In the name of synergy, precision and safety
Braskem is installing a Distributed Digital Control System that will fully automate its PVC plants in Marechal Deodoro, Alagoas, and Camaçari, Bahia,and the Chlor-Alkali unit in Maceió, using state-of-the-art technology
written by ◦ Milena Andrade

Two projects currently underway promise to make a positive impact on synergy rates, process precision and health, safety and environmental management at three Braskem units. All plants at the PVC units in Marechal Deodoro, Alagoas, and Camaçari, Bahia, and the Chlor-Alkali unit in Maceió will be controlled by cutting-edge computer systems. Not only that, but the control rooms’ operations will be centralized.

The PVC unit in Alagoas has already begun working towards these goals. In December 2004 it was first to begin operations under this new system. The other industrial units will complete the process by July 2005.

The company is investing BRL 40 million in the Digital Distributed Control System (DDCS), a new logic for integrating the control and automation of all three plants. In terms of technology, the equipment being installed in Braskem’s units in Alagoas and Bahia is the state-of-the-art for the international petrochemical industry.

According to Francisco Ruga, the Braskem officer Responsible for Manufacturing, one of the biggest advantages of this innovation is ensuring operational continuity, because the new control system has more functions and is much faster and easier to operate than the one currently in use. “Perception of the processes will increase, and the new system will be more sensitive, which means more rigorous controls,” he explains. The new resources are key to extracting more information from the plant in real time, which improves reliability and technical indexes, says Ruga.

Increased reliability, which will be expanded to all levels, is not the only item on the list of the main benefits these changes will make. When the automation process is in place, the teams at the plants benefiting from this change will receive specific training exclusively focused on the new equipment, providing a new model for the operations of these manufacturing plants. At the same time, these teams will receive follow-up at all stages of the conversion of their units, which will help them better understand the extent of the project and its impact on the daily routines of each member and the unit itself. “As a result, we were able to make sure that everybody understood the benefits and objectives of this project,” says Francisco Ruga.

The other project, which involves centralizing control rooms, will increase integration between the unit’s teams. “People will be able to work together in several areas at the same time, and that will result in greater synergy,” explains Francisco Ruga. The introduction of a new technology and a change in the control system is requiring a major investment in the training and development of people. The Marechal Deodoro PVC Unit is already going through the training stage.

This new tool will be a natural driver of continuous improvement, because the operator will have greater sensitivity, which will create prospects of getting more production with fewer raw materials. “When you can carry out a process with greater stability and reliability, you will tend to produce a more consistent and stable product,” explains Francisco Ruga. He believes that it will be possible to assess the results at the Marechal Deodoro PVC Unit within the year.

The new equipment includes gas detectors that monitor for several kinds of gases, and alarm indicators that show when the control room has to be sealed off in emergencies. These safety mechanisms enable operators to continue working normally, even in high-risk situations. Risks are already low, and they will be reduced even more.

In regard to the environment, the more control there is over production processes, the fewer deviations and unscheduled equipment shutdowns will occur, thereby avoiding the chief causes of increased plant emissions.