Doc. No. ISD-MASP-S02018 A dvanced A dvanced O peration O peration A ssistance ©Yokogawa Electric Corporation Solvay Minerals Green river, Wyoming Solvay

　©Yokogawa Electric Corporation 　 Doc. No. ISD-MASP-S02018

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AAssistancessistanceSolvay Minerals Green river, WyomingSolvay Minerals Green river, Wyoming

• Solvay was established in 1863Solvay was established in 1863 The company specializes in Pharmaceuticals,The company specializes in Pharmaceuticals, Chemicals, Plastics and Processing with over 400Chemicals, Plastics and Processing with over 400 entities operating in 50 countries. entities operating in 50 countries. • Altitude: 6300 ft., Sunny days: 300+, Rain fall: 6 in.Altitude: 6300 ft., Sunny days: 300+, Rain fall: 6 in. Lowest temp: -17 deg (Warm Winter!)Lowest temp: -17 deg (Warm Winter!)• Green River Operation opened in 1980Green River Operation opened in 1980 Capitalized at $650 MMCapitalized at $650 MM Sales amount $250 MMSales amount $250 MM Capacity of production 2.7 MM TPYCapacity of production 2.7 MM TPY 200 M TPY other products200 M TPY other products• CENTUM CS 3000 installed in 2000CENTUM CS 3000 installed in 2000


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AAssistancessistanceSodium Carbonate Decahydrate UnitSodium Carbonate Decahydrate Unit


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AAssistancessistanceSodium carbonate decahydrate unitSodium carbonate decahydrate unit

• Number of FCS: 1 FCSNumber of FCS: 1 FCS• Number of HIS: 2 HISesNumber of HIS: 2 HISes• Number of control loop: 162 loopsNumber of control loop: 162 loops• Number of operators/shift: 2 shiftNumber of operators/shift: 2 shift• Process equipment: Process equipment: Two crystallizersTwo crystallizers Refrigeration systemRefrigeration system Vacuum controls for barometric condenserVacuum controls for barometric condenser Pusher centrifugePusher centrifuge Crystallizer heating systemCrystallizer heating system Numerous pumps and tanksNumerous pumps and tanks• New process and new operatorsNew process and new operators• Many manual field operationsMany manual field operations


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AAssistancessistanceBuying motive (why we chose Exapilot)Buying motive (why we chose Exapilot)

Procedure: Operation on Water, Brine & Shutdown:Procedure: Operation on Water, Brine & Shutdown:• Difficult to implement in DCSDifficult to implement in DCS The operation involves unsteady state operation which includes The operation involves unsteady state operation which includes many manual operations for the field operator.many manual operations for the field operator. Exapilot is designed to handle both DCS and field operations Exapilot is designed to handle both DCS and field operations interactively.interactively.

• Operational procedure is not clear to the DCS engineerOperational procedure is not clear to the DCS engineer The skilled operator and operations staff (process engineer)The skilled operator and operations staff (process engineer) know the best procedure. However they are not in charge ofknow the best procedure. However they are not in charge of DCS engineering. Exapilot is the special automation systemDCS engineering. Exapilot is the special automation system for them, which is separated from the DCS.for them, which is separated from the DCS.

• Low-frequency program wastes FCS resourcesLow-frequency program wastes FCS resources FCS is more costly than Exapilot.FCS is more costly than Exapilot.


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AAssistancessistance

Eric C. BransonEric C. Branson

Joe MertenJoe Merten

Mike GanskopMike Ganskop

John BlaesiJohn Blaesi

Yasunori KobayashiYasunori Kobayashi

ImplementationImplementation

Project memberProject memberFive personsFive persons• Eric C. Branson (Solvay): Project leaderEric C. Branson (Solvay): Project leader• Mike Ganskop (Solvay): DCS TechnicianMike Ganskop (Solvay): DCS Technician• Joe Merten (YCA): SalesJoe Merten (YCA): Sales• John Blaesi (YCA): TechnicalJohn Blaesi (YCA): Technical• Yasunori Kobayashi (YHQ): ConsultantYasunori Kobayashi (YHQ): Consultant

Engineering resourcesEngineering resources1.5 man-month1.5 man-month• 64 hours (Mike)64 hours (Mike)• 36 hours (Eric)36 hours (Eric)• 20 hours (John)20 hours (John)• 20 hours (Joe)20 hours (Joe)• 20 hours (Yasunori)20 hours (Yasunori)

Term of implementationTerm of implementationOne monthOne month 28 Nov.28 Nov. TrainingTraining 29 - 30 Nov.29 - 30 Nov. ConsultationConsultation 10 - 14 Dec.10 - 14 Dec. EngineeringEngineering 07 - 11 Jan.07 - 11 Jan. Operator trainingOperator training 15 Feb. -15 Feb. - First operationFirst operation


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AAssistancessistanceSystem ConfigurationSystem Configuration

LFCSLFCSSFCSSFCS

HISHIS

EthernetEthernet

VL NetVL NetV NetV Net

ENGENG

LFCSLFCSSFCSSFCS

OPCOPCServerServer

Exapilot ServerExapilot ServerExapilot ClientExapilot Client

OPC ClientOPC Client

Exapilot ClientExapilot Client

Engineering DataEngineering Data

ProcessProcessDataData


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AAssistancessistanceApplication OverviewApplication Overview

• 300 icons300 icons• 24 sub-procedures24 sub-procedures• 90 tag data setting90 tag data setting• 44 tag data monitoring44 tag data monitoring• 52 confirmation52 confirmation• Execution period 5 secondsExecution period 5 seconds

BenefitsBenefits• Prevention of miss operationPrevention of miss operation• Reduction of engineering timeReduction of engineering time• DocumentationDocumentation• Reduction of operator actionsReduction of operator actions


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AAssistancessistancePurchase MotivationPurchase Motivation

• Reduce miss-operation from differencesReduce miss-operation from differences in operator knowledge, experience, etc.in operator knowledge, experience, etc.• Retain the best operating knowledge in a live format Retain the best operating knowledge in a live format with procedures that are fully documented and with procedures that are fully documented and maintained as a live part of the operationmaintained as a live part of the operation• Inheritance of operation know-howInheritance of operation know-how• Procedure optimizationProcedure optimization• Automation of manual operationsAutomation of manual operations• Lower cost than trying to implement in FCSLower cost than trying to implement in FCS


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AAssistancessistanceFirst Run Impression of ExapilotFirst Run Impression of Exapilot

• Guides the operator through every step of the Guides the operator through every step of the procedure. Very user friendly.procedure. Very user friendly.• Much easier to implement the procedureMuch easier to implement the procedure than in the DCSthan in the DCS• Expect reduction in operating time,Expect reduction in operating time, operator work load, and miss-operationoperator work load, and miss-operation• Procedures are fully documented as Procedures are fully documented as part of the development processpart of the development process• Easy to update and optimize the procedureEasy to update and optimize the procedure as the process knowledge improves i.e. the best as the process knowledge improves i.e. the best operating knowledge is retainedoperating knowledge is retained• Operator training for both off-line and on-lineOperator training for both off-line and on-line


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AAssistancessistanceFuture ApplicationsFuture Applications

• 6 Calciner refractory cure procedures6 Calciner refractory cure procedures• 4 MVR Crystallizer startup procedures4 MVR Crystallizer startup procedures• 2 Boiler Startup & Shutdown Procedures2 Boiler Startup & Shutdown Procedures

Documents

Doc. No. ISD-MASP-S02018 A dvanced A dvanced O peration O peration A ssistance ©Yokogawa Electric Corporation Solvay Minerals Green river, Wyoming Solvay