PCS migration & retrofit for aluminium oxide plant

Project description

Süd Chemie AG (now Clariant), the globally active and innovative speciality chemicals company, upgraded its aluminium oxide processing plant to state-of-the-art technology. We provided the EI&C planning and installation, as well as the automation and control technology and switchgear construction.
The outdated control technology has been replaced by a modern PCS7 process control system. For technical production reasons, the system migration was planned in three phases.
Phase I involved first implementing the new control system, and the redesign of one of five sub-systems. This was accompanied by renovation and extension works on the electrical infrastructure, including the electrical supply, UPS system and data network. Phase II involved expanding the plant with a new ball mill. Finally, phase III consisted of the switch over of the remaining sub-systems from the press house and slurry handling system, with more than three times the number of measuring points, as a separate project.
The main focus of the planning and upgrade phases was on maintaining production 24 hours a day, seven days a week. A preliminary inventory of the entire electrical engineering infrastructure established the necessary solid foundation for the detailed engineering. Working to detailed time and activity schedules, a skilled team of engineers and specialist EI&C fitters implemented the short upgrade phases to the highest satisfaction of the production management.

Scope of our services

PCT planning

  • Safety engineering for safety doors
  • SIL calculations and documentation
  • Electrical design
  • Procurement management and production control
  • Layout drawings and circuit diagrams with Elcad 7 CAE system
  • Topology planning, cabinets and consoles as well as emergency stop overviews.
  • As-built documentation

Automation and process control technology

  • PCS7 design and system configuration (engineering station, redundant server, 5 clients each with two 24” TFT screens, 12 IP cameras)
  • Profibus, Ethernet (fibre optic ring and Cu)
  • Implementation detail specifications
  • Migration strategy
  • Project planning for AS and OS level automatic, semi-automatic and manual operation
  • FAT with application simulation
  • Commissioning
  • Operator training (operator, maintenance and system support)
  • Remote maintenance via DSL
  • 24h on-call service

Switchgear construction

  • 2 feed cabinets, 4 control and power cabinets, 1 PCS cabinet,
  • 1 UPS system, 3 data cabinets, 4 sub-distribution cabinets

EI&C installation

  • Installation and assembly of control, power and field distributor cabinets
  • Extension of cable runs, cable laying and connection, grounding
  • Fibre optic splicing technology
  • Switch connection and shunting work
  • Cold testing of connections
  • Test and measurement protocols
  • Commissioning support



Elektro Kreutzpointner GmbH
Burgkirchener Str. 3
D-84489 Burghausen
Tel.: +49 8677 8703-270