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Holcim Mexico's Macuspana facility was operating with an outdated process control system at risk of obsolescence. The facility needed to a single, plantwide system to help standardize machine and process automation across each section of its facility, including its raw mill, cement mill and cooler. Partnering with Rockwell Automation, Holcim performed a phased-migration to a PlantPAx process automation system and seamlessly integrated control communication between processors.
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Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Holcim Macuspana Implements Plant-wide Automation
with PlantPAx System
Fernando Hernández
Automation and Control Supervisor
November 2014
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Challenges and lessons learned
Advantages & Benefits
Upgrade to PlantPAx
Precedents
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Holcim Highlights
• Holcim Mexico produces and sells cement, aggregates, ready-mix concrete and other products and services for construction.
• Currently, is one of the leading companies in the production and commercialization of cement and concrete in México.
• The company was founded in 1928, in the town of Apaxco (State of Mexico), and since 1964 is part of the Swiss cement group Holcim. To date, has the capacity to produce 12.6 million tonnes of cement capacity in this country.
• About 4,000 direct employees working in Holcim México. One of the world's leading suppliers of cement, aggregates,
concrete and asphalt.
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Holcim Highlights
• It has an extensive infrastructure, which translates into a total of eight cement plants in Mexico: Apaxco (State of Mexico); Acapulco (Guerrero); Macuspana (Tabasco); Orizaba (Veracruz); Ramos Arizpe (Coahuila); Tecomán, Colima and Hermosillo (Sonora).
• Moreover, operates 23 distribution centers, two marine terminals, more than 40 ready-mix plants, about 500 mixers pots and three plants producing aggregates
• Presence in over 70 countries on all continents and has approximately 80,000 employees.
• Since 2000 to date, Holcim has invested in Mexico over USD 2,200 million, equivalent to an average of 183 million dollars a year.
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Holcim Highlights
The eight cement plants of Holcim Mexico hold ISO
14001 and Clean Industry certificate.
In 1999 joined the World Business Council for
Sustainable Development (WBCSD), committing to
long-term progress, respecting the balance between
economic development, environmental performance
and social responsibility.
Named "Industry Leader" in the Dow Jones
Sustainability Index, 2005 to 2008 This was
recognized as the company with the best sustainability
performance of the cement industry for 4 years.
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Macuspana Facility Project Upgrade
Since the 80’s the complete control system of the plant has been
Allen-Bradley ®.
In 2012, the Holcim plant Macuspana conducted a migration of Allen-
Bradley PLC-5 ® Systems and RSView®32 visualization software throughout
the plant, due to the end of its lifecycle.
Corporate Holcim standard requires to update this type of systems each
determinated time; analyzing the lifecycle of our old system, that was the
right time to perform the migration,
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Precedents
Due to the age of the system, the operation was
becoming expensive and their performance was
not adequate to carry out the production process
of the plant.
The network performance was not optimal for the
changes that the plant was living and did not meet
to the speed of the current applications such as
EtherNet I/P, ControlNet and DeviceNet.
We initiate with the “Project Concept” in team
with local Rockwell Automation team since
2007
The quality and full support from Rockwell Automation® bring us the
confidence to continue working with the new Process platform.
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Rockwell Automation in Cement Process
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COP CANTERA
COAL MILL AUXILIARY
AFR’S KILN CRUSHER RAW MILL CEMENT MILL DISPACH
CNET/R 5 Mb DNET 250 Kbps DHRIO 57.6 Kbps DH+ FIBRA OPT. MODEM RF
Previous Architecture
PLC-22 APILADOR
COP
3 CCM
PLC-61
RACK
RACK
RACK
RACK
PLC-52
2 CCM
PLC-51
RACK
RACK
4 RTU PLC-31
RACK
RACK
PLC-32
RACK
RACK
PLC-5
PLC-46
RTU
FlexLogix
4 CCM
4 CCM
C-LOGIX
RTU
1771-ACRN15
CCM
PLC-AFRs
RACK
ENGINEERING
COP ENVASE
ControlNet ControlNet
COP CRUSHER
HIM RED SERVER
Ethernet Ethernet
ENGINEERING WS
ASSET CENTRE SERVER
TIS LINKMAN
19
.2 K
b
FlexLogix
3 CCM
PLC-41
RACK
RACK
2 CCM
PLC-42
RACK
RACK
CCM
PLC-43
RACK
RACK
PLC-21
RACK
RACK
RACK
PLC-61
RACK
RACK
COP DISPACH
WS
CCM
PLC-62
RACK
RACK
PLC-62
RACK
RACK
PLC-21
RACKS
Architecture w/first phase
PLC-31
RACK
RACK
Logix
PLC-32
RACK
RACK
RAW MILL WS
Architecture w/next phases
PLC-22 APILADOR
EXISTENTES
Final System Architecture
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Scope of Solution
Migration of PLC-5 System to PlantPAx
Using of MMCL (Cement Libraries)
RSView32 Migration to Distributed
FactoryTalk ® View Site Edition (SE)
4 redundant servers of HMI’s
TIS integration
1 domain redundant server
1 SQL data base server
1 FactoryTalk® Asset Centre server
Services for each stage:
Configuration and programming
Installation and commissioning
Training
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Process Graphics
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Process Graphics
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Process Graphics
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Process Graphics
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Process Graphics
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Process Graphics
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Process Graphics
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Advantage and Benefits
Standardization. One of the main goals, currently we sent online
information to corporate offices from the main operational data of the plant
and also alarms and events, a situation that has not happened before.
Optimization. The future is to leverage the capabilities that are not yet
exploited of the processors, to develop strategies to serve directly in the
plant process and achieve better power and thermal control, among other
variants.
Distributed Architecture. With the new HMI control system and diagnostic
tools, the plant will have fewer unplanned stoppages due to equipment
control.
Competitiveness. The new platform provides improved reliability of
equipment; more diagnostic tools in case of failure; lower maintenance costs
and downtime, result in higher level of competitiveness for the company.
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Challenges and Lessons Learned
The complete project needed to be implemented in 2 years. Was
completed in 1 year and 8 months
The main challenge was to have all the configurations in time and simulate
the sequence with the software previously to shorten the startups. The
time of commissioning were always shorter than those granted by the
plant
The commitment of integrators, Holcim and Rockwell Automation were
fundamental for success.
The service provided by Rockwell Automation for the implementation
of this project was excellent, was able to fully adapt to the corporate
guidelines required by the Holcim group.
"We have achieved concrete and efficient answers whenever we have required"
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Why Rockwell Automation?
Global Execution: The quality of products and the worldwide talent and
local expertise of Rockwell Automation was Key to select them to execute
the project.
Domain Expertise: Their industry and application experts give us the
confidence that the project will help us to increase productivity, lower
manufacturing risk, speed time to market, and reduce costs of quality and
compliance.
Project Management: The PMI certified personal of Rockwell Automation
use the Common Project Management methodology, based on the PMI®
PMBOK®, that helped ensure that we received consistent Project
Management for every stage.
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Questions
Fernando Hernández
Automation & Control Supervisor
November 2014