Cs06 calumet-malisko engineering
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Transcript of Cs06 calumet-malisko engineering
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Virtualized PlantPAx Improving Consistency and Throughput
Doug Stanek
Plant Engineer - Calumet
Tim Malyszko
Director of Operations – Malisko Engineering, Inc.
November 2014
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Future Expansions
Results / Lessons Learned
Selecting a PlantPAx Solution and System Overview
Project Goals
Introduction
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Who is Calumet?
A leading independent producer of high-quality, specialty hydrocarbon products.
Headquarted in Indianapolis, IN with locations throughout the United States.
Fortune 500 Company!
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Calumet Louisiana Synthetics – Louisiana MO
Produces Polyolester based synthetic lubricants
Refinery facility located in Louisiana, MO
36 Million Lbs./year capacity
Refines fatty acids and alcohols into Polyolester based synthetic lubricants
Batch esterification process
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Products
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Who is Malisko Engineering?
• Experts in manufacturing automation and validation
• Founded in 1994
• Headquartered in St. Louis, Missouri USA
– Historic Laclede’s Landing on the Mississippi Riverfront
• Regional office in Denver, Colorado USA
– Serving the Rocky Mountain region and the west
• Rockwell Automation® Solution Partner for control,
process, & information systems.
• CSIA certified member
Historic Laclede’s Landing St. Louis, MO
Denver, CO Malisko Western Regional Office
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Recognized As Experts
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Agenda
Future Expansions
Results / Lessons Learned
Selecting a PlantPAx Solution and System Overview
Project Goals
Introduction
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Project Goals – Phase I Existing Synlubes Facility
Automate a primarily manual operation
Convert manual valves to automatic control
Minimize operator intervention by reducing operator interactions in field by over 200
steps per batch
Automate pressure and temperature control
Manage formulations electronically
Migrate manual batch records to electronic batch records
Improve product consistency
Migrate antiquated tank farm HMI to new system
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Project Goals – Phase II Kettle Expansion
Double production capacity
Add two new fully automated kettles
Automate drumming station
Add a new centralized control room for all operations
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Project Goals – Phase II Kettle Expansion
Add fully automated intermediate and finished product tanks and acid storage tanks, truck and rail car loading stations
Automate loading and custody transfer
Add server redundancy to phase I PlantPAx® components
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Agenda
Future Expansions
Results / Lessons Learned
Selecting a PlantPAx Solution and System Overview
Project Goals
Introduction
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Choosing a PlantPAx Solution “Traditional” DCS vs. PlantPAx
Criteria Traditional DCS
Local Support Single Local Solutions
Provider
Local Eco-System consisting
of dozens of local Integrators
and Solution Partners
Scalability Hardware + Additional License
required for additional I/O
No additional licensing
required
Topology
Dedicated Servers. Software
and Hardware Upgrades
Expensive
Virtualization Fully Supported
– Decoupling Hardware from
Software
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System Overview – Phase I Define Control Strategy
Needed to estimate system parameters such as server tags, memory
usage and execution time.
S-88 modeling - define control modules, equipment modules, phases and
unit procedures
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System Overview – Phase I PlantPAx System Characterization
Characterization verifies that the system provides the required
performance
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System Overview – Phase I System Architecture
Single physical server with four virtualized images
FactoryTalk® View server ThinManager® remote desktop server FactoryTalk® Historian FactoryTalk® VantagePoint® & Transaction Manger Two View thin clients
Foundation Fieldbus
Move segments from existing DCS to PlantPAx® Combine 3 segments into 1 segment
“Traditional” I/O used for new field devices
Easier to troubleshoot for plant support No significant cost savings using bus technologies
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System Overview – Phase I System Architecture Continued
VPN connection into system for remote support
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System Overview – Phase I PlantPAx Process Objects
v3.0 PlantPAx process objects used
“Out-of-the-box” PlantPAx AOIs used
“Enhanced” PlantPAx global objects used
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System Overview – Phase I Formulation
All product formulas reside in the program
Formulations can be changed, added and removed from HMI with proper security
Formulations can be modified at start of batch by operators and changes reflected in batch ticket
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System Overview – Phase I Convert Log Sheets
Convert manual data collection to automatic data collection
Emergency events such as power loss now automatically recorded on log sheet
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System Overview – Phase I VantagePoint Reporting
All log sheets available via FactoryTalk VantagePoint
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System Overview – Phase I VantagePoint Reporting
Daily tank farm report ran and printed at 7 AM
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System Overview – Phase I ACP ThinManager® Deployment
Easily manage and deploy
FactoryTalk View clients
Application link locks down the
client so operators can only access
the FactoryTalk View client
application.
Shadow feature gives engineers
the ability to remotely monitor the
process and troubleshoot issues
remotely with the operator.
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System Overview – Phase II System Architecture
Add additional controllers and operator workstations for new process units
and tank farm.
Interface to new IntelliCENTER®
Add redundancy to PlantPAx components
Secondary FactoryTalk View Site Edition server
Redundant domain controllers
Mirrored ACP ThinManger servers
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Agenda
Future Expansions
Results / Lessons Learned
Selecting a PlantPAx Solution and System Overview
Project Goals
Introduction
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Immediate Results
Batch consistency All formula parameters reside in the system All operators now run the system the same
Batch cycle time optimization Roll from one step in the batch to the next No longer waiting for the operator to perform the next step before
moving forward
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Immediate Results Continued
Eliminate the “I Think” and turn it into “I Know” All devices historized
Batch records can be pulled from VantagePoint since batch number
one on the system
Identify opportunities to increase capacity beyond initial 4-5%
capacity by eliminating process bottlenecks
Heat cycle tracking Reliable data showing heat cycle and adjustments made during cycle
Optimize heat cycle over the course of a batch
Virtualization allowed us to move and redeploy server images and add
server redundancy with minimal interruption to the process
PID control adjustments can be done completely from PlantPAx faceplate
No need to open Studio 5000® when adjusting PID Control
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Long Term Benefits
Operator comfortable with system before major expansion
Ease of adding additional points to system
No additional licensing required Using prebuilt PlantPAx objects like the dosing AOI simplifies brining
in externally totalized additions into system Tracking additions gives Calumet ability to bill customers accurately
for formulation
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Lessons Learned
Use domain controllers
Even on small systems, managing
security becomes a challenge in a
workgroup environment
Foundation Fieldbus network
design
Verify network topology design
before commissioning
Poor design = poor signal quality &
loss of device communications
Remote support via VPN is a must!
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Agenda
Future Expansions
Results / Lessons Learned
Selecting a PlantPAx Solution and System Overview
Project Goals
Introduction
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Future Expansion
Migrate existing Traditional DCS controlling Kettle D to PlantPAx
Foundation Fieldbus, DeviceNet and AS-Interface
Add waste water treatment into PlantPAx system to reduces the risk of
costly need for off-Site process.
Convert existing manual tank farm operations unit-by-unit.
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Questions?
Doug Stanek
Plant Engineer - Calumet
Tim Malyszko
Director of Operations – Malisko Engineering, Inc.
11/15/2015