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1 What can TWO GUYS AND A TRUCK" do with PlantPAx? Insert Photo Here Bos Howard Johns Manville Rockwell Automation Process Solutions User Group (PSUG) November 14-15, 2011 Chicago, IL McCormick Place West Copyright 2011 Rockwell Automation, Inc. All rights reserved.
2 Abstract In today's business model, manufacturing facilities and integrators have to accomplish more with fewer resources. Our challenge at Johns Manville was how to modernize our aging controls systems with limited financial and personal resources and utilize internal resources as much as possible. Copyright Rockwell Automation, Inc. All rights reserved.
3 Johns Manville Spartanburg Facility Johns Manville's Spunbond Polyester, a continuous filament, needle punched reinforcement mat, is one of the strongest yet lightest and most flexible engineering materials known. When incorporated into multi-layer modified bitumen roofing products, it combines to create an effective barrier against forces of the great outdoors. 500,000 Sq Ft of manufacturing space Three production Lines Polyester Spunbond Roofing mat Filters
4 Roadmap Development DEFINE OBJECTIVES What do we have? Which problems do we want to solve? How will our new system perform with existing systems? What funds will be provided for these projects?
5 Roadmap Development SUPPLIER SELECTION Which controls systems can meet our needs? Design? Operate? Maintain? Lowest cost? Flexibility?
6 Roadmap Development PROJECT EXECUTION Involvement of operators and maintenance to help design and implement? Leveraging the best practices from suppliers? What will be our challenges?
7 Define Objectives System Level Totally intergrated controls system (One System; One Vendor) Reduce spare parts and training costs A simple interface to the MES and SAP systems Uniform display for operators Reduce costs to implement Reduce costs and time to maintain Reduce the skills to maintain Standard Equipment and Code Code must be modular and transportable between production lines and between facilities
8 Define Objectives System Level Existing controls systems were outdated on all lines. Plant did not desire a Hybrid system. DC and AC Line Drives were outdated. Alarm Management was implemented poorly in existing controls system. A Recipe Management system was required. Vibration shutdown needed to stop faults on large and costly equipment A need to reduce energy utilization Improve real time reporting
9 Define Objectives Operator & Maintenance Leverage local Technical College programs to train maintenance personal Operators will be able to quickly view process information needed to correct problems. Operators shall run production lines by exception, not by monitoring. Operators can assist maintenance to identify problems. The design shall have Production, Quality, Technical and Maintenance involvement. A Simulator needs to be created to train New Operators. Maintain the look of previous system, where possible. Need to define and implement integrated safety
10 Supplier Position and Selection Corporate Standard is Honeywell for DCS and Wonderware for Historian Honeywell promoted superior Advance Process Controls for upgrade. Entire Upgrade was to be done by one internal and one external resource. Small Rockwell installed base in the plant (one L1) Existing DCS was Provox (SR90 Controllers) and Delta V for Provox; Existing PLC (Modicon 984), Siemens (S-5; S-7).
11 Supplier Position and Selection Plant engineer had many years of DCS experience, and his PLC experience was limited to discrete (state machines). Experience in multiple DCS systems Internal resource had limited experience with Rockwell. Logix was in 2000 with L55 processor Last time engineer worked with RsView HMI was 15 years ago
12 Define Solution Equipment Selection DCS vs PLC Traditional DCS advantage Time and effort to implement Embedded tools Loop Control Traditional PLC advantage Cost of equipment and software license Flexibility of system Discrete logic (State Machine) Easier Drive integration
13 Define Solution Needed more than a Standard DCS or PLC to meet the design requirement We needed a Traditional DCS and PLC System together in one unit
14 Supplier Selection Plant & Corporate Engineering involved in decision making DCS Other PLC AB PLC Time & Effort to Implement Best Lowest As Good as a DCS Embedded Tools Good Average Good Loop Control Good Lowest Good Ease for Plant to use and troubleshoot Good Good Best Cost to Maintain Highest Lowest Lowest Flexibility of system Rigid Flexible Flexible
15 Supplier Selection PlantPAx selected PlantPAx is as good as DCS in two areas PlantPAx is capable of project configuration as fast as competing DCS systems. PlantPAx regulatory loops are as good as competing DCS systems. PlantPAx is better than DCS User can scale PlantPAx easier than a DCS system. PlantPAx has more flexibility and scalability than DCS. Better TCO
16 Supplier Selection PlantPAx selected PlantPAx negates DCS advantage Standard Faceplates added (not just Faceplates but a system) Enhanced PID Imbedded Advance Level controls Effort to code and develop screens has been greatly reduced AOI & Global Objects
17 Supplier Selection Execution Plan Design Resources One Control Contractor Mechanic Firm Vender Support McNaughton McKay Electric Support Drives PLC SCADA Rockwell Greenville/Atlanta Help Desk & Web
18 Project Execution PlantPAx is a System that the user can just use out of the box. Leverage Modular/Flexible Development AOI/FP Modules Describe how we modified Process Library Did very little modification on PlantPAx Library (Just Used it) Modified other FacePlates
19 Project Execution - Example of PlantPAx Faceplate Flexibility This is a standard loop FP. An alarm indicator and reset was added. The alarm indicator was added and will change color as to the severity of alarm. The alarm will also blink if un-acknowledged.
20 Project Execution PlantPAx Modified Faceplate The addition of some detail parameters was added for tuning and setup.
21 Project Execution - PlantPAx Modified Faceplate This is a standard accelerator FP, but the last alarm indicator was added.
22 Project Execution -PlantPAx Modified Faceplate Using the standard Interlock AOI and FP, but changing the I to an E for E-stop
23 PlantPAx Flexibility - Display Layout Two monitors are utilized to give the operator a rolling view of the process. The operator can scroll through the entire line or set up a favorite screens selection.
24 Event Alarms from PLC From Standard E-PID PLC Code for Simple Loop Point Custom Alarm Block (AOI) Alarm Severity: This parameter can be set dynamically
25 PlantPAx Flexibility - Data Base Recipe Management for Portability Recipe Selection The operator will single click on the merge number to select which recipe he desires. He then can publish it to the next up recipe page on the HMI by clicking the LOAD SELECTEN RECIPE button.
26 PlantPAx Flexibility - Recipe Code is simple NOT_FOUND:= 1; // Set for New recipe load FOR x := 0 TO 199 DO // Find active Recipe Index If(Working_Merge_String=SPT003LOOP_RECIPE_STORE_STRING[x]) THEN; // Check for Recipe Edit RecipeIndexFound:=x; NOT_FOUND:= 0; END_IF; END_FOR; IF (SPT003LOOP_RECIPE_STORE AND (NOT_FOUND)) THEN; FOR x := 199 TO 0 BY -1 DO IF(SPT003LOOP_RECIPE_STORE_STRING[x]=BLANK_STRING) THEN; RecipeIndexFound:=x; END_IF; END_FOR; END_IF;
27 Work Accomplished - First Phase The Plant selected the oldest Line to upgrade. The Line Points Analog 184 points Digital 2016 points VFD 32 Drives Need to produce 600 drawings Develop screens (96) Loop and Line drive code Completed
28 Work Accomplished - Second Phase The Plant selected the Largest Line to upgrade The Line Points Analog 286 points Digital 2856 points VFD 52 Drives Need to produce 1200 drawings Develop screens (43) Loop and Line drive code copied Complete March 2012
29 Conclusion Operators, Technical, and Maintenance personnel designed screen layouts- Reused Many Existing Familiar Displays Operators are able to locate production problems quickly through Better Alarm Management Added Screen Automatic Popup Display for critical events Screen diagnostic (I/O, Drives, Networks, Open Wire as well as Production Faults)
30 Conclusion More accurate control of pressures, temperatures, and speeds Vibration Monitoring incorporated into the system Flex I/O form factor allowed existing panels to be used Limited rewiring Can leverage Local Technical College training programs, which provides Rockwell Automation technology training Provided input to enhance PlantPAx capabilities
31 Conclusion The first phase was a roaring success. The Line # 3 project was completed on budget which is almost half the cost of a DCS controls system. Speed of design was equal to or better than a DCS system The second phase is on a successful track. Line #5 was designed using a GuardLogix Integrated Safety controller to meet the new Safety standard: Category 3 Safety and Category 1 Stop. Used more of the PlantPAx Library All of this was produced by two individuals within two years.
32 Conclusion - Keys to Success Keys to Success Involvement of Operator, Maintenance, and Process Engineering personnel in design Design team understood DCS and PLC strengths and weaknesses Review of limitations in technology early on in design phase set proper expectations
33 Conclusion - Keys to Success Leverage PlantPAx control modules & library of AOI and Faceplates for whole plant control Collaboration and teaming with Supplier Mc-Mc technology team support Critical design and architectureal reviews with Rockwell Automation technical team Work with Rockwell Automation through defined critical risk areas such as software installation and activation, Device Based Alarming, Display Conversions for re-use, etc.
34 Conclusion - Keys to Success End results: PlantPAx is a system, not a collection of pieces.
35 Questions Bos Howard Johns Manville Copyright 2011 Rockwell Automation, Inc. All rights reserved.
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