Buckeye Partners: Virtualized PlantPAx System Improves Risk Management
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Transcript of Buckeye Partners: Virtualized PlantPAx System Improves Risk Management
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Buckeye Partners, L.P. Perth Amboy Marine Terminal Virtualized PlantPAx Improves Risk Management
David Cortivo - Senior Engineer, MAVERICK Technologies
John F. Boyd - Technology Leader, MAVERICK Technologies
November 17, 2014
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Questions & Answers
Full Utilization PlantPAx DCS and Vantage Point System – New Beginning
Implementation the PlantPAx DCS – Journey
Why PlantPAx– Start
Introduction – Buckeye Oil and Gas Terminal
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Buckeye Partners - Introduction
Who is Buckeye Partners?
Buckeye Partners traces its roots to March, 1886, when The Buckeye Pipe Line
Company was incorporated as a subsidiary of the Standard Oil Company.
From its modest nineteenth century beginning as a local crude gathering subsidiary,
Buckeye in the twentieth century transformed itself into one of the nation's largest
independent common carrier refined products pipelines.
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MAVERICK Technologies - Introduction
Who is MAVERICK?
Broad and deep manufacturing technology specialist focused on delivering value to its clients
Total solutions provider – from the plant floor to the “C” suite
Good people to work with, relationship focused
A global network of more than 1,000 resources and partners
Value driven
Locations
Global Headquarters – Columbia, IL
Additional Locations – Nineteen (20) North American Locations
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Start
Grass Roots for a DCS Platform Selection
The Perth Amboy Refinery is a refinery built in 1920 and was owned and operated by chevron. In 2012
the facility was acquired by Buckeye Partners and a modernization effort to bring the facility into the 21
century as a terminal service provider was born.
Control System Hardware
“State of the Art” hardware, utilizing the latest in Virtual Server applications with remediation concerns at the
heart of the design. Perth received considerable damage during the hurricane Sandy and did not have
remediation ability on site.
Top of the line motor actuated control valves utilizing DeviceNet bus technology.
Remote cabinets with Point I/O™ for cost savings measures
Control System Software
Microsoft desktop and server operating systems, world class historian server, and automatic generation of real-
time/historical reports thru VantagePoint
DCS system easily supported by internal operations and remote support provided by Maverick Technologies 24/7
offerings.
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Journey - Planning
During the DCS Implementation MAVERICK used the project
complete process
Planning with the process needs of Buckeye thru structured collaboration.
Understanding the benefits of a automated facility
Working with the current need and vision for growth
Identifying the key drivers impacting business needs
Developing a tailored solution for the facility
Communication to all trades involved with the expansion effort
Project complete is the combination of Planning, Delivery and
Sustaining Services into one turnkey solution.
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Journey - Software
Software Implementation Process
Discovering the Existing System MAVERICK and Buckeye engineers analyze the existing system and
developed a functional specification
We took a fresh look at existing plant operations and we developed a structure
for the DCS system to integrate with current tank monitoring and vapor
recovery systems.
PlantPAx process objects where selected for the facility and development of
additional functionality commenced
Current RSView 32® operating systems are being migrated into the PlantPAx
DCS system to have a unified plant structure.
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Journey - Software
System Architecture
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Journey - Software
VMware Architecture
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Journey - Software
Software Application Process
Conceptual layout of screen navigation and content for rapid development among all parties
Built working model with standard control code. Standard code also vetted by Rockwell
Automation PlantPAx engineers for proper use and application
Long term simulation network built for operator training and testing applications.
Dynamic simulation model using Mynah Mimic software
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Journey - Software
Software Application Process – Selling a Standard
Built working model with standard control code. Standard code also vetted by Rockwell
Automation PlantPAx engineers for proper use and application.
Initial training and look and feel was presented to operations with a small model built with the
PlantPAx objects. With the defined standard model that PlantPAx brought to the project the
overall reaction to the model was well received.
Basic equipment operations supported without having to design special faceplates or control
code. 90% of the equipment at Buckeye is motor actuated valves which are supported with
PlantPAx.
No need for external databases as device information already housed in the PlantPAx
controllers.
Existing tools prebuilt by Rockwell Automation for rapid configuration of equipment
parameters. Both read and write ability supported.
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Journey - Software
Software Application Process – Virtual Machine Selection
Ability to remote build VM’s without having final server purchased due to the use of the VM
nature.
Cost savings with the use of VM’s as the development network and platform basis. The
exact VM images were directly installed into the plant environment once server structure and
network were in place. Minimal configuration changes had to be made in the transition to
operational.
Remote development teams operating thru the VM’s to keep project security and continuity
intact.
Virtual engineering workstations were built with all design software requirements. This
allowed for minimized software revision issues among configuration PC’s.
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Journey - Software
Software Application Process – Simulation Network
Long--term simulation network built for operator training and testing applications.
Selection of equipment for simulation network. Built on a single pc for mobility.
Emulator used for PLC backbone.
Dynamic simulation model using Mynah Mimic software for I/O tieback.
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New Beginning - PlantPAx
Process Screen - Concept
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New Beginning - PlantPAx
New Control Valves
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New Beginning - PlantPAx
Process Screen – Big Picture
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New Beginning - PlantPAx
Process Screen – All detail and overviews two button clicks with
quick area navigation
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New Beginning - PlantPAx
Process Screen – Paper reduction thru HMI and Historian
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New Beginning - PlantPAx
Reports – Secure remote live data without need to open the process
control network
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Questions
David Cortivo - Senior Engineer, MAVERICK Technologies
John F. Boyd - Technology Leader, MAVERICK Technologies
November 17, 2014