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When chemical company Quimikao decided to replicate its Japanese plant in Mexico, it enlisted system integrator PCEI to implement the PlantPAx process automation system in the new facility. One of the biggest challenges was the conversion of the Japanese system architecture design to the Mexican system in a Class I Division 2 hazardous area, while allowing for secure access and visibility into all aspects of processing. Since implementing PlantPAx virtual infrastructure and redundancy, the facility has increased production efficiency as well as product quality and consistency.
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Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Quimikao: PlantPAx System
Chemical Manufacturer Converts Japanese Plant
Processes to Mexican Facility
Miguel García Hoo / Salvador Alejandro Rivas Rojas
IT Coordinator / Project Manager
November 17-18, 2014
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Conclusions
Implementation Details
Production Process
PCEI Company Profile
Quimikao Mexico Overview
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Quimikao Mexico Overview
Quimikao S.A. de C.V. belongs to
Division Chemical of Kao Corporation
Group.
Kao Corporation Group has more than a
century of experience in the cosmetics
and detergents market with more than 30
affiliates worldwide.
Quimikao mainly produces Cationic
Surfactant derivatives of fatty acids.
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Conclusions
Implementation Details
Productive Process
PCEI Company Profile
Quimikao Mexico Overview
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PCEI Company Profile
PCEI was founded in 2004 at
Guadalajara, Jalisco México.
The company has developed automation
projects in different kinds of industries but
specially in chemical, food and beverage
industries.
PCEI works in Argentina, Brazil, Chile,
Colombia, Belgium, Italy, Japan and
others countries.
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Agenda
Conclusions
Implementation Details
Productive Process
PCEI Company Profile
Quimikao Mexico Overview
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Productive Process
N-2 Reaction system & Hot oil system
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Productive Process
N-2 Distillation system
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Productive Process
N-2 Complementary services/connections
Services
1. Steam system
2. Cooling water system
3. Fatty Acid supply
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Agenda
Conclusions
Implementation Details
Productive Process
PCEI Company Profile
Quimikao Mexico Overview
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Implementation Details
Project Specifications
1. PlantPAx platform 2. PlantPAx virtual infrastructure design 3. Asset Management system 4. PAC redundancy 5. Use of intrinsically safe barriers 6. MCC control by I/Os (communication just for status) 7. Energy management metrics by a PowerMonitor 8. Use of Modbus RTU communication to monitor secondary services 9. Use of Modbus TCP/IP communication to control steam system
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Implementation Details
Why Qimikao chose PlantPAx platform?
One single platform to control every phase of the nitrile production. An innovative system that handles process and discrete control with
communication. A system that could improve efficiency and decrease the downtime by
using virtual infrastructure. An advanced networking, monitoring and diagnostic system that could
increase preventative-maintenance capabilities, and reduced repair costs.
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Implementation Details
Project Timeline from September 18th2013 to April 29th 2014
Opening Meeting Control Engineering Design MCC Engineering Design Wiring Operation Sequences Review HMI Development PAC Program Factory Acceptance Test Installation and Site Acceptance Test
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Implementation Details
First steps
Application Checklist
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Implementation Details
First steps
Data Checklist
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Implementation Details
First steps
FTAssetCentre Checklist
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Implementation Details
First steps
FTView SE Checklist
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Implementation Details
First steps
Network Architecture
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Implementation Details
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Implementation Details
Rockwell Automation Validation
Architecture review PlantPAx system review Ethernet/IP network
architecture review
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Implementation Details
Engineering development
85-265VAC Power Supply
1756-PA75
Redundant PAC Racks 1756-
A4
I/O Racks 1756-A13
Stratix 8000 1783-MS10T
24V,10A Single Phase Input
PS 1606-XLE240E
Buffering for 24V loads 1606-
XLBUFFER. Guaranteed
hold-up time: 0.2s/20A to
3.6s/1A
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Implementation Details
Engineering development
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1. 1756 Chassis 13 Slots (1x1756-A13)
2. 85-265VAC Power Supply (2x1756-
PA75R)
3. ControlLogix EtherNet/IP 2-port
module (1x1756-EN2TR)
4. 10…30V DC diagnostic input module
(5x1756-IB16D)
5. 19.2…30V DC 16-point diagnostic
output module (6x1756-OB16D)
1. 1756 Chassis 13 Slots (1x1756-
A13)
2. 85-265VAC Power Supply
(2x1756-PA75R)
3. ControlLogix EtherNet/IP 2-port
module (1x1756-EN2TR)
4. ControlLogix HART Analog Input
Module (5x1756-IF16H)
5. ControlLogix HART Analog
Output Module (4x1756-OF16H)
6. Modbus RTU module (MVI56E-
MCM)
7. Modbus TCP/IP module (MVI56E-
MNET)
Implementation Details
Racks components
1. 1756 Chassis 4 Slots (2x1756-A4)
2. 85-265VAC Power Supply
(4x1756-PA75R)
3. ControlLogix 8MB Controller
(2x1756-L73)
4. ControlLogix EtherNet/IP 2-port
module (4x1756-EN2TR)
5. ControlLogix RM Module Fiber
Optic Cable (2x1756-RMC1)
6. ControlLogix Redundacy Module
(2x1756-RM2)
Check the product compatibility list before doing any
firmware changes
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Implementation Details
Controller Programming – Sequences development
Old way to programing
1. Internal status switch assignment
list
2. Table assignment list
3. Timer, preset, counter
assignment list
4. DO/DI assignment
5. Code Input/output assignment
6. NSM assignment
7. Annunciator assignment
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Implementation Details
Controller Programming – Sequences development
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Implementation Details
Controller Programming – Sequences development
The use of Sequential Function Chart is very helpful to compare and
understand routines, however it increases data logic memory considerably.
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Implementation Details
Controller Programming – Sequences development
How do we update a program that was developed 30 years ago?
The use of Rockwell Automation library reduces engineering time.
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Implementation Details
Controller Programming – Sequences development
How do we update a program that was developed 30 years ago?
Modular design eases construction of complex control strategies.
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Implementation Details
Controller Programming – Periodic Task Configuration
Refer PlantPAx reference manual (PROCES-RM001) for configuration guidelines
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Implementation Details
Server Virtualization.
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Implementation Details
Advantages Using Virtual Server System
1. High Availability
2. Disaster Recovering
3. Space and Energy Saving
4. Extend Life of older applications
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Implementation Details
Advantages Using Virtual Server System
5. Application Isolation
6. Optimize Computing Resources
7. Ease of Access and managing
8. Improved System Reliability and Security
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Implementation Details
Advantages Using Rockwell Automation Virtual Templates
1. Reduce Engineering Time And Validation Costs
2. Ease Lifecycle Management
3. Enhance Scalability
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Implementation Details
Rockwell Automation Virtual Templates
1. Engineering Workstation (EWS)
2. Operator Workstation (OWS)
3. Process Automation System Server (PASS)
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Implementation Details
Software Architecture
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Implementation Details
Virtual Server System
1
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Implementation Details
Setting up Redundancy
1. HMI Server Redundancy
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Implementation Details
Setting up Redundancy
1. Alarm Server Redundancy
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Implementation Details
Datalog and Reports.
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Implementation Details
Rockwell Automation Library
1. Using RA Library Templates is easy and reduces developing and debugging time.
2. They can be easily customized. The changes will reflect in all the instances of the object.
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Implementation Details
Final Results
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Implementation Details
Final Results
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Implementation Details
Final Results
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Conclusions
High availability.
Faster disaster recovering, fast equipment providing.
Space and energy Saving.
Extend life of applications.
Application Isolation.
Using Server Virtualization Advantages .
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Conclusions
Reduces developing, mantainance and debugging time.
Less error prone.
Customization.
Using RA Library Templates of Process Objects Advantages.
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Questions
Miguel García Hoo / Salvador Alejandro Rivas Rojas
IT Development Coordinator / Project Manager
November 17-18, 2014