Brennand & PlantPAx - Rockwell Automation · PDF filePlant expansion scheduled to February...

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Brennand & PlantPAx: Grass Roots Cement Plant

Eugênio Monteiro Neto Senior Automation Analyst, MBA Nov-12

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Agenda

Conclusion

Automation Project

The challenge

Brennand & Cement Market


Brennand - History

Created in 1917, started its business in the sugar-alcohol market

Based in Recife, state of Pernambuco, in the Northern Region of Brazil

It expanded operations to different markets: Ceramics and tiles Glass Power generation Cement

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Brennand - Businesses

Ceramic & Tiles Home utilities, art objects Ceramic: different styles, shapes, sizes available Product line for exportation Personalized products developed

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Energy: 335 MW installed capacity 2 Hydroeletric Power Plants (HPP) 13 Small Hydro Power plants (SHP) 2 HPPs under construction (+21 MW) 3 Wind Power plants under construction (+90 MW)

Juba 2 HPP Diacal SHP Station

Glass: Float glass plant under construction (start up scheduled to Aug-13) Investment : ~US$ 400 million Production capacity: 900 tons / day Aimed to the civil construction

1st Float Glass plant in the Northeastern region


Brennand – Other areas of investment

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Instituto Ricardo Brennand: since 2002 Museum, Ar Gallery and Library 200,000+ visitors per year Cultural activities and courses Educational programs for public schools

Gallery Inside

Educandário Nossa Senhora do Rosario Energy channeled to a better society Brennand Group maintains Educandario Children have constant medical, nutritional and educational

monitoring with music, art and education classes in early childhood

Brennand Plaza Building The Plaza has Brennand differentials that

come together in a place of tranquility and relaxation.

Castle

Reserva do Paiva Destination for tourism, leisure, housing


Brennand – Cement Business

Cimento Nacional in operation since 2011.

Currently, the most modern cement plant in Brazil !

Cimento Nacional comes with the most advanced technologies available: Integrated plant with the latest technology machines and state-of-the-art automation

Results: superior quality and high performance cement

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Cement Market - 2011

Cement consumption in Brazil: 63.5 Mt (8.3% growth vs 2010)

Brazil is in 4th place in the world (behind China, India and USA) Prices went up 5.8% vs 2010

14 groups with 79 cement plants all over the country (2011) Current production level does not meet market demand

Huge investments in infrastructure underway: “My Home, My Life” Program from Brazilian Governement (homes for lower class) “Growth Acceleration Program” from Brazilian Government World Cup FIFA 2014 in Brazil, 2016 Olympics Games in Rio de Janeiro

Demand expansion expected in 2012: 8.1% Domestic consumption growth rate higher than GDP Production capacity already compromised even with new plants being built

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Agenda

Conclusion

Automation Project

The challenge



The challenge

A cement plant build from scratch ! Total investment : US$ 300 million Capacity : 1,000,000 tons / year Start up : February 2011

Brennand was looking for : An automation solution for the optimal plant performance Open architecture (no proprietary networks) Infrastructure to support future plant expansion (less time, lower risk) Integration of plant data to support real time decision making by upper

management Lower cost of ownership

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Why did Brennand choose Rockwell ?

Process Optimization

Asset Management

Information Management

• Plant & HQ

• Control System • Instrumentation • Rotating Equipment • MCCIs

Process Control

• Control • Interlock • Safety • Power

x

x

Future


Agenda

Conclusion

Automation Project

The challenge



Process Control

29 Controllers – 80,000 I/O points 12 ControlLogix; 17 CompactLogix

71 AC Drives DeviceNet (+20 units out of DN)

650 HART instruments

Infrastructure Redundant PASS 09 Operating Work Stations (OWS) – Dual Monitor 02 Engineering Work Stations (EWS) 06 Virtualized Physical Servers

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Virtualization – 06 Physical Servers

Installed in 2 different locations

29 VMs (Servers)

2 Storage Dell II (9 HDs of 600 GB SAS 6 Gbps in each storage)

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Alarm Priorization


Web Visualization

Expands the ability of visualization Real time update, high quality screens, full animation,...

Expands the ability of visualization and real-time decision to remote users

Views screens, trend and alarms to simplify casual users access

Waives software installation and maintenance

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Web Client: Feed to Roller Mill


Asset Management

Rockwell Asset Management tools cover large breadth of equipment

Control System Automated backup of logic/files Traceability (Developer, Operator, Engineer)

Error, Warning, Audit, Information

Instrumentation Field device configuration Calibration management of field devices

Regulatory compliance, Staff effectiveness improvement, More repeatable process, Lower production cost,...

MCCIs Remote diagnostics Documentation repository

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Asset Management FT AssetCentre

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Traceability

Automatic Backup

Field Device Configuration


Information Management

Demand increase in cement requires real time tool to support quick & good decision making

Integration with different types of DataBases Connectors available (SQL Server, MySQL, Oracle,

devices in real time OPC DA, …)

Web based reports Trends, dashboards, XY charts,...

Information available throughout the plant

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Dashboards de Produção


Equipamentos Críticos


Energy Management

Full understanding of utilities consumption is key to deliver better results

Provides direct correlation of energy costs and production costs

Generates reports of a department, process area and entire plant

Allows real-time decision making

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Energy Management : Consumption Reports


Agenda

Conclusion

Automation Project

The challenge



Next steps...

Plant expansion scheduled to February 2013 Production will increase from 1 Mton to 1.8 Mton

New cement mill

New packaging line

New pallet line

Evaluating MPC deployment in different process areas Raw Mix Blending, Raw Mill, Pyro-Processing, Finish Mill

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• PlantPAx infrastructure in place already supports expansion

• Minor changes required ⇒ smooth plant expansion expected


PlantPAx - Key Benefits

High availability and Improved results with high performance controllers and software tools

Real time Automation Portal where upper management has easy access to KPIs like plant performance, energy consumption, process availabilty,… (decision support tools)

Lower maintenance costs Transparent integration of different disciplines (control, power, network,...)

reduces enginnering costs Remote access to operation screens simplifies manager task to track

process operation Integration of historical data with plant operation “ready”

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Final Conclusion

PlantPAx capabilities have delivered benefits in different areas allowing the

plant to operate at 115% of design capacity since start up!!!

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Questions

Eugênio Monteiro Neto Senior Automation Analyst, MBA Nov-12

Brennand & PlantPAx - Rockwell Automation · PDF filePlant expansion scheduled to February...

Documents

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