We boosted operational efficiency by implementing automated quality checks and alerts.
We integrated advanced sensor calibration with DCS programming to enhance precision.
We redesigned Evonik's monitoring systems for improved oversight.
Evonik, a prominent manufacturer of specialty chemicals, is continuously improving its production processes through innovation. The company reached out to us for a new project that required both E&I and OT expertise. The challenge was to maintain and optimise one of Evonik’s production lines by combining E&I engineering knowledge with DCS programming skills.
By combining his E&I engineering knowledge with expertise in DCS programming, our expert Simon De la Marche has not only optimised efficiency for Evonik but also reinforced the layers of safety required in chemical manufacturing. His expertise plays a crucial role in preventing incidents and ensuring robust safety measures are in place.
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Our expert Simon immersed himself in Evonik’s E&I department, where he oversees the ACA production process. He is responsible for maintaining and updating vital components, including control valves, modulators, and control systems. He strategically chooses and configures these components to ensure that the hardware aligns with the software.
By understanding the physical components and their limits and dependencies, Simon can tailor software parameters even more precisely to maximise the hardware’s capabilities. For example, he updated a system measuring gas emissions by reprogramming the temperature and pressure sensors to perform a time-based comparison instead of relying on constants. This ensured that the right amount of gas is taken in based on a mathematical formula, accounting for variables like sunlight on the pipeline.
Chemical companies like Evonik operate under a culture of continuous improvement. Simon and the other members of the E&I team scrutinise every aspect of the production process daily, adjusting where necessary. He is responsible for monitoring and tweaking the hundreds of components, such as dialling in sensors or replacing control valves. Simon compares it to working for a Formula 1 team:
"Keeping these production processes running is a bit like taking care of a Formula 1 car. Each day, as the 'race' progresses, we make superficial repairs and minor tweaks – even though we don’t have the luxury of pit stops. Between 'races,' we can make significant adjustments to gain an edge. Even the smallest components can have a profound impact on the entire system."
However, there is one critical difference in the approach. When it comes to chemical manufacturers, safety and efficiency obviously take precedence over speed. For example, the entire production facility and control room need to comply with the European Union’s ATEX directives, which are crucial for controlling explosive atmospheres in high-risk environments. This directive sets precise guidelines, including limitations on currents for sensors and the use of explosion-safe enclosures for specific equipment.
While safety is of the utmost importance, continuous operation of these production processes is nearly as important, as downtime can have severe consequences on revenue. That’s why the production processes feature a high level of redundancy: throughout the installation, safeguards have been integrated. In some cases, identical second setups are kept close, ready to be used immediately in the event of maintenance or emergencies.
At the time of writing, Simon is assisting Evonik with their yearly maintenance and testing of the ACA production installation from the control room. This highly orchestrated procedure ensures that maintenance activities have a minimal impact on production, and maintain the delicate balance between safety, efficiency, and productivity.
By combining his E&I engineering knowledge with expertise in DCS programming, Simon has not only optimised efficiency for Evonik, but also reinforced the layers of safety required in chemical manufacturing. It's a great example of how we tailor our approach for clients with unique demands.
Are you looking for experienced E&I engineers and IT-OT specialists who look at the bigger picture? Contact us today to discuss how we can help you achieve operational excellence with our Industry 4.0 services.
