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新浦化学(泰兴)有限公司系新加坡新浦化学私营有限公司全资子公司,位于泰兴经济开发区疏港路1#。公司成立于1995年12月30日,经过数次扩建和发展,现有年产75万吨离子膜烧碱装置、年产50万吨氯乙烯装置、年产32万吨苯乙烯装置、年产18.5万吨硝基苯装置、年产13万吨苯胺装置和自备热电厂。现投资总额为71052万美元,注册资本为35400万美元。2016年,成立新浦烯烃(泰兴)有限公司,建设110万吨/年轻烃综合利用项目;成立新浦化学(仓储)有限公司,建设40万立方米轻烃仓储项目。
新浦化学已经采用了近5套横河的DCS系统,还有变送器、流量计、PH计、色谱等产品。本项目中,横河电机(中国)有限公司成功的将离子膜烧碱四期所用旧系统替换为CENTUM VP R5控制系统。
挑战与解决方案
这个项目是烧碱四期改造项目,烧碱四期项目是一套年产15万吨烧碱、4.5万吨苯胺的装置,于2006年正式投产。经过一段时间的使用后,由于旧系统设备老化,后经过双方技术确认后决定更换为横河电机的DCS控制系统。
本次烧碱四期DCS系统改造工程包含烧碱和苯胺两个装置,总点数为1800点。项目面临的挑战是,要在保持原先现场电缆和机柜不被更换的前提下,仅将原先系统软硬件改造为当时横河电机最新的CENTUM VP R5控制系统。该装置已投运多年,用户为确保改造项目完成后的一致性,要求所有资料必须从原系统中导出。横河电机必须在规定时间内独立完成软硬件的调研工作,确保控制功能的完整性和一致性。停车改造时间仅为10天。项目工期紧凑,难度比较大。而且为了保证硬件的可靠性,在没有机柜的条件下,利用安装板完成出厂测试。
为此,横河电机(中国)有限公司成立了由工程、技术、营业人员组成的专门项目组,借助横河电机自主开发的系统升级工具,对该项目实施升级改造。由于采用专用升级工具,不仅大幅提高了前期对原系统软硬件调研的工作效率,也保证了项目的质量。通过用户的积极配合和横河电机的共同努力,加强工程各阶段与客户的充分沟通,仅用了5天的停车时间就圆满完成了本次改造工程,装置于2015年十一国庆前夕顺利按计划一次开车成功,并平稳运行至今。
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