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Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Tweet About It Using #PSUG PlantPAx Improves Functionality and Traceability in New Monsanto Greenfield Facility Monsanto and ESCO Automation Greg Boyce, Monsanto, Seed Process Engineer David Kaltmayer, Monsanto, NALAN Row Crops PCIT Lead Tom Miller, ESCO Automation, Director of Business Development Joshua Earls, ESCO Automation, Account Manager November 2014

Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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When Monsanto built a new greenfield facility in Grinnell, IA, the company needed a control system that was scalable and could consolidate its entire pre-commercial seed process, from bulk receiving to the office and lab facilities. Additionally, the project had to be complete within one year. ESCO Automation installed the PlantPAx process automation system and set up corporate standards for future expansion. Since its inception, the system has helped increase product quality and consistency, as well as traceability throughout the facility. Additionally, the facility was able to quickly double the number of production lines from two to four by utilizing standardized HMI faceplate objects.

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Page 1: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

Copyright © 2014 Rockwell Automation, Inc. All rights reserved.

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PlantPAx Improves Functionality

and Traceability in New Monsanto

Greenfield Facility

Monsanto and ESCO Automation

Greg Boyce, Monsanto, Seed Process Engineer

David Kaltmayer, Monsanto, NALAN Row Crops PCIT Lead

Tom Miller, ESCO Automation, Director of Business Development

Joshua Earls, ESCO Automation, Account Manager

November 2014

Page 2: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

Copyright © 2014 Rockwell Automation, Inc. All rights reserved.

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Agenda

Questions/Comments

Results

The Solution

Project Specifications

Company Introductions

Page 3: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

Copyright © 2014 Rockwell Automation, Inc. All rights reserved.

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ESCO Group: The Umbrella of Resource

Page 4: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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ESCO Automation

Company Facts

A company of ESCO Group

Offices in Marion and Des Moines, Iowa

Approximately 65 engineering

professionals

Wide client diversification

Team Structure

Wrap teams around clients

Integral part of client companies

History and experience with each plant

Affiliation with Rockwell Automation

Member of the Rockwell Automation

Process System Integrator Group

4

Page 5: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Monsanto, An Agriculture Leader

5

Monsanto is a global agricultural company that produces products for farmers. The Seed

& Traits and Crop Protection divisions are Monsanto’s primary business focus areas.

Headquartered in St Louis, MO

Globally: 21,200 employees at 400 facilities,

located in 66 countries

US: 10,300 employees at 146 facilities,

located in 33 states

Grinnell, IA Pre-Commercial Facility

Facility employs 65 people

Needed to increase conditioning capacity, due to

increased production volumes

Page 6: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Monsanto Seed Production

Monsanto’s Seed customers are Farmers around the world

1st Step of Monsanto Seed Production starts at: Williamsburg, IA, Othello, WA or Hawaii

2nd Step of Monsanto Seed Production: Williamsburg, IA, Othello, WA, Constantine, MI or Hawaii

Conditioning and packaging of this seed is completed at the Grinnell, IA Pre-Commercial facility

3rd Step of Monsanto Seed Production: Facilities located in the Midwest of United States

Page 7: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Project Background

Goal: Consolidate and update our North American Pre-Commercial Seed Conditioning Facilities

Solution: One new central facility for our

pre-commercial seed conditioning and

packaging, rather than updating several

existing small facilities

Scope: New Facility design would include

(5) conditioning lines and (3) packaging

lines with bulk storage, warehouse and

offices

Design and Execution: Partnered with ESCO to design and build a new state-of-the-art facility from the ground up

Page 8: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Project Schedule

Project Funded in May (Year 1) Monsanto Structural & Mechanical Design June – September (Year 1) ESCO Electrical Design August – November (Year 1) Civil, Structural, Mechanical & Electrical Construction October – August (Year 2) Checkout & Startup August – September (Year 2)

Operational September – October Year 2)

Page 9: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Project Design

Page 10: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Monsanto’s Seeds Division uses Allen Bradley and Rockwell Software as a

standard

Partnered with ESCO on many projects since 1998

Process control goals

Designed with intuitive process

information and operator ease of use

Start to finish automated product

traceability

Checkout & commissioning

Project Criteria

Page 11: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Solution

Design Build Solution

Electrical Design

Automation Design

Controls Objectives

Scalability

Line Independence

Distributed Safety

Standardized Code

AOI

Faceplates

Improved

Functionality

Page 12: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Objectives – Design Build

Assemble a team to complete the construction and commissioning phases of the

project. Including Project Management, Electrical Installation personnel, and a team of

Automation personnel to complete testing and commissioning

Work with Monsanto Engineering to develop a robust Electrical and Automation design

package

Develop usable budget for

Electrical Construction and

Automation packages

Develop Specific Scope of Work

and Construction schedule to

meet tight timelines

Page 13: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Objectives – Controls

Implement a control system to integrate the entire operation,

from bulk receiving to packaging and distribution areas.

Independent line design that was scalable for up to five

separate conditioning lines. Each line could contain separate

product, inventory tracking and traceability was critical.

Needed a flexible and expandable safety system that could be

distributed throughout the plant.

Develop a device level library of tested and re-usable code.

This library of AIOs, UDTs and Faceplates would be

customized to incorporate Monsanto’s existing standards

Page 14: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Design Build – Electrical & Automation

Complete Engineering Solution

13.2kV through Low voltage

Medium voltage system layout and design

Controls, communications layout and design

Complete Electrical & Automation Installation

Page 15: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Controls Objectives Line Independence & Scalability

Network Architecture scaled for full build out

Re-Usable Electrical Design for future lines

Line specific and facility equipment isolation

Page 16: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Controls Objectives Line Independence & Scalability

Line Independence

MCP & Controls Design

Safety Solution

LOTO Solution

Scalability – Facility designed for five

separate conditioning lines

Page 17: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Controls Objectives Distributed Safety System

Design Considerations for Safety

Requirement for no inter-

connected wires between

panels

Ease of expansion with

installation of future lines

Configurable control of each

safety device and

functionality

Logic programming, basic

function block.

All Data is exposed to PLC

for HMI and Data Collection

Page 18: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Controls Objectives Distributed Safety System

Page 19: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Controls Objectives Distributed Safety System

Page 20: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Controls Objective – tested re-usable code library

Customized AOI and Faceplate

Library based on existing

Monsanto standard using

PlantPAx architecture

Dynamically populated AOI and

Faceplates to simplify integration

and troubleshooting

Device specific Faceplates with

enhanced functionality for all

equipment

Page 21: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Standardized Code Development

Hardware based IO

mapping blocks for

standard Cards and Drives

Device level Library for

typical components such as

Motors, Valves, Gates,

Storage Bins

Page 22: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

Copyright © 2014 Rockwell Automation, Inc. All rights reserved.

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Standardized Code Development Results

Efficiency Increases

Estimate a 40% improvement in speed of deployment

More effectively develop periodic task based on device type

Improved Quality and Functionality

Every device includes standard tag structure, enhanced color control, alarming and

error checking, interlocks, lifetime and resettable timers for maintenance scheduling.

Improved versatility and modification, based on setup a FVNR device can be a VFD

with forward/reverse and frequency control.

Training and Troubleshooting

Easier troubleshooting by plant personnel, no need to look at device level code can

focus on permissives and other variables.

Page 23: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Process Control Network

Separate Business Network

ESX Host Virtualization

FactoryTalk ® View SE

FactoryTalk® Transaction Manager

Sequel Server

Visual Basic

MES Data

Visual

Asset Manager

Appliance & VMware

Page 24: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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SAP Integration

SAP iDOCS

Process Orders

Material Data

Classification Data

Data Collection

Reporting and Visualization

Page 25: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Mobility & Visualization

FactoryTalk ® View SE

Remote Visibility

Dash Boarding

Page 26: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Results

North American Pre-Commercial

Seed Conditioning Facility

constructed and operational

Increased efficiency and

productivity as business

continues to experience growth

Quickly and efficiently doubled

production lines from 2 to 4 lines

by utilizing standardized HMI

faceplate objects

Page 27: Monsanto: PlantPAx System Improves Functionality and Traceability in Monsanto Greenfield Facility

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Questions