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Mosaic PotashIntegrating 3rd Party Vendor Control Systems into 800xABelle Plaine, Saskatchewan, Canada
Who Are We?• The World’s largest potash solution mine.• Located in Belle Plaine, Saskatchewan, Canada.• Produce over 2.5 Million Tonnes / Year
• “Help The World Grow The Food It Needs”
Who Are We?• The World’s largest potash solution mine.• Located in Belle Plaine, Saskatchewan, Canada.• Produce over 2.5 Million Tonnes / Year
• “Help The World Grow The Food It Needs”
Bailey Infi90Bailey Infi90 AB PLCAB PLC DeltaVDeltaV
PCVPCV Factory LinkFactory Link Active FactoryActive Factory
Control SystemControl System
HMIHMI
Where We Were
2007 2008 2009 2010 2011 2012 2013 20142007 2008 2009 2010 2011 2012 2013 2014
Why 800xA?- Legacy HMI replacement- Multiple control systems in one HMI- Reduce HMI system maintenance- New features
- Asset optimization- Alarm management- Documentation links
- Robustness and redundancy- Object-oriented design
- Templates- Parent-child objects
• Reduce control room clutter – One workstation per operator– 2 or 4 screens
5
Bailey Infi90Bailey Infi90 AB PLCAB PLC DeltaVDeltaV
Harmony ConnectHarmony Connect
Where We Are
2007 2008 2009 2010 2011 2012 2013 20142007 2008 2009 2010 2011 2012 2013 2014
PLC ConnectPLC Connect
Domain ControllersDomain Controllers
Aspect ServersAspect Servers
Asset OptimizationAsset Optimization
ABB 800mABB 800m
PLC ConnectPLC Connect800m Connect800m Connect
System 800xA v5.0
Operator ClientsOperator Clients Engineering ClientsEngineering Clients
FlinkFlink AFAF
Remote ClientsRemote Clients
800xA Network
7
Asset Optimization
8
Asset Optimization
9
Asset monitors for motors
- # of Starts- Run time
Bailey Infi90Bailey Infi90 AB PLCAB PLC DeltaVDeltaV
Harmony ConnectHarmony Connect
Where We Are Going
2007 2008 2009 2010 2011 2012 2013 20142007 2008 2009 2010 2011 2012 2013 2014
PLC ConnectPLC Connect
Maximo / SAPMaximo / SAP
AMSAMS
Asset OptimizationAsset Optimization
ABB 800mABB 800m
PLC ConnectPLC Connect800m Connect800m Connect
Operator ClientsOperator Clients
Aspect ServersAspect Servers
Domain ControllersDomain Controllers
Alarm ManagementAlarm Management
Engineering ClientsEngineering Clients
System 800xA v5.1
Remote ClientsRemote Clients
PLC ConnectAllen Bradley Control Logix PLC
Why PLC Connect for Allen Bradley?• Interface PLC control into same HMI.• Operators can operate motors, gates,
control valves, etc. from the same graphic interface.
• All process alarms in one system.• Asset monitors for motors.
AB Control
Logix PLCs
AB Control
Logix PLCs
PLC Connect 27PLC Connect 27
Allen Bradley Control Logix
PLC Connect 28PLC Connect 28
Ethernet I/P
Ethernet I/P
Ethernet I/P
Ethernet I/P
HardwareHardware
SoftwareSoftware
OPCOPC RS LinxRS Linx Data HighwayData Highway
PLC Control Structure
PLC Faceplates
Example of Bailey and PLC Objects
Bailey Level, Flow, Control Valves, PressurePLC Motor status, Motor amperage
DeltaV ConnectEmerson DeltaV
Why PLC Connect for DeltaV?• Replace existing IT solution
– Web based graphics– Security concerns– Issues with robust and reliable control
• Integrated with rest of the facility• Access information from refinery• Reliable remote clients• Redundant OPC connection• Bulk Data Manager for mass system
changes.
Emerson DeltaVControl Network
Emerson DeltaVControl Network
DeltaV Connect 40DeltaV Connect 40
Emerson DeltaV
DeltaV Connect 41DeltaV Connect 41
HardwareHardware
SoftwareSoftware
OPCOPC
App Station xA1App Station xA1
App Station xA2App Station xA2
DeltaV – Navigation
Remote Connectivity Server
(10 Sessions)
Remote Connectivity Server
(10 Sessions)
DeltaV – Remote Clients
Creating Objects from Templates
Creating Objects from Templates
Creating Graphics from Templates
25
Creating Graphics from Templates
800xA ImplementationBelle PlaineMosaic Potash
800xA System Size
27
Item Current Count
Future Count
Bailey Tags 6,000 6,000PLC Tags 5,000 15,000DeltaV Tags 12,000 15,000800m Tags 4000 4000Asset Monitors 160 160+Engineering Workplaces 6 6Operator Clients 10 15Remote Operator Clients 8 20# of Control Platforms 4 4
Mosaic Graphics
29
• Bailey Feed gate position control, Weighbelt• PLC Motor status, Screen status, Bucket gate position
Mosaic Graphics
30
Mosaic Graphics
Conclusion• Successful connection to 4 different
control systems• Graphic development still in progress• Utilizing new features such as:
– Asset monitoring for motors– Asset monitoring for network devices– Bulk data management– Documentation linking within graphic displays
• Simplified operations with one common interface
• More readily available data to all operations groups
• Increased system reliability
31