Additionally, the legacy system was programmed with more than 4,000 alarms that notified operators of operational changes more frequently than needed. These nuisance alarms required operators to unproductively respond to hundreds of active alarms to identify and respond to those significant to the operation.
This made it nearly impossible to quickly recognize and respond to legitimate issues in the process that needed to be fixed. Limited visibility combined with too many alarm notifications resulted in extra work and lost productivity.
“Once the company decided to expand the facility, we made the business case to upgrade our process automation software, too,” said Josh Johansen, project engineer, The Mosaic Company.
“We needed contextualized information intuitive enough for any employee to use, and a resolution for our overalarming issues. This large-scale expansion was an excellent opportunity to finally move forward with a full visualization solution.”
Enhancing the View
Automated Controls of Tampa Inc. designed and implemented Mosaic’s new high performance HMI utilizing the PlantPAx® Library of Process Objects (PDF) from Rockwell Automation. The New Wales facility already had an installed base of Rockwell Automation hardware and software, so making the upgrade was a smooth transition.
The PlantPAx distributed control system is based on open communication standards to streamline control and information flow across the plant. It also provides a comprehensive and accurate picture of a facility’s operations, providing operators optimal and easy-to-understand insights, trends and alarms.