cpp – Process technology for the chemical industry 01.2019

High flexibility
“It was also crucial for us to increase the
availability of the process technology and
achieve a high level of flexibility while
using the control system”, Taube continues.
“At the same time, the objective was for
every point in the plant to ideally be acand
equipped for regular operation with
three operator stations each as well as one
reserve station. The control room is big
enough for 24 people at once. Since PCK
works in four shifts, there are normally 125
plant operators including standby personnel.
This will presumably be the case in May
2019, when all six control consoles are fully
staffed.
Implemented with partners
PCK developed the concept for this control
room itself and subsequently implemented
it together with partners. “For example, we
had a very clear idea from the outset of how
the production facilities should be controlled
in the future”, says Taube. “The fundamental
requirement was that the plant
should be operated via the video wall in
combination with smaller monitors.” Comprehensive
research and market analysis was
undertaken in the search for a suitable so -
lution. Following an extensive trial with a
test workplace, PCK opted for a holistic so -
lution from Jungmann Systemtechnik.
Amongst other things, this covered the
layout concept, furnishings, video systems
and multi-consoling hardware and software.
Virtual sky
The control room equipment from JST is
now located in a new, windowless bunker
building, which was constructed using
3200 m 3 of concrete and 520 tons of steel.
The building is protected against pressure
and explosion. Since windows had to be
dispensed with in the control room, the virtual
sky was installed as an alternative. This
is a 105 m 2 illuminated ceiling which PCK
developed together with the Fraunhofer Institute
for Industrial Engineering (IAO) in
Stuttgart. It simulates the sky at any time of
the day or night and thus ensures a pleasant
working atmosphere.
cessible from every workstation.” Apart
from the process control technology, this
is mainly the responsibility of the hardware
and software developed by JST for
controlling the workstations and video
systems: “Multi-consoling correlates
monitors, in other words each plant operator
always sees precisely the information
they need at any given time on one of
their monitors”, explains Jungmann. “Up
to 1000 different process images can be
connected to one workstation in this way.”
The number of monitors per workstation
was reduced as a result. The visualisation
surface on which a plant can be represented
was simultaneously increased fivefold.
Moreover, only one keyboard and mouse
are required for the different views on
each workstation. “In the past we had four
keyboards per workstation and were
forever jumping back and forth between
them”, Taube adds. That was not only inefficient
and inconvenient; the control room
operator also found it difficult to see at a
glance which monitor belonged to which
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