Visualization and control of the process of formaldehyde production at National Aerochem, Faisalabad, Pakistan

January 27, 2016 | Reliance SCADA

Located in Faisalabad, Pakistan, National Aerochem is a chemical plant that produces formaldehyde (CH2O). The plant’s production capacity is 140 tons per day. By the cracking of methanol, formalin is produced – it is 37 weight percent of formaldehyde in water. Formaldehyde and urea are used to make urea-formaldehyde resins, which are used as adhesives and binders for chipboard and plywood.

In 2015, Alpha Engineering installed a SCADA-based control system at the plant.

Control system

The system consists of a control cabinet, which houses a Siemens S7-1200 PLC, and the Reliance SCADA/HMI system, which provides an overview of the production process. The Siemens PLC collects and controls the process parameters and communicates with Reliance over Ethernet.

The Reliance 4 system is used as front-end SCADA software. Bringing some new features, it is
a replacement for the existing DCS system.

The Reliance SCADA system provides monitoring and control of the following:

  • Graphics-oriented operator screens displaying important information obtained from different transducers with the remote control of valves, motors, etc.
  • Status and important parameters of all parts of the production process
  • Real-time and historical trending of all the important parameters
  • Archiving of reports, alarms/events, and trends

Example of a visualization window

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National Aerochem, illustrative image

Alpha Engineering