INDUSTRY: HYDROCARBON PROCESSING Chevron Oronite...

“We were looking for a SCADA system that would be easy to connect to our ERP application and we also wanted to implement the ISA-95 standard. The Wonderware System Platform met our expectations.”

Serge TalleuxIndustrial IT Director

Making it Easy to Connect to an ERP Application While Monitoring the Production of Additives for Oil and Gas

Goals• ImplementaSCADAsystemforanewadditive

productionunit• Facilitateinformationsharingbetweenshop

applicationsandtheSAPERPapplication• UsethinclientstoconnecttotheSCADAservers• Determinestandardsthatmakeiteasiertoreuse

andupdateapplications

Challenges• Addingdifferenttypesofequipmenttothe

ERPapplication• Standardizingcurrentterminology• Meetingveryshortimplementationdeadlines• AdoptingtheISA-95standardtodefinedata

sharingbetweentheshopfloorandtheERPapplication

Solutions and Products• WonderwareInTouchHMIforTerminalServices• WonderwareEquipmentOperationsModule• WonderwareSystemPlatform

Results• Terminologyfordifferentproductsand

measurementunitswerestandardized• InformationsharingbetweentheERP

applicationandproductionunitsnolongerrequiresmanualintervention

• Launchinganewproductandaddingnewitemsishandledwithoutjeopardizingtheexistingproduct

• Modificationstoanobjectareimmediatelytransferredtoallofthegraphicdisplays,resultinginsignificanttimesavings

INDUSTRY:HYDROCARBONPROCESSING

Chevron Oronite Company LLCwww.chevron.com/products/oronite/

Gonfreville l’Orcher (Le Havre), France-ChevronOroniteisasubsidiaryoftheChevronCorporation,oneofthelargestoilcompaniesintheworld.Thecompanyspecializesintheproductionofadditivesforfuelsandlubricants.ItisdueinlargeparttotheseadditivesthatonecanmakeitalmosttheentirewayacrossFranceononetankofgasanddrive40,000kmbetweenoilchanges.

Aproductionvolumeof300,000tonsperyearmakestheGonfrevillel’Orcherfactoryoneofthecompany’slargestmanufacturingunits,alongwithOakPointintheUnitedStatesandSingapore,whichhasfour,moremodestsites.However,theirprimaryroleistomeettheneedsoftheareainwhichtheyarelocated.TheGonfrevillel’OrchersitecoversthemarketsinEurope,Africa,andtheMiddleEast.Eachgeographicalareaalsohasitsownsalesforceandsignificantautonomy.Thisautonomyexistsevenwhenitcomestotechnicalchoices.However,certaindecisionsaremadeatthecorporatelevel,andcanhaveasignificantlocalimpact.ThisispreciselywhathappenedwhencorporatemanagementdecidedtodeployintegratedERP(EntrepriseResourcePlanning)managementsoftwarefromSAPonallofthemanufacturingandcommercialsites.

Theobjective,asitalwaysisinthistypeofdecision,wastoimprovethemanagementandcontrolofallofthecompany’soperations,costsanddeadlines.Todothis,theERPapplicationsendsmanufacturingorderstotheequipmentconcernedwiththespecificationstobeapplied.Inturn,supervisorsprovidetheERPapplicationwithmanufacturingreports,rawmaterialvolumes,finishedproductquantities,andinventorystatus.

Two Simultaneous Operations: Connecting to an ERP System and Implementing a New SCADA Application

TheannouncementabouttheimplementationofanERPapplicationwasmadeatatimewhenthefactoryalsohadtosetupanewreactor.

“Thiswasalottohandleatonce.WerealizedhowbeneficialanERPapplicationwouldbeforthecompanyandwehadstudiedtheentiresituation,bothexistingapplicationsandthenewonetobeputintoplace.Wedidthisallonourown.Frankly,wehavealwaysdevelopedourownapplicationsandkeptupwiththestate-of-the-artintechnology,”saidSergeTalleux,directoroftheindustrialITservice.

Ifthesite’sonlyneedhadbeentoconnecttheexistingsystemstotheERPapplication,theproblemwouldhavebeenapproacheddifferently.Inthiscase,however,anewcontrolapplicationalsohadtobeimplemented,whichpromptedahigher,broaderapproachtotheproblem.

Itwasquicklydecidedthataprogrammablelogiccontroller(PLC)shouldbeusedbecausecontrollerswerealreadypartofthefactory’senvironment,whichincludedsixtycontrollersmanagingapproximately15,000inputs/outputs.

ISA-95 - A Key Advantage for the Wonderware System Platform

TheremainingtasksweretochoosethesupervisorycontrolsoftwareforthenewequipmentandtoconnectallofthecontrolsystemstotheERPapplication.Thistaskwasdifficultgiventhefactory’spreviousexperienceinthisarea.

Afewyearsago,arelativelybasicERPapplicationwasinstalledandtheindustrialITdepartmentdevelopedaprogramtoenablecommunicationbetweencontrolsystemsandthisERPapplication.

“Theconnectionprogramthatwehaddevelopedhadseveralthousandlinesanditonlyincludedafewofoursupervisoryservers.Inaddition,itwasanightmaretomaintain,becauseforanynewitemtobemanufactured,oranexistingitemtobemodified,youhadtomakesomesortofchangetotheprogram.Itwasoutofthequestiontodothesamethingagainbecausewehavebetterthingstodothanalignprogramlines,”saidGuillaumeLabadie.

TheSAPERPapplicationhasbroughtwithitastandardthathaschangedeverything.Thisstandard,theISA-95(knownbetterunderitsformername,S95)beganintheUnitedStatesandisnowawidelyadoptedinternationalstandard(ISO/IEC62264andAfnorNF62264,inparticular).ThisstandardhasthemajoradvantageofstandardizingexchangesbetweentheproductionsystemandtheERPapplication.

“Forthesupervisionofournewreactor,wedecidedtogoinanewdirectionandusethelatestincomputertechnology.Morethananything,wewantedasoftwareprogramthatwascompatiblewithISA-95becauseitguaranteedthesimplificationofexchangesbetweenthecontrolsystemandtheERPapplication.Wewerealsolookingforasolutionthatacceptstheconnectionforthinclientworkstations.Andfinally,andthiswasaveryimportantaspect,wewantedasoftwareprogramthatenabledustodesignobjects,”saidTalleux.

A Major Project – Standardizing Terminology

TodeploytheWonderwareSystemPlatform,theChevronOroniteGonfrevilleindustrialITteambeganbybecomingfamiliarwiththeISA-95standard.

Thestandardconsistsofterminologyandmodelsthatdescribeboththestructural(products,materials,productionfacilities,andhumanresources)andoperational(capability,production)aspectsoftheproductionsystemsusedtosupportinformationsharing.Italsodefinesdataattributesandstructures,productionoperationmanagementmodels,andtransactionsbetweenmanagementandtheshopfloor.

“Itiswell-structuredanddetailed,butaswithmanynewstandards,ittakesamajorefforttoabsorbitall.Tobetterunderstandit,andto‘pickout’whatwasmostsuitableforoursituation,ourteamattendedatwo-daytrainingsessiononsitegivenbytheControlChainGroup(CGC).Thishelpwasveryvaluabletous,”saidTalleux.ImplementingtheISA-95standardinvolvedamajorefforttostandardizeinternalterminology.Asisoftenthecaseonmanufacturingsiteswith

alonghistory,severaldifferentnamesandlabelsthatmeanthesamethingemergeovertheyears,andseveralmeasurementunitsmaybeusedtoquantifyoneparameter.

Inadditiontothisstandardizationwork,routineshadtobecreatedtocalculatetheparametersrequiredbytheERPapplication.Thus,newcountershadtobecreatedthatwouldenabletheuploadalloftheconsumptioninformationthatwasneededfortheERPapplication.ApreviousdecisiontoreducethenumberofcontrolsystemsinstalledonsitehadalreadyledtheindustrialITteamtoundertakeasimilarstandardizationproject.

“Weknewthatitwouldtaketime,butnotthatmuch.Butonceeverythingisstandardized,theconnectionbetweentheWonderwareSystemPlatformandtheERPapplicationisveryfastbecausethetwodatabaseshavethesamestructure.Andifwewanttoaddanewmodelorparameterlater,itcanbedoneimmediately,nothingisaffected,”saidLabadie.

Objects and Thin Client Workstations - A Bonus for the SCADA System

InchoosingtheWonderwareSystemPlatform,thesimpleconnectionwiththeSAPERPapplicationwasnottheonlybasisforthedecision.Beingabletoworkwiththinclientswasalsooneofthecriteria.Inparticular,thisenabledChevronOronitetomaintainacertainconsistencybetweentheirtwosystems.

Toaccessinformationonthesupervisoryserversinstalleduptothispoint,theGonfrevillesiteisworkingwiththinclients.Thisapproachhastheadvantageofusingmorerobust(nomovingmechanicalparts)andcost-effectiveworkstations,whichdonotrequireupdating.WonderwarealreadyofferedthisoptionwithWindowsworkstations.

“WeweredelightedthatthecompanyexpandedthisoptionandthatwecannowuseLinuxworkstations.Intermsofupdatefrequencyandanticipatedcomputersecurity,wewillhavealotlesswork,”saidTalleux.

RedundancywasalsoastrongargumentforchoosingtheWonderwareSystemPlatform.Toensurehighdataavailability,thedataacquisitionsystemnativelyintegratesaredundancyfeatureusingsimpleconfiguration,whichmeansthatsomeapplicationscanbeputononeserverandothersonasecondserver.Ifoneoftheserversfails,theapplicationsonthefailedserverareautomaticallytransferredtothesecondserver.

Gonfreville’sindustrialITdepartmentalsowantedtotaketheinitiativewiththesupervisoryfeaturesoftheplatformaswell.

“Wemonitortechnologicaldevelopmentsandwewantedtoprogresstotheobjectconcept.AcquiringtheWonderwareSystemPlatformenabledustoreachthisnextlevel.Heretoo,wehadtochallengeourselvesbecausetheobjectconceptmeansaprofoundchangeinhabits,”saidOliverGodard,whofocusesonsupervision(SCADA).

Todothis,ChevronOroniteGonfrevillewasabletocountonskilledadvicefromWonderwareFrance,whocautionedthemagainstrushingforwardwithnewsoftwaredevelopments,and

advisedthemtoattendtrainingsessionfortheircurrentproductsandtospendmoretimecreatingstandardsinstead.

“Normally,whenwedevelopsupervisoryapplications,weobtainthefirstgraphicdisplaysveryquickly.Foradepartmentdirector,thisisreassuringbecauseheseesthattheworkisprogressing.Withtheobjectconcept,it’sbetternottothinkaboutit.Youwaitimpatientlyformonthswithoutseeingasinglediagram.However,oncethebasicobjects(valves,regulators,displaydevices,pumps,etc.)havebeencreated,everythinggoesveryquickly,”saidTalleux.

Andinthelongrun,thissavestime.Itisveryeasytomodifyboththegraphicsandattributes(variables)ofanexistingobject.Modificationsareimmediatelymadeonallofthedisplaydiagramscontainingtheobjectinquestion.Infact,evenachildcancreatethesesupervisorydisplays.Godardremembersahighschoolstudentonadiscoveryinternshipthatwasabletocreateblockdiagramsontheveryfirstday.

NormallywithSCADAapplications,aneffortismadetonotinterferewiththeproceduresoftheoperatorsstationedinthecontrolrooms.Inthiscase,however,operatorsweredirectlyinvolvedintheimprovementsmadetotheircontrolinterfaces.

TheSCADAdesignersavoidedtheoveruseofcoloronthescreendisplays.Instead,theyusedmoreneutralcolorsandonlyusedbrightcolorsforimportantinformationsothatitstandsoutbetter.Majorworkwasalsodoneonalarmdisplays.Bannerswithendlesslistsofalarmsaregone,andonlythealarmsusedfortheoperatoraredisplayedonthescreen.

ThedesignoftheWonderwareSystemPlatformsupervisorysystemhasenabledChevronOroniteGonfrevilletoturnanewcorner.

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