Rotterdam, Netherlands – September 2024 – A major petrochemical plant in Rotterdam has eliminated €180,000 in annual compliance fines and boosted process efficiency by 25% after deploying the ABB PP886H 3BSE069297R1 HMI panel. The upgrade, finished in Q3 2024, addressed the plant’s struggle to track and document critical process data— a requirement under EU REACH and OSHA regulations—with its outdated control interface.
The Problem: Outdated HMI Failed Compliance, Slowed Operations
Before adopting the PP886H, the Rotterdam plant used a legacy HMI system to control its ethylene production process (a key chemical for plastics manufacturing). The system’s limitations created two urgent issues:
- No Automated Compliance Logs: The old HMI couldn’t automatically record process changes (e.g., adjustments to reactor temperature, pressure) or operator actions. Technicians spent 15+ hours weekly manually logging data into spreadsheets—leading to errors that resulted in two EU REACH fines totaling €180,000 in 2023.
- Poor Remote Monitoring: The system didn’t support remote access, so operators had to be on-site to adjust settings or troubleshoot issues. During a 2023 storm that closed roads, the plant couldn’t adjust a reactor’s pressure remotely—leading to a 12-hour shutdown and €350,000 in lost production.
- Hard-to-Read Displays: The old panel’s 10-inch, low-resolution screen made it difficult to spot subtle parameter changes (e.g., a 0.5°C drop in reactor temperature) that signal potential issues. This led to three minor equipment failures in 2024 alone.
“We were drowning in manual paperwork and blind to process issues when operators weren’t on-site,” said Jan van der Meer, the plant’s process engineering manager. “Compliance fines were hurting our bottom line, and we couldn’t expand production without a better HMI.”
After testing two competitors, the plant chose the ABB PP886H 3BSE069297R1 for its compliance features, remote capabilities, and rugged design:
- Automated Compliance Logging: The PP886H automatically records every process change, operator action, and alarm with time stamps—generating audit-ready reports in seconds. It stores 2 years of data locally and syncs with the plant’s cloud-based document management system, ensuring compliance with REACH and OSHA requirements. “We’ve gone from 15 hours of manual logging to 0,” van der Meer said. “The EU inspector visited last month and was impressed—no fines this year.”
- Secure Remote Access: The panel supports encrypted remote access via ABB’s Control Builder software, letting operators adjust settings or troubleshoot from anywhere. “During a recent maintenance shutdown, our lead operator adjusted reactor pressure from home—saving us a 4-hour round trip,” van der Meer added.
- 15-Inch High-Contrast Display: The PP886H’s anti-glare, 1920x1080 touchscreen makes even small parameter changes visible. Operators can customize color-coded alerts (e.g., red for critical pressure spikes, yellow for minor temperature drifts) to prioritize issues.
- Rugged Design for Harsh Environments: The panel’s IP65-rated front resists chemical splashes and dust—critical in ethylene production, where harsh fumes can damage sensitive electronics. It also operates in -20°C to +60°C, so it works reliably in the plant’s hot reactor rooms.
Results: Fines Eliminated, Efficiency Soars
Four months after deployment, the Rotterdam plant has seen dramatic improvements:
- Compliance fines reduced to €0: Automated logging eliminated errors, and the plant passed its 2024 EU REACH audit with no violations.
- Process efficiency up 25%: Faster issue detection and remote troubleshooting cut unplanned downtime by 38%, allowing the plant to increase ethylene production by 10,000 tons annually.
- Technician time saved: 15 weekly hours of manual logging are now used for preventive maintenance, reducing equipment failures by 60%.
“The PP886H didn’t just fix our compliance problem—it made our process smarter,” van der Meer said. “We can now track every change, act remotely, and spot issues before they escalate. It’s been a game-changer for our operations.”
Sophie Laurent, ABB’s senior HMI product specialist, emphasized the PP886H’s value for regulated industries. “Chemical plants need HMIs that do more than control processes—they need to simplify compliance and enable remote operations,” she said. “The PP886H 3BSE069297R1 delivers on both, helping plants reduce risk and boost efficiency.”
The plant plans to install 6 more PP886H panels in its propylene production unit by Q1 2025.
