DAKAHLYA SUGAR COMPANY Greenfield Sugar Production Complex – Plant-Wide DCS Implementation A leading industrial developer embarked on the construction of a brand-new, state-of-the-art sugar production complex. The project required a robust, scalable, and highly reliable plant-wide Distributed Control System (DCS) to automate the entire production process from raw material intake to final product. The challenge […]
A leading industrial developer embarked on the construction of a brand-new, state-of-the-art sugar production complex. The project required a robust, scalable, and highly reliable plant-wide Distributed Control System (DCS) to automate the entire production process from raw material intake to final product. The challenge was to design and deploy a unified control architecture capable of managing thousands of I/Os across a vast plant area with maximum uptime.
• Design and Development of a Complete DCS: Full lifecycle responsibility for the process control system, from initial design and engineering to development, deployment, and commissioning for the entire new sugar factory.
• Centralized Operations Infrastructure: Implementation of a high-availability central control room featuring dual redundant servers for data integrity and ten client operator workstations for comprehensive plant visualization and control.
• Distributed & Resilient Control Architecture: Installation of four redundant, fault-tolerant Siemens PCS7 controller systems to ensure uninterrupted automation of critical processes, linked to 44 distributed I/O panels (30 field remote, 14 MCC-based) managing over 3,500 I/O points.
• Comprehensive Network Integration: Deployment of a plant-wide, dual-redundant fiber optic network ring spanning 5 kilometers to seamlessly connect all controllers and workstations, alongside a Profibus PA network for integrating 900 smart field transmitters.
• Unified Plant Control: A single, integrated DCS platform provides operators with a holistic view and centralized control over the entire sugar production process, enhancing coordination and efficiency.
• Maximum System Availability: Redundancy at every level—servers, controllers, and network—ensures fault-tolerant operation, eliminating single points of failure and guaranteeing continuous production.
• Enhanced Data Intelligence: The Profibus PA network enables advanced diagnostics and data from 900 smart transmitters, facilitating predictive maintenance and improved process optimization.
• Scalable and Future-Ready Foundation: The distributed I/O and robust network architecture provide inherent scalability, allowing for easy future expansion or process modifications with minimal disruption.
The successful implementation of this cutting-edge DCS created the digital backbone for the new sugar complex, empowering the client with a world-class automation infrastructure. The system ensures safe, reliable, and efficient plant operation, optimizes production yields, and provides a solid foundation for long-term operational excellence.
Dual Redundant Siemens PCS7 Servers & Ten Client Workstations
Control Layer: Four Redundant Fault-Tolerant Siemens PCS7 Controllers
Field Layer: 30 Remote I/O Panels & 14 MCC Panels (3,500 I/O)
Network: Dual Redundant FO Ring, Profibus PA & DP
