Digitalisation | Elkem Solar

Control system upgrade lifts furnace SI5-5 to a new level

Init helped Elkem Solar upgrade the control system on furnace SI5-5 to System 800xA on virtual servers, completing the switchover within a single shutdown and giving operators better decision support.

 

Elkem Solar produced high-purity silicon for solar cells at Fiskaa in Kristiansand, a process that demands precise control and stable furnace operation.

To keep the control system on furnace SI5-5 secure, up to date and fit for the future, Elkem Solar engaged Init Kristiansand (then Necto) in 2016–2017 to carry out a complete upgrade.

Operator in the control room for furnace SI5-5 with new high-resolution screens

ASPIRATION

A secure, modern control system without disrupting production

Regular upgrades, updates and migrations are necessary to maintain a secure control system. Elkem Solar wanted to modernise the software and operator environment on SI5-5 and give metallurgists and operators better tools for decision-making, while keeping the impact on production to an absolute minimum.

SOLUTION

A complete upgrade, within a single shutdown

The delivery covered an upgrade of the PLC software, upgrades of the software libraries, and replacement of older operator screens with new, high-resolution versions. The new system was installed on virtual servers, and Init Kristiansand was responsible for the commissioning.

To reduce risk, the old and new systems ran in parallel, and the switchover was carried out during a planned shutdown of the furnace. The upgraded process control system is based on System 800xA 6.0.3, with two clients and three AC800M controllers.

RESULT

Connecting people, process and equipment

By adopting the System 800xA digital platform, SI5-5 can draw on the values of collection, automation, optimisation and collaboration. The Aspect Object Model digitalises the physical plant and ties people, process and equipment together, creating value through increased operator efficiency, improved equipment availability and better visualisation of process data.

Metallurgists and operators on SI5-5 now have a powerful tool that helps them make the right decisions based on the right information. It is now possible to close the loop between production and maintenance, drive production optimisation and build a better understanding of the current situation. Together with Elkem Solar, Init Kristiansand has lifted SI5-5 to a new level.

Reach out

for more information

Geir Kulia

Commercial Manager

[email protected]

Init Kristiansand,

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