Flexibility with Fieldbus
Plant rebuilt in record time
For Harald Liebisch, team leader for automation at Basell in Frankfurt, an exciting phase started in December 2005 when the polymerization plant had to be rebuilt in record time: “Once the initial decisions regarding the new plant had been made at the end of the year, things moved very quickly”, Liebisch summarizes. “We were able to update the plant within three months and equip it with Foundation fieldbus lines.”
Liebisch had already had some initial experience with multibarriers, though he was not entirely satisfied with the results. When the Turck solution was presented, the decision was made very quickly: “We were immediately impressed by the full galvanic isolation of the Turck multibarriers,” the automation manager explained, “it was exactly this feature that was missing before.”
Multibarriers with full galvanic isolation
The Turck MBD-49-T415/Ex multibarrier allows for the installation of Ex-i drop lines up to 120 m in length. The full galvanic isolation is provided both between the trunk line and the output circuits as well as between the four output circuits. This prevents compensation currents from developing due to potential differences. The integrated short-circuit protection is activated if a short-circuit occurs at a fieldbus node. Only the output affected is disconnected – the trunk line and the other outputs of the affected fieldbus segment remain in operation.
Actual planning was able to be completed just as quickly as the decision process, thanks to the configuration tool from Turck. “We used the tool to make a preliminary plan of the segments. The length of the fieldbus lines, the division of the fieldbus barriers, the assignment of inputs to multibarriers – the configuration tool allowed us to define all these points very quickly,” Liebisch explained.
Broad base
A total of nine fieldbus lines are currently in operation at the Basell polymerization plant. Power conditioners connected upstream from each one are provided for supplying the fieldbus segments. The scope of this project also includes plans for expanding the Foundation Fieldbus network to 15 segments. “We are very happy with the Turck products,” Harald Liebisch says. “In addition to the galvanic isolation, their reliability and simple operation are outstanding. Since we have completely migrated to Turck, we have not had any more difficulties. We therefore also intend to implement the next expansion stage using Turck products.”
Conclusion
The changeover to fieldbus technology has enabled the installation planners at Basell in Frankfurt to create the basis for a flexible response to market requirements. The speed at which the installations can be adapted has already been put to the test with the first FF project. The installation in the polymerization plant had to be made operational as quickly as possible without a test phase.
- Automotive
- Press Shop – Tool Identification
- Sheet Metal Thickness Measurement
- Body Shop – Welding Nut Detection
- Paint Shop – Skid Identification
- Area Guarding for Robotic Cells
- Final Assembly – Robot Assembly
- Inspection of Tips on a Welder
- Final Assembly – Diagnosis of Leaks
- Tier 1 – Bumper Identification
- Manual Feeding in Weld Cell
- Powertrain – Contactless Verification
- Body Detection in Automobile Production
- Detecting Black Parts on Black Door Panel
- Item-level Detection with UHF RFID
- Moonroof Clear Glass Detection
- Long-Range Inspection in Automotive Assembly
- Rubber Washer Detection on Engine Block
- Engine Block Part-In-Place Detection
- Electric Vehicle Detection in Charging Station
- Vehicle Detection in a Self-Serve Car Wash
- Success Stories
- RFID Guides AGV in Suspension Production
- IO-Link Wired Silencer Production
- Workpiece Carrier Identification in Rear Vent Production
- Weld Nut Sensing
- RFID Traceability
- RFID in Engine Production
- Bumper Production with Identification
- Solutions for Paint Shops
- Welding and Assembly Sensors
- Angle Sensors for Assembly Systems
- Tool Identification
- RFID Identification of Injector Nozzles
- RFID in the Body Shop
- Pick-to-Light for Bumper Assembly
- IO-Link Eases Differential Gear Production
- RFID and I/O modules for Safe Tool Changes
- Ply Orientation Inspection
- Chemical
- Detection of Pigs
- Remote Signal I/O
- Easy Connection of Field Devices
- Signal Processing with System I/O in the Control Cabinet
- Remote Tank Level Monitoring with DX70
- Signal Separation with Interface Technology in the Control Cabinet
- Identification of Hose Connections
- Efficient Monitoring of Cabinets in the Field
- Monitoring of Quarter Turn Actuators
- Planning and Assembly of System Solutions
- Success Stories
- I/O System Excom Creates Space in the I&C Rooms
- Zone 2 and 22 RFID
- Efficient Testing Control
- Intrinsically Safe Field Communication
- Process Control System Partnership
- Hazardous Area Remote I/O
- Dual Valve Position Feedback
- Flexibility with Fieldbus
- Asset Management with Remote I/O
- Correct Positioning with RFID in Carbid Production
- Energy
- Food and Beverage
- Dough Height Inspection for Accurate Measurement
- Leading Edge Detection of Plastic Container
- Dough Thickness Control in Rolling Machines
- Identification of Food Containers
- Date/Lot Code Verification
- Container Check
- Detection of Valve Position
- Barcode Reading on Depalletizer Station
- Reliable Cap Orientation Verification in Aseptic Areas
- Clear and Tipped Bottle Detection on Depalletizer
- Detection of Pipe Elbows
- Clear Plastic Bottle Detection
- Identification of Chocolate Moulds
- Frozen Food Packaging Label Inspection
- In-Line Bottle Accumulation on Single Filer
- Detecting Refrigerated Breakfast Rolls on a Multi-Lane Conveyor
- Success Stories
- Track and Trace in Meat Production with RFID
- Contact-free Encoder in Potato Production
- UHF RFID in Food Distribution Center
- RFID for Chocolate production
- Distributed I/O for Food Equipment
- Remote I/O for Distilleries
- RFID and Autoclaves
- IP67 Power Supplies for Conveyors
- Transparency in Chocolate Manufacturing
- Identification in Food Product Storage
- Mobile Equipment
- Distribution Lines for Field Sprayers
- Loading Dock Occupancy Monitoring
- Measuring the Ground Clearance on a Field Sprayer
- Monitoring Railcars Wheels Wirelessly
- Reach Stacker Status With Bright Lighting Indicators
- Angle Measurement on a Field Sprayer
- Determining the Boom Angle Position
- Material Flow Monitoring on a Combine Harvester
- Vehicle at Loading Dock
- Equipment Compartment Illumination on Fire Engines
- Wireless Forklift Signaling
- Two-Axis Tilt Measurement on a Combine Harvester
- STS Collision Avoidance
- Collision Protection on Reach Stackers
- Success Stories
- Position Measurement with RFID and Encoder
- Speed Control via Radar Sensor QT50
- RFID Guides AGV in Suspension Production
- Block I/O Modules on Super Yacht
- Wear-free Encoder on Hopper Dredger
- I/O for Dust Suppression
- Cabinet Cooling
- Quick Disconnect Connectivity
- Automation Solutions for Extreme Cold
- Remote I/O for Cranes
- Rugged Heavy Metal Lifting
- Rollercoaster Positioning
- Mobile Machinery Solutions
- Exact Height Positioning
- Critical Angle Sensing
- Angle Sensor Detects Platform Lift
- Predictive Maintenance of Machine Parts at Port-Based Coal Conveying Facility
- Oil and Gas
- Packaging
- Identification of Printing Color Cartridges
- Reliable Operation of Machines
- Monitoring of Caps in Filling Lines
- Monitoring Changeover Processes
- Identification of Test Bottles
- Level Monitoring of Ground Coffee
- Box Insert Detection
- Level Detection in Vessels
- Carton Dimensioning
- Detection of Transport Containers
- Clear Container Detection
- Correct Label Verification
- Detecting Different Size Packages on a Conveyor
- High-Speed 2D Barcode Inspection
- Multicolored Reflective Package Detection
- Plastic Roll Diameter Measurement
- Tube Positioning Using a Registration Mark
- Vertical Form Fill Seal Machine Solutions
- Success Stories
- Pharma
- Monitoring of Quarter Turn Actuators
- Detection of Pipe Elbows
- High-Speed Tablet Counting With Fiber Amplifier
- Remote Signal I/O
- Planning and Construction of Super Skids
- Easy Connection of Field Devices
- I.V. Bag Liquid Detection
- Identification of Portable Tanks
- Identification of Cryovessels
- Identification of Mobile Containers
- Liquid Level Monitoring In A Large Tank
- Identification of Mobile Containers with Handheld Devices
- Identification of Hose Connections for Precursors
- Identification of Hose Connections in Sterile Areas
- Identification of Hose Connections in Ex Zone 1
- Identification of Big Bags and Bioreactors
- Identification of Single-Use Applications
- Success Stories
- Semiconductor