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SUCCESS STORY

Morris, IL, USA

2003

2004

Chemical

Executive Summary

With 19 manufacturing sites and four technology centers in 13 countries, Reichhold is one of the world’s largest suppliers

of unsaturated polyester resins for composites and a leading supplier of coating resins for a wide variety of markets and

applications. Reichhold is committed to being the preferred and responsible supplier of both conventional and specialty

products to an increasingly diverse group of global customers. To serve these customers, Reichhold has expanded into

rapidly growing markets such as India and China.

Reichhold is dedicated to providing its customers innovative and high quality value-added products and services. Under

such well known brand names as POLYLITE

, HYDREX

, DION

, and NORPOL

, the company offers a complete line of

resin products, gelcoats, and bonding pastes for a wide variety of composites end use applications. Four state-of-the-art

technology centers support the development of new materials for both advanced and conventional composite applications.

The company is committed to developing new resin systems based on renewable, recyclable, and environmentally friendly

materials,and it markets these under the ENVIROLITE

brand.

Reichhold began using Yokogawa’s Micro-XL distributed control systems at its emulsion and polyester plants in 1993 and

experienced no major problems while they were in operation. When the end of support was declared for Micro-XL and its

batch recipe package, Reichhold chose to upgrade to Yokogawa’s CENTUM CS 3000 production control system and CS

Batch package. The installation was a success and both remain in use today.

High Reliability Assured through Upgrade to Yokogawa’s

CENTUM CS 3000 Production Control System and CS Batch

Package

Central control room

ISD-SP-R135

SUCCESS STORY

The Challenges and the Solutions

1. Production excellence with CS Batch

More than 200 main recipes and 50 blending recipes are used in eight reactors and blending tanks at the Morris plant,

and reaction times vary from eight to 28 hours. In addition to preventing contamination, it is important to maintain efficient

production operations by optimizing the utilization of resource cycle times and minimizing downtime. Yokogawa’s CS Batch

package supports the complex batch operations at this plant. The CS Batch package includes flexible and scalable batch

management software for centralized recipe/process management and distributed unit supervision. CS Batch is used to

automate a wide range of Reichhold’s batch processes and multi-product/multipath processes, thereby demonstrating

ease of use, outstanding reliability, and sophisticated functionality. Using the CS Batch package, Reichhold has reduced

lifecycle engineering costs,shortened time to market, improved plant performance, and kept unexpected control failures to a

minimum.

A large amount of operational data that is vital for making business decisions on productivity, quality,and safety

was transferred from the CENTUM CS 3000 to an existing PI data historian system via an OPC interface. Reichhold analyzes

this data to identify improvements that can be made to operations.

2. Asset management: FOUNDATION™ fieldbus devices, AS-i system, and PRM

Reichhold is always striving to apply new technologies that minimize maintenance costs and make maintenance more

proactive. Nearly 300 FOUNDATION fieldbus-enabled devices are utilized in the Morris plant. Data such as temperature,

pressure, and flow rate from individual transmitters can be monitored at the same time and easily assigned to

different instrument blocks, with minimal engineering. In addition to reducing wiring costs, this makes it possible for process

engineers to analyze a process in real time.

An Actuator Sensor Interface (AS-i) system is used in this plant to connect more than 700 valves,achieving a major reduction

in wiring costs. AS-i offers many of the benefits of more complex and costly bus systems, but at a substantially lower cost,

and with greater simplicity.

All FOUNDATION fieldbus devices can be monitored from the engineering room using the Plant Resource Manager (PRM)

asset management software package. Using this package, process engineers can immediately find out the status of every

field device without having to do an onsite inspection. An engineer is able to identify what went wrong, pinpoint the failure

location, and identify suspect parameters from the comfort of an office desk. A plant maintenance technician can then

schedule a check of the problem devices. In this way, PRM introduces an entirely new approach to field device maintenance.

Fieldbus temperature transmitter

Fieldbus pressure transmitter