Distributed Control System
KNI uses an up-to-date Distributed Control System (DCS) as technology for the supervision and control of the Ammonium Nitrate Plant. KNI'S DCS Technology was initiated/installed in 2010 and software upgrades were carried out in 2019.
Topology Operational Technology at the KNI Plant is divided into 3 levels.
- Controller & Field Level
KNI has 3 controllers: Nitric Acid (NA), Ammonium Nitrate (AN), and Utility (UT). These three controllers have the task of supervising 24/7 every process taking place during operation, such as temperature processes, vessel levels, tank pressure, etc.
Any anomalies that occur during operation will be adjusted by their respective controllers so that they remain within their normal operating window
On this level, KNI has 1 Emergency Shutdown (ESD) System unit. The ESD system functions to lock down the KNI Plant when process parameters exceed safe limits. For example, when catalyst temperature increases rapidly and significantly and the NA Controller cannot respond, the ESD system will take over and shut down the plant to to keep factory personnel safe.
- Supervisory Level
The DCS Operator and DCS Superintendent oversee plant conditions and observe plant visualizations of Nitric Acid, Ammonium Nitrate and Utility displayed on the screen of each station operator.
The DCS Operator can make process adjustments in line with instructions from the DCS Superintendent to maintain safety and optimum levels of each plant.
- Management & Planning Level
The condition of the KNI plant is also visible from the corporate level. On this level, engineers can perform analyses of plant conditions from their own laptops, without having to be in the Operator Room, troubleshoot remotely, open plant history data, and create the formulas and make decisions based on that data.
Also on this level, high-level management can collect historical data and live/actual data to support the making of strategic decisions at the KNI Plant.
All of the divisions above work 24/7 to maintain the operational continuity of the KNI Plant in safely producing high-quality products.