KuibyshevAzot chemical plant

Case Study: KuibyshevAzot Chemical Plant, Russia

Russian chemicals giant KuibyshevAzot uses DataHub software to link Yokogawa DCS to proprietary system in QNX

Deep in the heart of Russia, on the banks of the Volga River, stands one of the country’s most successful chemical plants: KuibyshevAzot. Founded in 1966, the company produces over 1.5 million tons of chemicals per year, with sales volumes averaging around ½ billion dollars. Through constant technology upgrades, the plant maintains the highest efficiency levels in all of Russia for ammonia production—and higher than average efficiency levels for nitrogen fertilizer production.

One of the goals at KuibyshevAzot is to update and re-equip the plant to optimize the consumption of raw materials and energy. To meet this goal they recently installed a Yokogawa CENTUM CS3000 Distributed Control System to control their ammonia production process. They were satisfied with the performance of this state-of-the-art system, but there was one question – how to interface with their Plant Information System Server?

The Plant Information System Server is KuibyshevAzot’s proprietary system that collects live process data, calculates technical and economic performance indicators, and generates reports—processing more than 900 variables simultaneously in real time. Due to its mission-critical status, the system runs on the QNX real-time operating system. Getting the data from the Yokogawa control system into the Plant Information System was vital to the overall success of the project.

To create the data link, KuibyshevAzot chose the Windows and QNX versions of DataHub® software from Cogent Real-Time Systems.

Each of these DataHub instances is an off-the-shelf middleware program that collects and distributes real-time data. The DataHub instance that runs in Windows can connect to any OPC server, such as the Yokogawa ExaOPC Server used in the project. On the QNX side, the QNX version of DataHub software was connected to the Plant Information System server. Once connected to their respective systems, the two DataHub instances establish a TCP tunnel/mirroring connection across the network to create a Windows – QNX real-time data link.

“This connection has saved us a lot of money in development time,” said a company spokesperson. “The major requirement was to continue using our existing information system. The deployment of DataHub software saved us time and money because there was no need to purchase, develop, or configure a new information system. The update process was seamless. We kept our existing information display consoles and report forms. All we had to do was add more report forms and update the information displays.”

“KuibyshevAzot needed something robust, something they could trust with their vital data,” said Leonid Agafanov, Managing Director of SWD Software, Cogent’s local distributor who was involved in the project. “Linking the DataHub software in QNX to DataHub software in Windows combined the strengths of both systems.”