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  • HOME > Case Studies > Industrial Automation > Usina Coruripe Plant Campo Florido Unit

    Usina Coruripe Plant Campo Florido Unit

    Selecting a reliable product to improve productivity and reduce workload

    Azbil’s smart valve positioner attached to a valve that controls the flow of syrup during the processes of boiling down syrup and producing crystals (decoction and crystallization). The positioner is installed using a mounting plate which differs in

    In the examination of many manufacturers’ positioners, the quality and cost effectiveness of Azbil Corporation’s smart valve positioners became apparent through actual demonstrations. The plant utilizes valves made by a number of manufacturers, both Brazilian and foreign. If a positioner fails, the company must ask the manufacturer for repair, which is a heavy burden on the maintenance site. Azbil’s smart valve positioner received high marks for its compatibility with various manufacturers’ valves of differing specifications used at Campo Florido, as well as for its quality and cost-effectiveness. Azbil’s positioner was selected in June 2018. In July of the same year, smart valve positioners and 10 sets of mounting plates for installation on other companies’ valves were delivered, and the positioners began operation.

    “Although we do our best to improve the quality of the plant instrumentation air, we cannot completely prevent contamination by water and oil. In operating Azbil’s positioners*, we found that they continue to operate without failure better than other manufacturer’s positioners,” says Wilson Angelo de Menezes Junior.

    In addition, the installation and adjustment of positioners differ depending on the valve manufacturer, so with many brands of positioner the operators must learn many different procedures. However, since Azbil’s positioners can be mounted on any manufacturer’s valve, it is now possible to handle all valves by learning just one installation procedure and adjustment procedure.

    “If positioners are standardized throughout the entire plant, we can reduce the workload on the staff. Azbil’s positioners are less likely to break down, are easier to maintain, and put less of a burden on the staff. Although it has only been a year since they were installed, they have earned a high level of trust,” says Instrumentation Supervisor Cacinildo Silva.

    Not only have repair costs been reduced, thanks to the elimination of failures, but also the standardization of positioners has made quick replacement work possible. As a result, the time required to stop the plant has been shortened, and the plant’s availability factor has improved.

    “The most important thing is that the equipment continues to operate. For that purpose, a situation in which no products fail is a must. Sugar and ethanol production processes run for 7 to 8 months, leaving a 4 to 5 month outage for regular repairs. If the equipment stops due to a positioner problem during the 7 to 8 months of operation, production efficiency is greatly affected. By changing to Azbil’s positioners, we were able to increase availability and production efficiency,” says Plant Manager Geovani Araujo da Silva.

    Azbil’s smart valve positioner attached to a steam release valve。

    * The positioners used in the plant are designed in such a way that the section housing the electric and electronic parts are isolated from the air circuits, thereby reducing the risk that the instrumentation air, which contains oil and moisture, affects those parts.
    This case study was published in the 2020 No.2 issue of the azbil Group's corporate magazine, azbil.