ALEXANDRIA SUGAR COMPANY- Greenfield Sugar Production Complex – Plant-Wide DCS Implementation This project involved the creation of a complete, state-of-the-art Distributed Control System (DCS) for a new, large-scale sugar production complex. The objective was to deliver a unified, highly available, and scalable automation backbone to control and monitor the entire production process from raw material […]
This project involved the creation of a complete, state-of-the-art Distributed Control System (DCS) for a new, large-scale sugar production complex. The objective was to deliver a unified, highly available, and scalable automation backbone to control and monitor the entire production process from raw material intake to final product, ensuring maximum operational efficiency and reliability from day one.
• Design & Engineering of a Complete DCS: Full lifecycle responsibility for the automation system, including the design of the system architecture, network, and control strategies, followed by detailed panel building.
• Core PCS7 System Deployment: Installation and configuration of a robust Siemens PCS7 system, featuring 4 multi-clients controllers, dual redundant servers for high availability, and 9 client operator workstations for comprehensive plant oversight.
• Extensive Distributed I/O Network: Implementation of a massive I/O structure comprising 30 field remote panels for process areas and 14 Motor Control Center (MCC) panels for electrical integration, managing a total of approximately 4,900 I/O points.
• Plant-Wide Network Infrastructure: Construction of a resilient 7-kilometer multi-mode fiber optic ring network to seamlessly connect all controllers, servers, workstations, and distributed I/O panels, ensuring high-speed and fault-tolerant data exchange.
• Unified Plant Control: Centralized monitoring and control of the entire sugar production process from a single, integrated platform, breaking down operational silos and improving coordination.
• Maximum System Availability & Data Integrity: The redundant server architecture and fiber optic ring network guaranteed continuous operation and protected against single points of failure, critical for 24/7 production.
• Optimized Operational Efficiency: Distributed I/O located close to field equipment minimized wiring costs, simplified troubleshooting, and provided a clean, organized interface for both process and motor control.
• Inherent Scalability for Future Expansion: The PCS7 platform and extensive network infrastructure were designed to easily accommodate future process expansions or modifications with minimal disruption.
The successful implementation of this plant-wide DCS created a powerful and reliable nerve center for the new sugar production complex. It empowered the owner with advanced process control, unparalleled visibility into operations, and a robust foundation for sustainable and efficient production for years to come.
iemens PCS7 with 4 Multi-Clients, Dual Redundant Servers, 9 Operator Workstations
Network: Multi-mode Fiber Optic Ring (7 km)
I/O Structure: 30 Field Remote Panels & 14 MCC Control Panels (4,900 IOs)
