Post on 25-Jun-2015
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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
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Agenda
Questions/Comments
Results
The Solution
Project Specifications
Company Introductions
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ESCO Group: The Umbrella of Resource
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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
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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
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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
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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
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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)
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Project Design
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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
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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
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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
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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
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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
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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
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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
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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
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Controls Objectives Distributed Safety System
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Controls Objectives Distributed Safety System
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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
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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
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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.
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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
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SAP Integration
SAP iDOCS
Process Orders
Material Data
Classification Data
Data Collection
Reporting and Visualization
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Mobility & Visualization
FactoryTalk ® View SE
Remote Visibility
Dash Boarding
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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
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Questions