Azoty Tarnow: AVEVA solutions improved efficiency and safety in a Polish chemical company
The new control and monitoring system at chemical industry company Azoty Tarnow has significantly improved the company's production efficiency, traceability, and safety. By adopting advanced AVEVA solutions and expanding their monitoring capabilities, Azoty Tarnow has optimized its operations, reduced costs, and demonstrated a strong commitment to quality, safety, and environmental care.
Azoty Tarnow S.A. has significantly increased its chemical plant productivity by implementing a new control and monitoring system. This system aims to enhance efficiency, traceability, and production safety through centralized management and monitoring. The company faced challenges such as high operating costs, particularly in electricity and methane consumption.
To address these issues, Azoty Tarnow adopted several AVEVA solutions, including AVEVA Historian, AVEVA InTouch®, AVEVA Historian Client, and AVEVA Information Server.
At Azoty Tarnów, the AVEVA InTouch system is used for local monitoring and control, allowing the company to collect necessary data on electricity consumption, control and regulate methane and steam consumption, and manage water supply and wastewater treatment systems.
Reducing production costs and real-time data access for improved efficiency
The new monitoring system has successfully reduced production costs and provided real-time access to key parameter analysis, thereby increasing production efficiency. Additionally, the system has optimized the flow of information, ensuring that reliable data is delivered to process engineers.
The chemical industry involves the production of various toxic, flammable, and explosive substances, requiring high energies under extreme pressures and temperatures. Safety and compliance with standards are paramount, making it crucial to monitor and adjust key production parameters.
Monitoring system expanded to all plants
Based on the positive experience with existing solutions, the Azoty Tarnow’s board of directors decided to expand the enterprise-level monitoring system. This expansion required creating a system that could monitor all plants, store information in a central database, and generate reports on quality and consumption levels.
The new monitoring system allows controlling various indicators, such as electricity, air supply, process water for heating and drinking, steam pressure, and water and wastewater treatment.
The monitoring system covers the supply and consumption of raw materials, production, and delivery of the final product, enabling efficiency control and production cost calculation.
Data collection used for occupational safety with AVEVA Historian
The industrial database collects and archives data obtained from automation and measurement equipment, which is sent to the AVEVA Historian system. This provides a centralized source of historical data.
In addition to regular process monitoring, the AVEVA solution collects data from weather stations within the plant. This is crucial in case of emergency gas leaks, as it allows knowing the wind direction during personnel evacuation.
Data collection is carried out from various third-party devices, each using its own communication standards.
Top 5 benefits for chemical industry of AVEVA solutions:
- Enhanced Real-Time Monitoring and Control:
- AVEVA InTouch provides an intuitive graphical interface for real-time monitoring and control of production processes. This allows operators to quickly identify and respond to issues, ensuring smooth and efficient operations.
- Improved Data Collection and Analysis:
- AVEVA Historian collects and archives data from various automation and measurement equipment. This centralized source of historical data enables detailed analysis, helping to optimize production processes and improve decision-making.
- Increased Operational Efficiency:
- By providing real-time access to key parameters such as quality and consumption, AVEVA solutions help increase production efficiency. This leads to reduced downtime, optimized resource usage, and lower operational costs.
- Enhanced Traceability and Compliance:
- The ability to track and record production data ensures that all processes comply with industry standards and regulations. This traceability is crucial for maintaining product quality and safety, as well as for regulatory reporting.
- Scalability and Flexibility:
- AVEVA solutions are designed to be scalable and flexible, allowing companies to expand their monitoring and control capabilities as needed. This adaptability ensures that the system can grow with the company and accommodate future technological advancements.