Die Bayer Crop Science Division entwickelt Wirkstoffe für den Pflanzenschutz und entsprechende Herstellungsverfahren. Um schneller und individueller zu produzieren, wollte der Hersteller nun die dafür nötigen Prozesse unter einem Dach zusammengefassen. Als Automatisierungsspezialist und langjähriger Geschäftspartner wurde Festo frühzeitig in die Planung mit einbezogen.
Das Projekt erwies sich als anspruchsvolle Aufgabe für die Ingenieure: Die neue Anlage gestaltete Bayer so, dass die vorhandenen Teilanlagen und Apparaturen flexibel miteinander verbunden und betrieben werden können. Das Prozessleitsystem ist in 67 Automatisierungssysteme aufgeteilt, sodass auch die Prozesssteuerung flexibel anpassbar ist. Zugleich galten verschärfte Anforderungen an den Explosionsschutz: Bayer verarbeitet in dieser Vielzweckanlage betriebsmäßig brennbare Flüssigkeiten, und die laufende Verfahrensentwicklung macht darüber hinaus zahlreiche Schnitt‐ und Eingriffsstellen erforderlich, da sich die Prozesse häufig ändern. Die Gesamtanlage war daher in explosionsgefährdete Zonen 1 und 2 eingestuft.
The more reliable the ICE components are, the more efficiently the process system functions. Even if a process engineering system has already been largely optimised, increased output is still possible with a system without downtime. Tried and tested ICE components, certified to IEC 61508, reduce inspection cycles and inspection time to a minimum and ensure that no unplanned downtime occurs due to repairs. As a result, the entire facility remains productive continuously.
Bayer is not the only company that is very satisfied with our products. The multi-purpose facility has demonstrated that this faith in our products is justified. More than 1500 solenoid valves from the VOFC series were installed, in safety-related as well as other control circuits. To date, none of these components has failed, nor is there even the slightest indication that they will. 14 of these valves were also subjected to an endurance test in 2015, the results of which have led the German Technical Control Board TÜV-Rheinland to issue a new certificate. Since then, Festo is the first company to be able to forego any reference to a limitation of the valves' service life. Of course, you always must implement the necessary precautions to avoiding errors, and ambient conditions also have to be taken into consideration. But in principle, you, as the system operator, specify the duration of use of our certified solenoid valves VOFC yourself.
Another Festo product that has been paying off for Bayer for many years is the polyurethane tubing in combination with the push-in fittings NPQH. It is used as compressed air supply lines for the solenoid valves. It is quick to assemble and flexible in installation. The tubing clip mechanism in the fitting has an integrated sealing ring which prevents the loss of compressed air and can be quickly released if necessary.
Other advantages for Bayer are the tubing’s strong resistance to UV radiation and its resistance to chemicals. We can supply tubing in various colours, making identification by the customer unnecessary if nitrogen is used in addition to compressed air. Thanks to our bulk packs, there is no need for connector fittings even when long tubing lengths are required. This reduces the possible number of leaks to an absolute minimum.
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