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© ABB Inc. April 25, 2012 | Slide 1
APW – C551I BASF Windsor - Harmony system evolution success to System 800xA
Jiri Prochazka (BASF) & Jim Luffman (ABB), April 25, 2012 – Session 12
C551I BASF Windsor - Harmony system evolution success to System 800xA
Speaker name: Jiri Prochazka
Speaker title: Instrument & Electrical Engineer
Company name: BASF
Location: Windsor, Ontario, Canada
Co-presenter
Speaker name: Jim Luffman
Speaker title: Project Manager
Company name: ABB Inc.
Location: Burlington, Ontario, Canada
© ABB Inc. April 25, 2012 | Slide 2
Agenda BASF Windsor
Introduction
About BASF – a brief overview
The BASF facility in Windsor, Ontario (Canada)
Evolution timeline summary
Project integration highlights
AC800M control
HPG (Harmony PCU Gateway)
Profibus
Intrinsic Safety
Project execution & coordination
Questions?
Key Learnings (Measureable Results)
© BASF April 25, 2012 | Slide 8
Introduction About the Speaker
Instrumentation & Electrical engineer at the BASF
Windsor, Canada – Paint Plant
18+ years experience in this position
Responsible for maintenance and new installation of
instrumentation, control systems as well as all mid &
low voltage electrical infrastructure for the facility
Mandated with the challenges of:
Enhancing overall installed base of electrical,
instrumentation and process automation
Increasing productivity and overall equipment
effectiveness
Balancing maintenance and operating costs
Maximizing equipment uptime
Maintain “Best-in-Class” approach through the
application of most up-to-date technology while
balancing best utilization of installed
infrastructure
Training staff
Jiri Prochazka
© BASF April 25, 2012 | Slide 9
About BASF History and products
BASF The Chemical Company was first incorporated (as Badische Anilin & Soda Fabrik) in 1865 for production of coal tar dyes and other products.
Today, BASF is the world’s leading chemical company
We aim to constantly increase the value of company by
profitable growth and to remain the number one in chemistry.
We combine economic success with environmental protection
and social responsibility.
BASF is a publically traded company with ~ 111,000 employees and 2011 annual sales of 73.5 billion Euros
BASF is an innovative solutions provider, comprised of chemical, plastics, performance products, functional solutions, agricultural solutions and oil & gas segments
BASF is focused on sustainable development for long term growth and profitability
The automotive paint plant in Windsor, Ontario (Canada) is part of BASF’s Coatings Division, which is part of the functional solutions segment.
© BASF April 25, 2012 | Slide 10
About BASF Paint plant facility in Windsor, Ontario, Canada
Products: OEM coatings, waterborne & solvent borne primers, and basecoats (automotive paints), and refinished products
Area: 8.5 acres, land locked
Site: over 100 years old
Floor space: 110,000 ft2
Total headcount: ~145
Average experience: 20 yrs
The site became BASF as part of the Inmont acquisition in early 1980’s
© BASF April 25, 2012 | Slide 11
2007 (June) – Evolution implementation Operator consoles & engineering work stations
Conductor
VMS
Redundant
Servers
Conductor VMS
Clients
1994 2007 (June) 2007 (July)
© BASF April 25, 2012 | Slide 12
2010 (September) Adding new controls for refinishing product line
In 2009 BASF made the strategic decision to expand the Windsor
facility to include refinishing products
Existing system has approximately 2000 I/O points for process
automation of blending, mixing, batch processes and dispersions
Project Scope:
New refinishing product line has ~ 600 I/O points
Addition of 800xA controllers to existing INFI 90 system including;
HPG (Harmony PCU Gateway)
2 x AC800M controller pairs
S800 I/O modules (with embedded intrinsic safety)
3 new operator client stations
New sequences implemented in AC800M controllers (using
Sequential Function Charts) and modified existing BATCH90
configurations
Addition of INFI 90 library into AC800M controllers
© BASF April 25, 2012 | Slide 13
IS Interface
AC800M
2010 (September) Status Adding new controls for refinishing product line
2007 (June) 2008 2010 (March) 2010 (Sept.)
BRC400
HPG
AC800M
S800 I/O S800 I/O
Profibus to 3rd
party devices
(eg. VFD’s &
PLC’s)
Profibus to 3rd
party devices
(eg. VFD’s &
PLC’s)
System 800xA New refinishing line
Challenges and solutions HPG – Harmony PCU Gateway
Challenge:
Operators need to seamlessly control the new refinishing
products line while operating the existing blending, mixing,
batch processes and dispersions lines
Existing plant equipment was moved to the new refinishing
products line, yet field wiring remained unchanged, therefore
INFI 90 needed to interface with System 800xA
Solution:
HPG (Harmony PCU Gateway) to connect the existing
BRC400’s to the new refinishing products AC800M controllers
The Harmony PCU Gateway (HPG 800) is designed to provide
a robust, peer-to-peer communications with AC 800M
controllers via CI867 Modbus TCP CEX modules
Operators have seamless control of the new refinishing line
with the addition of some new graphics
© ABB Inc. April 25, 2012 | Slide 14
Challenges and solutions AC800M Controllers
Challenge:
New refinishing product line has ~ 600 I/O points. BASF
wants to adopt new control technology and integrate it with
existing control technology
Solutions:
Using AC800M controllers (part of the System 800xA) for the
new refinishing products inputs/outputs
2 x AC800M controller pairs (allowed us to communicate to
third party devices using Profibus DP), including interfacing to
variable frequency drives connected to motors
Using Profibus with AC800M allowed BASF to utilize remote
I/O distributed to many buildings, minimizing field cabling.
This saved many hours of labour and testing
Addition of INFI 90 library into AC800M controllers to maintain
operator interface standards
New sequences implemented in AC800M controllers (using
Sequential Function Charts) and modified existing BATCH90
configurations
© ABB Inc. April 25, 2012 | Slide 15
AC 800M Controller(s)
Motor
Variable Speed Drives
Challenges and solutions S800 Input & Output Cards
Challenge:
Our process operates in a Class I Zone I environment. We
were limited on real estate space with the addition of the new
refinishing product line
Solutions:
S800 I/O modules were added for the new refinishing product
line
S800 I/O has embedded intrinsic safety in the modules
Total of 6 I/O cabinets distributed throughout the process
areas
Solution minimized footprint required in limited real estate
space
© ABB Inc. April 25, 2012 | Slide 16
Challenges Project execution and coordination
Challenges:
Time was a challenge. The equipment was received at site in June 2010 and commissioning with loop checks & sequencing needed to be started September 2010
Site equipment and configuration had to be phased in existing process which was still in operation (switched one line at a time)
© ABB Inc. April 25, 2012 | Slide 17
Solutions Project execution and coordination
Solutions:
The project was planned and scheduled with configurations combined and tested ahead of time
The hardware was shipped ahead of time so the wiring could be completed
Planned loading of graphics and configuration was used as equipment came on-line, others phased out
The final installation was implemented during a weekend shutdown “plug and play”, once final equipment swing over was complete
The upgrade was transparent to the operators, eg. Faceplates, etc. looked the same and operated the same on either the INFI 90 or 800xA system.
ABB was able to pool their resources together, plan hardware, loop checks, final configuration and sequence testing
© ABB Inc. April 25, 2012 | Slide 18
Evolution Can you see the difference?
© ABB Inc. April 25, 2012 | Slide 19
INFI 90
Operator graphic
System 800xA
Operator graphic
© BASF April 25, 2012 | Slide 20
2011 (December) Tank farm PLC replacement and power system upgrades
In 2011 BASF made the decision to replace the programmable
logic controller (PLC) on the tank farm and upgrade the INFI 90
power supplies to MPSIII power systems
Existing PLC had approximately 300 I/O points for automation of
tank farm
Project Scope:
Addition of 800xA controllers to existing system;
1 x AC800M controller pair
S800 I/O modules
1 x new operator client station
New sequences implemented in AC800M controllers (using
Sequential Function Charts) and modified existing BATCH90
configurations
Replaced INFI 90 power systems with 2 x MPSIII power systems
Add 5 new VFD’s for mixer control.
© BASF April 25, 2012 | Slide 21
IS Interface
AC800M
2011 (December) Status Adding tank farm PLC replacement and power upgrade
2007 (June) 2008 2010 (March) 2010 (Sept.)
HPG
AC800M
S800 I/O S800 I/O
Profibus to
3rd party
devices
(eg. VFD’s
& PLC’s)
Profibus to
3rd party
devices
(eg. VFD’s
& PLC’s)
System 800xA New refinishing line
BRC400
Tank Farm
AC800M
S800 I/O
2011 (Dec.)
Tank farm PLC replacement challenges Project execution and coordination
Challenges:
Time was a challenge. The tank farm need to be moved from existing PLC to 800M in a single weekend, including complete loop and functionality checks
Minimal training for Tank Farm operators.
Upgrade INFI 90 power systems without affecting operations or tank farm upgrade
Add 5 variable frequency drives (in phases) with minimal effect on system interruption
© ABB Inc. April 25, 2012 | Slide 22
Tank farm PLC replacement solutions Project execution and coordination
Solutions:
Project design included I/O with pre-terminated field cabling, 100% tested before shipment
Interconnecting cabling was designed to match the existing PLC cabinet terminal block grouping
New cabinet was installed ahead of shutdown.
New I/O marshaling cables wired to existing PLC termination panel in less than 1 day (Saturday).
New 800xA client computer was installed and tested before replacement Controller, S800 panel installed
All control standards from previous project were used for PLC replacement. Complete plant now looks and controls to the same standards –> minimized training.
© ABB Inc. April 25, 2012 | Slide 23
Tank farm PLC replacement solutions Project execution and coordination
Solutions continued:
INFI 90 power supply upgrade installed weekend before tank farm PLC replacement. This concluded the DCS migration planned since 2005.
New variable frequency drives added to Profibus segments with minimal new wiring requirements
Variable frequency drive logic copied from existing configuration with minimal effort adding logic, updating graphics and checking I/O
© ABB Inc. April 25, 2012 | Slide 24
Tank farm PLC replacement solutions
© ABB Inc. April 25, 2012 | Slide 25
Tank farm control panel Power supply system upgrade
Evolution Next steps
The BASF Windsor site continues to evolve
Next steps include existing (obsolete) PLC’s evolve to ABB’s AC800M controller and S800 input & output cards
and thus eliminating control islands.
Special reporting for Filler Machine using Information
Manager.
Expansion of existing pigging system.
© ABB Inc. April 25, 2012 | Slide 26
© BASF April 25, 2012 | Slide 27
Key learning's and conclusions
1. We made the right decision….
Protected original
investment
Innovative approach to
evolution as opposed to
replacement
Minimized staff retraining
2. The new System 800xA
systems are stable and
reliable
3. All process information is available to operators / management through a single interface, plant controls are transparent to site staff whether they operate an INFI 90 or 800xA system
4. The plant’s control system
technology is new and up to
date
Minimizing maintenance
costs
Easy expandability
Low cost hardware
Flexible licensing
5. Minimized footprint of new equipment
6. Intrinsic safety embedded
7. Integrated services provided with ABB single contact representative
© ABB Group April 25, 2012 | Slide 30