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Automation for Fertilizer Plants

TDL has upgraded control systems at Phu My Fertilizer Plant (PVFCCo) since 2015, four of the projects for the EPC contractor: the natural gas compressor and the 40-PK-5001 ammonia compressor, the demineralization system, the fuel gas control system, the FAM conveyor and Libra packing system, and the conveyor tripper car. Five of the six projects moved SLC 500, PLC-5, GE Fanuc or ControlLogix 5555 systems to newer ControlLogix. The projects below are grouped by plant area.

By plant area

• Gas compression

  The GE Fanuc PLC and GE SCADA of a motor-driven natural gas compressor migrated to redundant ControlLogix 5580 with 1715 redundant I/O, keeping the Bently Nevada 3500 machinery protection, the anti-surge and performance controllers and the Modbus links to the plant DCS.

  Project references

  • 2023Phu My Fertilizer Plant – Natural Gas Compressor Control System Migration

• Ammonia compressor

  The PLC-5 control system of the 40-PK-5001 ammonia compressor replaced with redundant ControlLogix 5580, FLEX 5000 I/O and a PanelView Plus 7 HMI in the retrofitted existing panel, keeping all existing control logic and system interfaces; FAT with I/O, diagnostic and redundant processor tests, then SAT.

  Project references

  • 2025Phu My Fertilizer Plant – 40-PK-5001 Ammonia Compressor Control Replacement

• Demineralized water

  The demineralization system control moved to new ControlLogix hardware, with the redundant ControlLogix program migrated and a new FactoryTalk View ME application for the PanelView terminal.

  Project references

  • 2021Phu My Fertilizer Plant – Demineralization System ControlLogix Relocation

• Conveying and packing

  The FAM conveyor and Libra packing control system upgraded from ControlLogix 5555 and RSView32 to ControlLogix 5570 and FactoryTalk View, with control panel fabrication, PLC and HMI programming, network engineering and third-party interfacing.

  Project references

  • 2015Phu My Fertilizer Plant – FAM Conveyor and Libra Packing Control System Upgrade

• Conveyor tripper car

  The SLC 500 control of the belt conveyor tripper car replaced with ControlLogix 5580 XT and Flex XT remote I/O on an EtherNet/IP DLR with a ControlNet fibre link, in a new stainless-steel IP55 panel; position and fault signals go to the plant's FAM system.

  Project references

  • 2023Phu My Fertilizer Plant – Tripper Car Control System Upgrade

• Fuel gas

  The SLC 500 fuel gas control system upgraded to redundant ControlLogix with redundant I/O, with control panel fabrication and installation, PLC and HMI programming and commissioning.

  Project references

  • 2017Phu My Fertilizer Plant – Fuel Gas Control System Upgrade

Related services

• PLC & Control System Migration

  Allen-Bradley PLC-5, SLC 500 and MicroLogix, GE Fanuc, Siemens S5 and HIMA systems upgraded to ControlLogix and CompactLogix; ControlNet and DeviceNet to EtherNet/IP; older HMI/SCADA (RSView32, Citect, PanelView) to FactoryTalk View and PanelView Plus 7. Drive upgrades: DC drives to PowerFlex DC, legacy servo drives to Kinetix. Site survey, code conversion, FAT/SAT and planned cut-over, onshore and on offshore platforms.

• Control Panel Engineering

  Control and marshalling panels: design, schematics, fabrication, wiring and factory acceptance testing before shipment. Ex-rated enclosures for hazardous areas.

• Industrial Networks & OT Security

  EtherNet/IP networks on Stratix managed switches, with redundancy by DLR rings, PRP and HSR. VLAN segmentation, firewalls and secure remote access following IEC 62443 zone and conduit principles. Interfaces to third-party systems over Modbus and OPC UA.

Project references

• 2025 – Phu My Fertilizer Plant – 40-PK-5001 Ammonia Compressor Control ReplacementPLC-5 → redundant ControlLogix 5580 · FLEX 5000 I/O · PanelView Plus 7
• 2023 – Phu My Fertilizer Plant – Natural Gas Compressor Control System MigrationGE Fanuc → redundant ControlLogix 5580 · 1715 redundant I/O · anti-surge integration
• 2023 – Phu My Fertilizer Plant – Tripper Car Control System UpgradeSLC 500 → ControlLogix 5580 XT · Flex XT I/O · stainless-steel panel
• 2021 – Phu My Fertilizer Plant – Demineralization System ControlLogix RelocationRedundant ControlLogix relocation · program migration · PanelView HMI
• 2017 – Phu My Fertilizer Plant – Fuel Gas Control System UpgradeSLC 500 → redundant ControlLogix with redundant I/O
• 2015 – Phu My Fertilizer Plant – FAM Conveyor and Libra Packing Control System UpgradeControlLogix 5555 / RSView32 → ControlLogix 5570 / FactoryTalk View