultaneous communication between the DCS, the skids, and various plant floor devices using a mixture of different communication protocols. To resolve these issues, we used a Siemens’ SIMATIC CN 4100, which sits on the plant bus and uses redundant PROFINET communications to talk to the PCS 7 controller. 

We then configured this communication node to simultaneously manage both OPC UA and MODBUS TCP/IP communications to all the field devices and relay the necessary data for visualization between the PCS 7 and the CN 4100. While the CN 4100 handles communications to and from many different connected field devices, it provides the PCS 7 system with just a single block to read and write, preserving resources in the PCS 7 for running the plant. 

This configuration was made more challenging by the fact that the skids were being developed by multiple vendors around the world who were each following the control system master plan to varying degrees. We also did not have all the equipment on site at the same time, and once the equipment was received, we had to independently decipher each skid’s control system setup. 

Additionally, for critical redundant systems, such as fire and gas controllers, we had to implement both hardware and software redundancy to ensure system reliability and safety. In parallel to configuring the control system, we also took on the task of building and implementing a comprehensive historian for the plant, further enhancing its operational capabilities.

 

Successfully Navigating the Challenges of Building an Innovative Greenfield Facility

New facility projects often present a variety of challenges, ranging from logistical issues to the complexities of getting personnel into their roles, resolving unforeseen problems during the plant’s initial operations, and establishing long-term operational standards. At ACE, we are always prepared to guide our customers through these challenges to ensure the successful deployment of new facilities. We work alongside our customers every step of the way to ensure not only a smooth start-up but also ongoing success in the operation of their plant.

Learn more about our comprehensive automation and system design services.

Learn more about our automation and system design services