Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

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Rockwell Automation

Process Solutions User Group (PSUG)

November 14-15, 2011

Chicago, IL – McCormick Place West

Rockwell Automation

Process Solutions User Group (PSUG)

November 14-15, 2011

Chicago, IL – McCormick Place West

What can “TWO GUYS AND A

TRUCK" do with PlantPAx?

Bos Howard

Johns Manville

Abstract

Copyright © 20011 Rockwell Automation, Inc. All rights reserved.

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.

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

Roadmap Development

• 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?

DEFINE OBJECTIVES

Roadmap Development

• Which controls systems can meet our needs?

• Design?

• Operate?

• Maintain?

• Lowest cost?

• Flexibility?

SUPPLIER SELECTION

Roadmap Development

• Involvement of operators and maintenance to help design

and implement?

• Leveraging the best practices from suppliers?

• What will be our challenges?

PROJECT EXECUTION

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

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• Existing controls systems were outdated on all lines.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• DC and AC Line Drives were outdated.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

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

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 1756-

L1)

• Existing DCS was Provox (SR90 Controllers) and

Delta V for Provox; Existing PLC (Modicon 984),

Siemens (S-5; S-7).

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

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

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

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

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

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

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

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

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.

Project Execution – PlantPAx Modified

Faceplate

• The addition of

some detail

parameters was

added for tuning

and setup.

Project Execution - PlantPAx – Modified

Faceplate

This is a standard

accelerator FP, but the last

alarm indicator was added.

Project Execution -PlantPAx – Modified

Faceplate

Using the standard

Interlock AOI and FP,

but changing the I to

an E for E-stop

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.

Event Alarms from PLC

From Standard

E-PID Custom Alarm Block (AOI)

PLC Code for Simple Loop Point

Alarm Severity: This parameter can be set dynamically

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.

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;

Work Accomplished - First Phase

• 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

The Plant selected the oldest Line to upgrade.

Work Accomplished - Second Phase

• 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

The Plant selected the Largest Line to upgrade

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)

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

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.

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

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.

Conclusion - Keys to Success

End results:

PlantPAx is a system, not a

collection of pieces.

Questions

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Bos Howard

Johns Manville