Upgradation of DCS and ESD Systems into Integrated Control System at IFFCO Phulpur Plants

摘要

Indian Farmers Fertiliser Cooperative Limited (IFFCO) Phulpur Unit is operating two large Ammonia and Urea plants. All the plants were commissioned with separate dedicated Distributed Control System (DCS) and Emergency Shut-Down (ESD) System along with Mosaic display. The Ammonia-ll and Urea-ll plants have Yokogawa Centum-CS DCS and Hima ESD Systems since commissioning in year 1997. The Ammonia-I and Urea-I plants have Centum-CS DCS and Honeywell ESD Systems since modernization in year-2000 from the pneumatic control systems. The DCS and ESD systems have incidence of CPU failures from the year 2009 onwards and resulted in tripping of the plant. In view of this, the entire DCS and ESD systems of both Ammonia and Urea plants along with Offsites were changed into latest Integrated Control System (ICS) of M/s Yokogawa in the year 2012 for the uninterrupted and smooth operation of the plants. The article gives the details of upgradation projects of DCS and ESD systems.