IC697ACC722

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　Tereos France 是法制糖业的一家企业，拥有九家制糖厂，五家酿酒厂和四家包装厂，每年从甜菜中生产出 150 万吨糖以及 500,000 立方米酒精和生物乙醇。
　　每年，位于阿拉斯(在加来海峡省地区)附近的 Tereos Boiry Sainte Rictrude 制糖厂为农工领域的制造商(饮料、巧克力、果酱、饼干和制品制造商)生产 250,000 吨白糖。这种糖只能在一个很短的时间段内生产，从每年的 9 月中旬开始至 12 月结束。这段时间被称为“制糖期”。在这个时间段内，甜菜会被收割运输到制糖厂进行加工。
　　在制糖期的每一天，Boiry 加工 20,000 吨甜菜，生产出 2,800 吨糖，消耗 15 兆瓦的电!这家制糖厂通过两台锅炉为汽轮发电机供应蒸汽，自己发电。工厂只在启动阶段和非制糖期才会接入家电网 (EDF)。
　　挑战
　　这两台锅炉是制糖厂的命脉，每小时分别可以生产高达 140 和 120 吨蒸汽。其中 85% 的蒸汽用于发电，剩余 15% 的蒸汽用于制糖的各个环节。2009 年，控制这两台锅炉的分布式控制系统有些过时了，Tereos 决定换掉这个系统。
　　Tereos 的目标：升级和优化这两台锅炉的控制，并将这两台锅炉集成到整个工厂的单一控制和命令系统中。这家公司联系了许多供应商，在审查这些供应商给出的建议后，选择将锅炉命令移植到 Rockwell Automation PlantPAx 系统。
　　该公司于 2009 年 3 月作出了这个决定，而 9 月制糖期就要开始了。这对 Rockwell Automation 来说是一个相当大的挑战，因为工厂若没有锅炉是无法运营的。此外，锅炉控制需要非常具体的专业知识：极复杂的调控算法、燃烧器的调整以及用于预期负载需量的极其复杂的计算。
帮助确保限度地降低这次移植的风险，并且在截止时间之前完成移植 — 这需要各种各样的专业技能。这正是 Rockwell Automation 解决方案大显身手之处。其锅炉管理方面的专业知识和风险管理方面的丰富经验在这种情况下是不可或缺的。Rockwell Automation 解决方案团队对既有系统进行了回顾性分析，并制定了一个移植解决方案，该方案能够使锅炉在风险的情况下实现运营。
　　该解决方案以 PlantPAx 过程自动化系统为中心，基于三个冗余的 Allen-Bradley® ControlLogix® 可编程自动化控制器并完全集成到工厂的整个系统中。Rockwell Automation 的锅炉管理专家调整了燃烧控制和命令所需的设置和连续自动化过程。
　　2009 年 8 月底，就在制糖期开始之前，该工厂进行了长达一周的“空运行”，在此期间，这家制糖厂的团队和 Rockwell Automation 团队进行了调整，并检测了负载。系统的后调整只能在生产启动阶段进行，因此，没有任何出错的余地。
　　制糖期天一帆风顺，供电能力和预期的一样大幅提高。Boiry 制糖厂电力 - 自动化经理 Michel Hennebique 确认说：“在 Rockwell Automation 管下的启动阶段和试运行进展得很顺利，所有调整工作都在这两天里完成了。整个制糖期间没有出现任何故障。”
Tereos 现在完成了两个制糖期，从 Rockwell Automation 解决方案带来的改进中获益颇丰。负责 PlantPAx 系统的 Rockwell Automation 解决方案团队已经证明了该系统取代传统分布式控制系统解决方案的能力以及它作为这种解决方案的竞争优势。
　　“锅炉控制得到改善，特别是在控重新加热方面;锅炉产出现在达到 96%。锅炉运行也比之前更加可靠。使用 Rockwell Automation 解决方案，可将两个锅炉相互连接，并且功率匹配现在由 PlantPAx 系统自动执行。所有这些改变都归功于 Rockwell Automation 团队在整个项目中提供的技能和可靠的支持。”Boiry 电力和自动化经理说道。
　　锅炉控制和命令系统现在与其工厂设备完全集成在一起，使整个生产点的追溯操作可以统一管理：报、操作员操作和流程历史。“们利用这次移植，与 Rockwell Automation 一起对们的督工作站进行了工程学方面的审查，Plant PAx 系统变得更具用户友好性，们的操作员特别喜欢这一点。”Boiry 自动化团队补充道。
　　利用 Rockwell Automation 的解决方案，Boiry Sainte Rictrude 制糖厂的大多数制造工艺(渗出、提纯、结晶)现在都实现了自动化。自 2012 年以来，两个车间(洗涤和筛选)也将由 Rockwell Automation 控制。这家制糖厂被视为 Tereos 集团的基准工厂。
　　但是 Hennebique 并不打算就此停下脚步。已经制定了实施具体 Rockwell Automation 软件的计划，以在能耗方面实现节约，并且还制定了计划来使用 FactoryTalk AssetCentre — 可追溯性软件，对制糖厂运营流程中实施的所有更改进行控。


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