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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
Anchor GlassReduces Energy Costs with Information - Enabled PlantPAx Solution
Kyle FiebelkornBatch and Furnace Manager
Brad DownenMES Project Manager
Agenda
Introductions
Company Overview
Making a Glass Bottle
Goals
Operational Benefits
Cost Benefits
Wrap Up / Q&A
AGEN
DA
Introduction
Kyle Fiebelkorn – Batch and Furnace Manager Anchor Glass Container – Shakopee, MN
Brad Downen – MES Project Manager Stone Technologies
Audience – How Many ... End Users System Integrators Rockwell Automation® Distributor Other
PRESENTERS Experience with…
PlantPAx® Operations PlantPAx® Development
Anchor Glass Container - Background
Anchor Glass A leading North American manufacturer of glass containers with annual revenue of approximately $550 – $600
million and employing approximately 2,000 people. 6 glass manufacturing facilities, consisting of 11 furnaces and 31 lines 2 Oxy/Gas furnaces, 9 Gas/Air Reversing furnaces Lots and Lots of bottles!!!! Up to 600/min => 300,000,000 bottles/yr
Controls History 1986-1995 – Deployed Leeds and Northrup Micromax DCS controls system throughout the company 2003* – Established new corporate standard HMI and Controls with Rockwell Software® RSView®32 and
ControlLogix® processors 2012 – Adopted Rockwell Automation PlantPAx controls strategy layered with Rockwell Software’s interface
solution: FactoryTalk® View SE, FactoryTalk® Historian SE, FactoryTalk® Alarms and Events, FactoryTalk® VantagePoint®
COM
PANY O
VERVIEW
Anchor Glass – What we are doing
Convert crunched, recycled glass or raw materials into a liquid Create a stream of lava and condition the stream of lava to a consistent temperature and weight Physical items to control
Burners (many, many) Pressure (helps prevent flames from shooting out) Glass Level (weight of the bottle) Electric Boost Reversal (conserves heat)
MAKIN
G A G
LASS BOTTLE
FurnaceForehearth(3)
Hole located here drops the gob of glass to make the bottles
Original Goals with replacing old DCS system
Provide more intuitive operator interface
Better Data
Tighter Controls
Configurable!!! (especially for reversals)
Better historical data for analysis (both Process & Alarming)
Better Alarming. Manageable (Alarming without overwhelming noise)
Extendibility: capable of expanding to other areas of plant
Remote access – Corporate viewing
Low maintenance
PROJECT
Operational Benefits
Improved visibility of both current status, but also monitor operational trends Many more alarms providing detailed notifications…..but manageable too Minimized need for controls engineer HMI with detailed sequencing allows fine tuned process enhancements to achieve
more energy efficient operations Consistent faceplates so training of operator was minimal Process tuning (PID) provides much finer or coarser adjustments
BUSIN
ESS
VisibilityO
PERATION
AL BENEFITS
VisibilityO
PERATION
AL BENEFITS
VisibilityO
PERATION
AL BENEFITS
Usable & Detailed AlarmsO
PERATION
AL BENEFITS
Configurable via HMI (Controls engineers not needed)O
PERATION
AL BENEFITS
Consistent Faceplates – Minimal TrainingO
PERATION
AL BENEFITS
Motor Operated Valve Limit Switch PID
“Show Me the Money”CO
ST BENEFITS
18 months in operation – Early results (Savings are contributed to both new bricks and better controls)
Gas Savings Total ~ 350 dekatherm/day
~$6/dekatherm => 350*$6.00*365 = $766,500 / yr
Electrical Savings Total ~ 12,000 to 15,000 KWH per day
~$0.077/KWH => 12,000 * $0.077 * 365 = $337,260 / yr
Longevity: Typical furnace is rebuilt every 10-12 years. Early signs show furnace may last 1-1/2 to 2 years longer. Estimate of $1M/year goes to the bottom line.
“Based on my experience with this system, I would contribute an average of 15% of the cost savings to having the better controls systems on the furnace”…Kyle F. 2015
Soft costsCO
ST BENEFITS
More time to focus on tweaking the process vs. learning system Pinpoint trouble areas quicker Recognize operational trends and patterns easier Less labor required for maintenance
COM
PANY O
VERVIEWStone Technologies
$15M 2014 revenue 61 full-time employees Average 20% year over year growth for past 10 years
Stone Technologies, founded in 1996, is a national system integrator providing automation/control, information (MES) and operational consulting solutions. Based in St. Louis, MO with resources in 15 states/ 1 province.
Employee BusinessSatisfied people deliver successful projects and provide long-term continuity
Stone Technologies long-term relationships built on performance, trust, & keeping promises.
Average 95% employee retention rate for the last 10 years
The technical staff has an average of 22 years of experience
Of our top 20 clients (by services revenue) since the inception of the company 15 years ago:Doing business with ALL of them today
Average relationship is over 9 years Average of 50 projects per client Average adding 2 – 3 new clients a year
We have paid employee bonuses every year since inception Our best revenue generating tool is the successful delivery of projects
CON
TACT US
Contact Information
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
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