Hubei Sanning: Black-screen operation reaches new heights in smart factory construction

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Hubei Sanning: Black-screen operation reaches new heights in smart factory construction. Author/Source: Compiled and published by Sanning Chemicals, Nitrogen Fertilizer and Methanol Technology Network. Date: May 22, 2019. Clicks: 55. Good news has come recently from the site where an advanced control system was developed for the hydrogen peroxide production unit at Hubei Sanning Nylon Company – the unit has now achieved “driverless” operation with black-screen control. “The “black screen operation” system represents another new development resulting from the company’s efforts to create smart factories. With the introduction of this first such system, it has become possible to carry out automated operations for the entire process related to hydrogen peroxide production, with one-click control, black screen operation, alarm functions, and monitoring of operation records. This represents an important improvement in the quality of operations and the level of automation within the company, and it is crucial for ensuring smooth operations, increasing production volume, and raising the quality rate of products. It is understood that the advanced control system for the hydrogen peroxide production plant is the company’s second fully integrated intelligent control system developed independently, and it represents a first in China. This system is designed with high standards and a high level of intelligence, aiming to achieve \"driverless, screen-free operation\" throughout the entire process. It took 4 months to develop and build this system. Through the combination of model control and expert control, various control variables are dynamically adjusted in an appropriate manner using methods such as model prediction, rolling optimization, and feedback correction, in order to stabilize key process parameters. After the system was put into operation, the average standard deviation of each controlled variable decreased by 51.5%, and the number of operations per day dropped from over 1,000 to almost zero, achieving intelligent control throughout the entire process. At the same time, on the basis of achieving intelligent control throughout the entire process, a \"black-screen operating system for hydrogen peroxide production plants\" was developed using the APC server system, DCS system, and Windows system as platforms, enabling the company to save over 500,000 yuan in costs associated with purchasing external software. Once this system is in operation, it will take full control of the process monitoring for the entire facility. It is capable of scanning all the process parameters of the facility within 200 milliseconds. If the facility operates smoothly without any warning signals for 5 minutes, the DCS display will go black, enabling what is known as \"black-screen operation.\" Should any abnormality in the process parameters be detected while the system is running, the DCS screen will light up, displaying warning messages and guidance on how to proceed. Next, the applications for “driverless operation” and “screen-free operation” will be rolled out across the entire company, and software copyrights will be applied for to protect this knowledge.