CSPS is a petrochemicals complex in Guangdong, China, that was completed in December 2005 at a total investment of US$4,3 billion. Yokogawa was the main automation contractor for this project and the project team has been involved from the engineering design phase to ensure consistency in specifications. The functional design specification phase, detailed design phase, staging, factory acceptance test, site acceptance test, and commissioning were all organised and carried out together with contractors through a project management contractor.
The system has approximately 60 000 I/O points installed, of which 16 000 are Foundation Fieldbus devices. There are 200 000 software I/O tags and around 3000 segments which are controlled by nine CENTUM CS 3000 distributed control systems and 120 field control stations. Three control centres and 15 field auxiliary rooms control the field instrumentation. These are connected by fibre-optic cables to form a plant control information network (PI-LAN).
Plant Resource Manager (PRM) is a realtime device management and advanced diagnostics software package. It connects the Foundation Fieldbus devices which enables a problem to be diagnosed and an alert issued before the instrument actually fails and disrupts a process. The system continuously monitors the physical condition of the instrumentation which results in increased reliability and fewer questionable measurements. With this preventive maintenance capability, plant operators can have greater confidence that their facility will perform as expected.
The DCS anywhere concept stresses the importance of having access to the control room from any location in the plant or office to perform diagnosis, monitoring, and management. The plant information network is, according to the company, one of the most advanced in the world today.
Two features of this project worth mentioning are the long term maintenance contract that is in place and the sustainable development programme which involves the training of local employees in process control and current process instrument technology.
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