Process Solutions User Group (PSUG)

Transcription

Process Solutions User Group (PSUG)
Pennsylvania Convention Center | Philadelphia, PA | November 5-6
For more information about our process automation solutions, please visit: www.rockwellautomation.com
Rockwell Automation, Inc. (NYSE:ROK), the world’s largest company dedicated to industrial automation, makes its customers more
productive and the world more sustainable. Throughout the world, our flagship Allen-Bradley® and Rockwell Software® product
brands are recognized for innovation and excellence.
Follow ROKAutomation on Facebook & Twitter.
Connect with us on LinkedIn.
Allen-Bradley, CompactLogix, ControlLogix, eProcedure, FactoryTalk, Integrated Architecture, LISTEN.THINK.SOLVE., PlantPAx, PhaseManager, PowerFlex,
ProcessLogix, Rockwell Automation, Rockwell Software, RSBatch, RSLogix, RSView, Trusted and VantagePoint are trademarks of Rockwell Automation, Inc.
EtherNet/IP, ControlNet and DeviceNet are trademarks of ODVA. All other trademarks and registered trademarks are property of their respective companies.
November 2012
Copyright ©2012 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
2012
TABLE OF CONTENTS
Process Solutions User Group 2012
Welcome Process Users,
On behalf of Rockwell Automation, I would like to thank you for joining us in Philadelphia, for
our annual Process Solutions User Group (PSUG) meeting. This year’s PSUG meeting promises to be an extraordinary learning and networking event for all attendees. It’s an
excellent forum to hear about new process solutions and expand your peer network. You will have the opportunity to interact directly with other process
Table of Contents
3
Agenda
11
Speakers and Customer Advisory Board
15
Educational Sessions
19
Town Hall Voting Sessions
users who are improving their business processes, creating new revenue 23
Customer Application Sessions
streams and establishing best practices by implementing the
31
Process Solutions User Group (PSUG) 2013
Rockwell Automation PlantPAx process automation system for their applications.
Take the opportunity to provide us with direct feedback on new features, functions and offerings
at the Town Hall Voting sessions. We remain focused on your needs and continue to invest in our
technologies and solutions.
Enjoy your Process Week at PSUG and Automation Fair.
Best Regards,
John A. Genovesi
A Special Thank You To Our Advertisers
2
ProSoft Technology
8
Panduit Corporation
10
Endress+Hauser, Inc.
20
Phoenix Digital Corporation
22
Spectrum Controls, Inc.
30
Hardy Process Solutions
Please visit the booths of HART Communication Foundation,
FDT Group, ODVA and Fieldbus Foundation.
Vice President and General Manager
Information Software and Process Business
WE’VE GOT
HART
®
FIELD COMMUNICATIONS PROTOCOL
ABILITY
PROCESS SOLUTIONS USER GROUP PSUG 2012 | PHILADELPHIA
1
AGENDA
AGENDA
MONDAY | NOVEMBER 5, 2012
5
AGENDA
TUESDAY | NOVEMBER 6, 2012
7
PSUG Breakout 4 & 5
Tech Session
PSUG Breakout 6 & 7
Tech Session
R
R
R
R
Process Solutions User Group 2012Up to Ballroom A&B
To Exhibit Hall
GRAND HALL
R
204 A
Bridge to Philadelphia Marriott
R
R
R
201 A
204 A
201 A
204 B
201 B
204 C
201 C
203 AB
202 AB
PSUG Breakout 1
Tech Session
PSUG Breakout 10
Tech Session
204 B
PSUG
PSUG Breakout 9
BREAKFAST
Tech Session
& LUNCH
204 C
PSUG Breakout 8Ballroom B
Tech Session
201 B
PSUG
PSUG Breakout 2
GENERAL
Tech Session
SESSION
201 C
Ballroom A
PSUG Breakout 3
Tech Session
202 AB
203 AB
PSUG Breakout 6 & 7
Tech Session
Food
Staging
Food
Staging
PSUG Breakout 4 & 5
Tech Session
R
R
R
R
Up to Ballroom A&B
Down to Breakout Rooms
GRAND HALL
GRAND HALL
Bridge to Philadelphia Marriott
9
SPEAKERS AND
CUSTOMER ADVISORY BOARD
SPEAKERS
Stephen E. Pulsifer | Global Director, Process Market Development, Rockwell Automation
Nancy Youn | Director, Global Strategic Alliances, VMware, Inc.
Stephen E. Pulsifer and his team are responsible for all Commercial Programs and Activities as they relate to the Process business.
He joined Rockwell Automation in 2007 as the Director of Life Sciences, Market Development. He attended Wentworth School
of Technology (C.E.T.) and Northeastern University (B.S.B.A.) in Management Information Systems. In 1983, he went to work for
Analog Devices Semiconductor (Wilmington, MA). He held various positions including Reliability Lab Department Manager. In
1991, he went to work for Total Control Products (Melrose Park, IL), a designer and manufacturer of operator interfaces, control
technology and industrial process software. Steve worked as a sales engineer and was promoted to Southeast District Sales
Manager. In 1999, the company was acquired by GE Fanuc Automation (Charlottesville, Virginia). Steve became the Northeast
Regional TCP Sales Manager. In 2000, Steve moved into strategic marketing and became the Life Sciences Market Development
Manager. In 2003, he went to work for GE Sensing as the Global Healthcare Product Marketing Manager and, in 2006, Steve
became the Marketing Operations Leader for GE Sensing and Inspection.
Nancy Youn is Director of Alliances within VMware’s Global Strategic Alliances Organization. She is responsible for building and
managing VMware’s ISV partner ecosystem. This encompasses market-leading technology vendors spanning joint collaborations
on product integrations, go-to-market programs and business alignment.
John Genovesi | Vice President & General Manager, Information Software and Process Business,
Rockwell Automation
John Genovesi is Vice President and General Manger of the Rockwell Automation Information Software and Process Business.
He is responsible for leading growth, profitability and development strategies globally. In this role, John implements strategies
to ensure delivery of value-based solutions in support of our customers’ global productivity initiatives. John’s prior role was
Vice President, Global Accounts since 2008. Prior to that, he was appointed Vice President, Automotive and he was appointed
Vice President Automotive and Tire Industry Initiative in 2006, District Manager in Cleveland in 2001, and branch manager in
Rochester NY in 1998. John joined Rockwell Automation in 1989 as a senior account manager in Buffalo, NY, where he
became the branch manager in 1996. John holds a Master of Business Administration (MBA) from Case Western Reserve
University, in Cleveland Ohio. He also has a Bachelor of Science (B.S.) degree in Electrical Engineering from
Youngstown State University.
Nancy earned a B.A. from Stanford University as well as a J.D. from University of California, Davis School of Law. She has over
15 years of legal and technology experience in alliances, sales and marketing.
Ben Mansfield | Marketing Manager, PlantPAx System, Rockwell Automation
Ben Mansfield is the Marketing Manager for the PlantPAx Process Automation System, responsible for driving the future of the
product portfolio to meet the needs of our process industry clients. During his time at Rockwell Automation, Ben has provided
technical consultation for large process applications and worked in product marketing with a focus on bringing new capabilities
to PlantPAx. Ben has over 13 years experience in process automation, delivering solutions to clients in the Chemical, Life Sciences,
Water/Wastewater and Mining industries.
Som Chakraborti | Business Director, Process Business, Rockwell Automation
Som Chakraborti is the business director of the Process Business within the Architecture and Software Portfolio Management
organization. He is responsible for the profitable growth of the PlantPAx system in Process applications. Som has extensive
experience in the process arena, including process solutions project engineering, automation services and solutions
delivery management with a competitive DCS supplier and most recently as a Marketing Manager for PlantPAx within
Rockwell Automation. Som brings over 16 years of engineering and business experience. He joined Rockwell Automation
from ABB in 2004 as a manager of Engineering Process Automation and has held positions of increasing responsibility across
a variety of business groups in his time here. Most recently he was Manager, Marketing, PlantPAx within the Architecture and
Software Portfolio Management organization. Som earned his Bachelor’s of Engineering from the India-Birla Institute of
Technology and Science, Pilani, India. He also earned a Master’s of Science from West Virginia University and his
MBA from The Ohio State University.
13
MEET THE CUSTOMER ADVISORY BOARD
The Customer Advisory Board, representing a broad set of process industries, is
the key to the success of this forum. We thank them for their ongoing contributions!
Bob Wetter
Director, Instrument,
Electrical & Computer
Engineering
Archer Daniels
Midland
Jay Hardison
Operations
Superintendent,
Project Manager
Colorado Springs
Utilities (CSU)
Nadine Arens
Consultant,
Process Dynamics &
Control Group
DuPont Electrical &
Communications Group
Gary McKenzie
Process Control
Specialist
Gerrie Process
Group
Michael Hilton
Director,
Electrical &
Instrumention
Industrial Furnace
Company
Darren Twyford
Control System
Specialist
JNE Automation
Bob Kilas
Electrical & Controls
Technical Leader
Kimberly-Clark
Corporation
Mark Hron
C&D Electric
Engineering Manager
Kraft Food
North America
Kris D. Jentzsch
Project Engineer
Pacific Gas & Electric
(PG&E), Diablo
Canyon Power
Plant (DCPP)
Jim Labonty
Director, PGE Process
Automation
Pfizer, Inc.
Don Geers
Senior Process
Controls Engineer
Pharmaceutical
Manufacturer
Larry Grate, P.E.
Account Delivery
Manager, Decatur
Business Unit
Premier System
Integrators
Pat Dollard
Process Control
Section Lead
Procter & Gamble, Inc.
Trung Nguyen
Project Engineer
Shell Global
Solution
EDUCATIONAL SESSIONS
These sessions, offered to provide technical information,
are free to all attendees. You can receive Professional
Development Hours (PDH) and the corresponding
documentation.
ED01: PlantPAx System Overview
Presenter: Jason Wright, PlantPAx Product Manager
Gain a comprehensive perspective on the capabilities of the
PlantPAx system including system Virtual Image Templates. This
discussion is ideal for end users, OEMs and solution providers
who are looking for true plant-wide control, information integration,
engineering efficiencies and right-sized process designs.
ED02: Using the PlantPAx Library and Engineering Tools
Presenter: Dale Reed, Senior Project Engineer
The PlantPAx Library and Tools are key ingredients for project
implementation methodology. This session defines the operation
of common objects, such as modes and alarming, and reviews each
library object for its functionality and typical application. Walk away
with a basic understanding of the libraries and tools available to
more efficiently develop process sytems and OEM skids.
ED03: PlantPAx Field Device Networks
and Asset Management
Presenter: Brian Root, Senior Systems Engineer
Simplify the connection of smart process instrumentation via
EtherNet/IP, HART, FOUNDATION Fieldbus, and Profibus PA through
device integration tools and documents available with PlantPAx.
See how to implement Process Library objects for instrumentation
and gain valuable insight into the ROI associated with easy
device integration.
ED04: PlantPAx Virtual Image Templates Overview
Presenter: Greg Hood, Product Manager
This session provides an in-depth introduction to our Virtual
Image Template product. Learn how this product will enable
you to deploy PlantPAx in a virtual environment. Gain an
understanding of benefits that can be achieved with the
product from a PlantPAx system perspective; and, potential IT
administration and infrastructure cost savings that can further
reduce the total cost of ownership of a PlantPAx system.
ED05: Turning Process Data into Production Intelligence
Presenter: George Peters
Increase the value of PlantPAx with Production Intelligence
capabilities. See how role-based dashboards and key performance
indicators can improve operation efficiencies from an operator to
plant manager and beyond. You’ll turn raw data into actionable
information including trends, golden batches and more. Understand
the time-saving features of a Production Intelligence strategy in
improving business decisions.
ED06: Addressing the Security of Industrial
Automation and Control Systems
Presenter: Thomas Good, Automation and Process
Control Engineering Consultant (Dupont)
It seems that every day there is a cyber-security breach somewhere
in the world. It is very important that we be aware of the significant
changes that have occurred in the last year regarding the likelihood
of cyber-security incidents in industrial automation and control
systems. This presentation will provide updates on recent security
trends/happenings and discuss new measures that should be
incorporated into standard security practices to preserve the
integrity of industrial automation and control systems. The
presentation will review the excellent advice released by ICS-CERT
to address the changing landscape and where to go to get
assistance. In addition, it will discuss the security lifecycle
impact on the industrial control system operational lifecycle.
ED07: Identify, Mitigate and Eliminate the
Risks of Process Automation Obsolescence
Presenter: Lonnie Morris
As DCS systems approach the end of their expected life, the
availability of parts and resources become more difficult to maintain,
until the point where one or both are exhausted. Learn how to
proactively manage your automation system lifecycle to maximize
uptime, prioritize migrations and bridge to new technology.
ED08: Gaining New Performance and Improved Time to
Results in the Life Sciences Industry with PharmaSuite
Presenter: Mark Drochek, Information
Solutions Business Consultant
This session provides a basic introduction to the general functionality,
technology and value behind Rockwell Software PharmaSuite. Learn
how this software suite tracks material, equipment, and personnel
involvement and maintains a complete electronic batch record –
allowing regulated manufacturers to meet operational goals and
productivity requirements in a consistent and predictable way.
ED09: Improving Safety and Reliability
with High Performance HMIs
Presenter: Mark Carrigan, Vice President, PAS
For over 3 decades, industrial processes have been controlled
through computerized schematic representations of the plant.
The typical process schematic display in use today often contains
too much data that is poorly conveyed, causing inefficiencies
in the operation of the plant. Upgrading to high-performance HMIs
increases the situational awareness of your operators, resulting
in safer and more reliable operations. This session shall include:
history of HMIs in the process industry, benefits to implementing
high-performance HMIs, methods and technologies to design and
implement high-performance HMIs.
ED10: PlantPAx System Sizing and Selection
Presenter: Alex Cherpakov, Manager,
Process System Engineering
Learn how to select the appropriate PlantPAx system architecture
for an application whether it’s intended for a process equipment
builder or a large end user. This session will explore system sizing
rules derived and tested in our process system characterization lab
to warrant specific system performance. In addition, you’ll use the
PlantPAx Selection Guide and System Estimator to select your
architecture and prepare a process system bill of materials.
ED11: Best Practices when Designing a PlantPAx System
Presenter: Jason Wright, PlantPAx Product Manager
Best practices can lead to achieving optimal performance.
Learn about tools and techniques you can use to maximize the
functionality and efficiency of your PlantPAx system. Avoid common
application pitfalls as we review the PlantPAx Reference Manual for
proper implementation guidelines and application rules.
ED12: Integrating Motor Control Devices to
the PlantPAx System
Presenter: Sergio Gama
An overview of the integration capabilities of Rockwell Automation
motor control devices to PlantPAx and how the integrated system
enables multiple continuous improvement strategies along the life
cycle of the system.
ED13: Use Existing Automation to Save
Energy by Managing Electrical Demand
Presenter: Tim Schmidt
Learn how you can effectively manage your electrical demand
by using your existing automation investment to visualize and
integrate Demand Response/Control into your production
automation systems. Transform your plant from a passive
energy user to an active energy manager.
ED14: Design Consideration for Automated
and Manual Sequences of Your Batch Process
Presenter: John Robert Parraga, Product Manager
Learn how a modular design can help you achieve maximum
process agility, clearly define and enforce operating procedures to
help you meet regulatory compliance while lowering your total
cost of ownership.
ED15: Logix Batch and Sequence Manager
for Smaller Batch Applications
Presenter: Bruce Lightle, Process Consultant
This scalable, controller-based batch and sequencing solution
significantly reduces engineering time for system integrators and
OEMs. Learn where and how it can be applied to achieve the most
value. Use core system functions to the Logix control platform
and FactoryTalk® View to configure equipment, build recipes and
execute a running batch/sequencing production process without
application servers and/or software. Start small and easily scale into
a comprehensive software solution without costly reengineering
and testing.
ED16: Maintain Data Continuity When Networks
Fail with FactoryTalk Historian ME
Presenter: Timothy J. McCain, Information Software
Regional Manager
Data collection for regulatory compliance is a crucial function for
many manufacturers and network reliability and data continuity are
of upmost importance. Learn how FactoryTalk Historian Machine
Edition (ME) achieves excellent reliability, requires no server or PC,
and significantly reduces the risk of data loss due to network or
other system interruption. FactoryTalk Historian ME is easy-to-use,
provides plug-and-play access to real-time process and production
data, stands alone or rolls up into a plant-wide historian, and is ideal
for remote or difficult locations.
ED17: Fault-Tolerant and Fail-Safe Architectures
for Process Safety Applications
Presenter: Pete Skipp, ISA S84 SIS Fundamentals Specialist
Turbo machinery, burner management and other applications
in process industries typically require a high Safety Integrity
Level (SIL) to ensure the safety of personnel, assets and the
environment. Many of these same applications in continuous
processes also require fault-tolerant architectures to eliminate
the risk of costly downtime, as well as increasing safety. Rockwell
Automation addresses these applications with technology and
services that improve efficiency and performance by providing the
highest availability and lowest cost of ownership of any available
SIL3-rated system.
17
ED18: Advanced Process Control (APC)
for Improved Yield and Throughput
Presenter: Ric Snyder, Senior Product Manager
Remain competitive by maximizing utilization of your existing assets
before considering expansion. The PlantPAx APC portfolio – from
model based regulatory control blocks to model predictive control
– provides a comprehensive suite of tools and applications to assist
you in improving product yield and process throughput.
ED19: Alarm Management
Presenter: Mark Carrigan, Vice President, PAS
Poor performing alarm systems overwhelm the operator with alarm
floods and hinder the ability to effectively manage plant upsets.
Industry incident investigations have shown that time is the most
critical factor in a console operator’s ability to deal with abnormal
situations. They must often be able to take action within seconds
in order to safely mitigate the impact of an upset. In this session
we shall discuss the operator’s role in providing safe and reliable
production, typical causes of alarm system problems, and strategies
for improving alarm system performance.
ED20: Monitoring Controller Performance
and Production Reliability
Presenter: Bob Rice, Vice President, Control Station
Real-time controller performance and production monitoring
are integral parts of any advanced manufacturing strategy. With
numerous options available it is essential to understand both the
capabilities and limitations of those technologies. This session
introduces PlantESP – a complete platform for monitoring both
controller performance and production reliability. Specifically,
the session highlights KPIs used in maintaining optimal process
control. It also details the use of predictive analytics as a
complement to existing production analysis tools in the
avoidance of process failures.
ED21: Testing Your Logic in the 21st Century with Simulation
Presenter: Winston Jenks, Technical Director,
Cape Software, Inc.
As new technology improves at an ever faster rate,
Rockwell Automation users now have more and more options
for testing logic before it goes online. The ability to run large
simulations with a lot less hardware now makes it easier to know
that your automation code will perform like you expect it to when
you need it – on Day 1. Leveraging emulators or even hardware
processors can reduce your expensive startup time dramatically.
Various testing architectures and guidelines will be presented to
help you choose what fits your project best.
ED22: Extend PlantPAx System Functionality
with ThinManager
Presenter: Matt Crandell, President and CEO,
Automation Control Products
The ThinManager platform from ACP extends PlantPAx system
functionality when using thin clients or terminal services. This
easy-to-use, centralized thin client and terminal server management
solution allows administrators to publish applications and
desktops to virtually any thin client. ThinManager offers
enhanced network security, multiple monitor support, IP camera
management, virtual machine management, touch screen drivers
and easy client replacement & configuration. ThinManager also
offers a free mobile management app plus the iTMC app that turns
any iPad into a thin client. ThinManager works seamlessly with
PlantPAx and the Integrated Architecture™ allowing smooth
integration into new and existing plant floor installations.
ED23: Implementing Continuous Product Quality
Measurements to Minimize Product Loss
Presenter: Kevin Lavelle, Flow Product Manager,
Endress+Hauser
Utilizing fit-for-purpose technology is helping to identify major
sources of product loss in continuous and batch manufacturing
environments. The implementation of in-line, continuous product
quality capabilities, combined with real-time condition monitoring,
is resulting in plant-wide reduction in incremental and operational
costs. By leveraging advanced process instrumentation with
embedded EtherNet/IP protocols, integrators and OEMs are now
able to extract and deliver valuable process intelligence.
TOWN HALL VOTING
TOWN HALL VOTING SESSIONS
Here’s your chance to shape the future of Rockwell
Automation process control functionality. These Town
Hall Voting Sessions are a prime opportunity to give your
input on specific key priorities as we continue to expand
our PlantPAx Process Automation System capabilities.
Your input is provided to Rockwell Automation business
and product management for response and consideration
in their development roadmaps.
PlantPAx Advanced Process Control
PlantPAx encompasses an advanced control suite of offerings for
process optimization capabilities including modeling, scenario
analysis, multiple model management and much more.
PlantPAx Batch Management and Control
PlantPAx batch management and control solutions offer flexible
production, equipment-independent recipe management, batch
independent equipment control, and regulatory compliance.
Operation functions provide batch visualization, analysis, and
web-based reporting. These scalable integrated solutions meet
industry standards to meet small, basic batch/sequencing needs,
as well as distributed, comprehensive batch/sequencing needs.
PlantPAx Process Information
The PlantPAx process information solution offers an integrated
set of decision-making tools and dashboards that help provide
real-time access to and analysis of process and production
information throughout the enterprise, produce Web-based KPI
dashboards and reports and deliver timely information throughout
manufacturing – derived from various manufacturing processes.
PlantPAx Process Safety and Critical Control
PlantPax is a comprehensive automation solution from
Rockwell Automation. Where process safety and/or critical control
are a key component of the automation solution, PlantPAx offers a
wide range of architecture capabilities from simplex (fail-safe)
to fully triplicated (fault tolerant) to support process safety and
critical control applications.
PlantPAx System Core
PlantPAx System Core consists of the base hardware and
software required to build a PlantPAx system including
controllers, visualization, their associated programming
software, and infrastructure.
PlantPAx Libraries and Engineering Tools
PlantPAx Libraries and Engineering Tools consist of the libraries and
tools provided by Rockwell Automation to extend the PlantPAx
system to make it easy to develop your process application and to
provide a rich operating experience.
PlantPAx Device Integration
PlantPAx Device Integration consists of hardware and software
required to integrate and optimize the value of the information
contained in today’s smart field devices into PlantPAx whether the
devices are process sensors, power control or actuation connected
on open networks such as EtherNet/IP, DeviceNet, AS-i, HART,
FOUNDATION Fieldbus and ProfibusPA.
21
CUSTOMER APPLICATION SESSIONS
23
an
This year’s presenters represent companies from many
different countries and industries. Each presentation
addresses different applications, critical issues, best
practices and solution benefits.
Abonos de Colombia
“PlantPAx Helps Fertilizer Plant Meet
Their Expansion and Upgrade Plans“
Presenter: Lina Guevera, Process Instrumentation Engineer
In continuing their expansion and upgrade plans, Abonos de
Colombia (Abocol), the largest fertilizer producer in Colombia,
faced the challenge of choosing a technological path to meet the
growing market needs but at the same time provide a sustainable
solution. They decided to go with Rockwell Automation and replace
their legacy systems as well as build a new plant standarizing
current and future projects. Through the implementation of
PlantPAx, Abocol was able to achieve full integration of power
and automation, reduce startup times, optimize maintenance
procedures and set a clear technological roadmap. In this session
Abocol will present the implementation of PlantPAx throughout
their production facilities which include processes such as nitrate
ammonium and nitrate calcium fabrication.
Amylin Pharmaceuticals, Inc.
“VMware Integration at a Pharmaceutical
Manufacturing Facility”
Presenter: Bob Fulop, P.E., Director, Engineering
Running highly automated pharmaceutical manufacturing plants
makes reliability a must in today’s highly competitive environment.
Downtime is not an option. Amylin is leveraging state-of-the art
VMware software to ensure its automation and IT systems are
robust and dependable. VMware technology makes it possible
to run multiple virtual machines on a single physical computer
server, with each virtual machine sharing the resources of the single
physical computer server across multiple environments. Different
virtual machines can run different operating systems and multiple
FactoryTalk software applications on the same physical computersaving costs on hardware (less servers needed), maintenance,
energy, etc. With VMware high availability and the redundancy
model from Rockwell Automation, learn how to create an
environment that provides the highest availability for your
critical process applications.
Applied Control Engineering, Inc.
“Implementing a Safety System for Process
Gas Compressor and Equipment Control”
Presenters: Thomas G. Bubenheim, P.E., Operations Manager
and John P. Benitz, Jr., Senior Team Leader
Petrochemical refinery process units centered around high speed
turbo compressors present a unique set of challenges for the
control system supplier. The Rockwell Automation Trusted™
controller provides the capabilities necessary to meet these
challenges – triple redundancy to handle SIL3 rated safety
integrated functions (SIFs), performance to fit the machine
monitoring and control role, flexibility to integrate into a
plant-wide DCS, and the serviceability demanded by the long
operating campaigns. This session describes the methodology
employed by the CSI to achieve successful implementation in
the complex and dynamic process environment of a
Brazilian oil refinery.
Argotec, Inc.
“Improved Productivity in Plastics Extrusion Utilizing
PlantPAx, Virtualization and Add On Instructions”
Presenters: Rich Kuklewicz, Director, Engineering and
Jacob Smith, Network Administrator
Argotec has differentiated itself by taking on seemingly
impossible application challenges and providing effective
solutions. This session will cover two recent challenges and how
they overcame them using PlantPAx, VMware, and Add-On
Instructions (AOIs). Argotec’s first challenge was to install two new
lines and modernize others. They selected a solution using VMware
and PlantPAx. Virtualized servers running applications (such as
FactoryTalk View SE, Historian SE, etc.) employ redundancy and
high availability. Argotec’s second challenge was gaining tighter
extruder and die temperatures to better than ±1°F, a processing
requirement. They initially used traditional PIDe control which was
difficult and time consuming to tune. They will describe how using
PlantPAx and P_Temperature AOI for controlling the heat and
heat-cool zones met this requirement.
Aryzta LLC and Optimation Technology, Inc.
“Replacing a Legacy ABB DCS to PlantPAx
with Minimal Downtime”
Presenters: Michael Triassi, Business Development Manager
and Harry Howell, Chief Engineer
Needing to replace a legacy ABB DCS without stopping
production for longer than 12 days, Aryzta chose the PlantPAx
process automation system to provide plant-wide functionality.
In addition, FactoryTalk® Batch and its full complement of S88 batch
features, batch reports, and phase management were chosen
to manage and execute recipes. To help minimize downtime,
Optimation, a Rockwell Automation system integrator, built panels
in a staging area for operators to be trained using a simulated
model of their production environment. Concurrently, they
performed electrical installation of new conduit and pre-bundled
electrical cables in advance of the planned shutdown window.
Once the entire installation team was comfortable with the
simulation, a round-the-clock dismantlement and install effort
commenced. Learn about the entire project, best practices, and
quantifiable results in this session.
Companhia Nacional de Cimentos, (Brennand)
“Building a Grass Roots Cement Plant from Scratch
and Running at 115% Nominal Capacity”
Presenters: Eugênio Monteiro Neto, Senior Automation Analyst
and Jaci Gomez de Oliveira, Electrical Maintenance Coordinator
Companhia Nacional de Cimentos is a company of the Brennand
Group and it has become the most modern cement plant in Brazil.
The project consisted of a greenfield cement plant with a production
capacity of 3000 tons/day of clinker. Rockwell Automation was
responsible for supplying the plant automation including process
control, operation, information management, asset management,
energy management and power. The project also included the
virtualization of six physical servers with VMware. This session will
discuss the architectural design of the system from controllers, PASS
and OWS to networks and devices. In addition, it will review the
real-time production intelligence reports that are generated to help
support optimization. Companhia Nacional de Cimentos was built
with a strong focus on energy efficiency so it has adopted advanced
equipment of control and automation, thereby providing resources
to optimize processes, making it a highly competitive company in
the cement segment in Brazil.
ConAgra Foods, Inc. and ESCO Automation
“Optimizing Processes Through PlantPAx and Production Data”
Presenters: Tom Miller, Director of Operations & Sales,
Evan Hand, Director, Electrical & Controls and
Tim Beauchamp, Account Manager
ConAgra Foods makes great food in extraordinary ways. Recently,
its frozen foods plant in Council Bluffs, Iowa, was looking to optimize
its sauce manufacturing process in order to reap cost savings in
production, energy and finished product. It turned to ESCO
Automation, a Rockwell Automation Process System Integrator, to
help deliver needed improvements. The solution incorporated a
PlantPAx system with Logix Batch & Sequence Manager in addition
to real-time information delivery through Historian and
VantagePoint. The expertise of ESCO, together with the capabilities
and flexibility of the system, enabled ConAgra to reap a 58% cost
savings over the existing process, improve energy cost savings
and finished product quality through a more consistent base
ingredient. Learn how ESCO delivered the solution and the best
practices employed at ConAgra.
Covidien, plc and Stone Technologies, Inc.
“Planning, Design & Implementation of a
Plant Floor Virtualization Environment”
Presenters: Thomas Oberbeck, Senior Electrical Engineer and
Alan Stanfill, MES Project Manager
Covidien, a global healthcare products leader, needed a centralized
control room to monitor and control its utilities plant, as well as its
existing equipment. Stone Technologies, a Rockwell Automation
Solution Partner, implemented a virtualized system that also
supported high availability requirements for mission critical
applications throughout the facility. Learn how Covidien was able
to save money by avoiding rework and how the new infrastructure
will help in future projects, including upgrades to the system and
implementation of an MES system.
Detroit Water & Sewerage Department and
Process Control & Instrumentation (PCI), LLC.
“PlantPAx Process Library and WWW Accelerator
Toolkit Save Integrator and City of Detroit a Bundle”
Presenters: Anil Gosine, PNS & S Group Leader,
and Barry Clay, President, PCI
Detroit operates eight sewer overflow basins which serve to retain
storm runoff and protect the surrounding watersheds, people and
wildlife. Each basin had its own legacy process control system
making integration difficult, hampering troubleshooting and
maintenance, and prolonging the stocking of disparate and
overabundant spare parts. They selected PCI to help them
leverage the PlantPAx system in two of its facilities. With total costs
and downtime a huge factor for winning the bid, PCI opted to use
the PlantPAx Process Library and WWW Accelerator Toolkit to remain
on target. Learn how these tools enabled PCI and the City of Detroit
to cut engineering time in half, save additional dollars in FAT and
startup costs, and reduce design time, contract oversight, and
post-contract support.
25
Dr. Reddy’s Laboratories
“Expectations from MES in Generic Drug Industry”
Presenter: Roy Atanu, Vice President & CIO
This session will focus on the desired manufacturing business
outcomes of a global generics organization and the reference
architecture that helps achieve it. It will also discuss the role MES
plays in the overall controls architecture and production processes.
DTE Energy Company
“Plant-Wide Optimization in the Power Industry”
Presenters: Richard Wright, Principal Analyst,
and Brian States, Engineering Support and IT
Detroit-based DTE Energy is committed to provide the most reliable
and affordable energy possible to its customers. It demonstrates
this commitment by continuously optimizing its operating plants.
In order to achieve this goal, DTE Energy uses time and resources to
maintain and improve its energy infrastructure and has overcome
the challenges of acquiring plants with legacy controls, old
proprietary networks, and information management systems.
These accomplishments have come by creative and cost-effective
solutions while utilizing a limited budget. By deploying Rockwell
Automation PlantPax system technologies, DTE Energy has been
effective in its ability to successfully compete in a fast paced ever
changing energy marketplace.
Energy Control Technologies, Inc.
“Redundant Integrated Turbomachinery Control
for a Refinery Cryogenic Unit”
Presenter: Nikhil Dukle, Vice President of Engineering
An oil and gas refining company was initially looking to upgrade its
unit control with Siemens S7 and its turbomachinery control system
to the latest proprietary system. Instead, it selected the PlantPAx
process automation system because of its integration capabilities.
Using PlantPAx and its Add on Instructions (AOIs) with execution
speeds and algorithms that equal or better the proprietary
systems, the company saw cost reductions of 40-60% due to
lower project costs, downtime avoidance, and meantime to repair.
A turbomachinery control system simulation will be used to
demonstrate the capability of the turbomachinery control system
using RSLogix™ Emulate.
Gallus BioPharmaceuticals, LLC and Malisko Engineering
“Biopharmaceutical Manufacturer Adds Process
Flexibility with Virtualized PlantPAx System”
Presenters: Jeff Moore, Senior Electrical Engineer
and Steven Schneebeli, Lead System Engineer
Gallus BioPharmaceuticals was challenged with stand-alone
control systems for its bioreactors based on fixed legacy hardware
and software. Malisko Engineering designed and deployed a
virtualized PlantPAx system using FactoryTalk Batch and
RSLogix™ 5000 with PhaseManager™ in a validated environment.
The new infrastructure provides a distributed system with mobile
control system I/O cards used with a variety of mobile bioreactors.
The combined mobility of controls and process equipment allows
multiple bioreactors to be connected to a combination of I/O
panels giving Gallus ultimate process flexibility. In addition, Gallus
was able to develop product recipes in an R & D environment,
then quickly replicate the results in production. The PlantPAx system
includes visualization, virtualized servers, thin clients, redundant
PACs, and a device level ring topology.
Grupo Mexico and Electrocontroles de Noroeste
“Migrating a Legacy Bailey DCS to PlantPAx in a Copper Mine”
Presenters: Alvaro Rendon, Project Manager
and Carlos Tapia, Production Manager
At Grupo Mexico, one of the largest cooper producers in Mexico,
keeping production plants running is imperative. When its legacy
DCS consoles started to fail, it experienced downtime due to lack
of spare parts and no support for the system. Migration became
a priority, but production was the highest priority. Grupo Mexico
selected the PlantPAx system as the best option for implementing
a phased migration. ECN developed a totally on-line migration
reducing downtime. It also helped reduce risk and gave operators
confidence as the operator displays and faceplates were designed
very similar to the existing equipment.
Huhtamaki, Inc.
“Creating a Sustainable, Secure Virtual Infrastructure
for a Multi-Site Rollout of PlantPAx”
Presenter: Stewart Whitlow, Manager, Manufacturing Systems
This session will discuss the lessons learned by Huhtamaki as its
infrastructure evolved from an initial installation of the PlantPAx
system, converting from ProcessLogix™ and RSView®32, to the
infrastructure used to host a Valmet DCS conversion. The
discussion will include the best practices of the company in
using FactoryTalk View SE, related network support, and
engineering workstations.
Interstates Control Systems, Inc.
“Managing Anti-Virus and/or Software Update
Solutions in a Process Environment”
Presenter: Marty Van Der Sloot, Division Manager
Interstates supports global patch management and anti-virus
solutions and will demonstrate its deployment in single and multisite environments. This session will also demonstrate the patch
lifecycle and how to integrate a vendor approved patch solution.
Kimberly-Clark Corporation
“Migrating a Legacy Honeywell TDC 3000 to
PlantPAx on a Tissue Machine”
Presenter: Robert Kilas, Electrical & Controls Technical Leader
Kimberly-Clark elected to upgrade the Honeywell TDC3000 control
system on a tissue machine with PlantPAx as a key component
of a larger upgrade project. Factors in the decision were
(1) obsolescence and high cost of hardware; (2) difficulty in
obtaining spare parts; (3) high cost of system support by
Honeywell; and (4) standardization of controls. The scope
included replacement of the entire TDC system including I/O,
control code and HMI screens. The architecture for the new control
system included conversion of existing PLC-5 logic to ControlLogix®
and consolidating the PLC-5 logic and the converted Honeywell
logic into common processors segregated by functional areas.
The project was developed using the Global Engineering Modular
Standards (GEMS) pre-developed modules. All servers were
virtualized. The new ControlLogix hardware was mounted on
multiple small subpanels designed to retrofit into the existing
Honeywell cabinets to facilitate the I/O wiring.
Kozy Shack, Inc. and Automated Control Concepts
“Implementing Batch and Recipe Management
on an Existing Architecture”
Presenters: Michael Blechman, President, and
Robert Witt, Project Manager
Kozy Shack was looking to improve cycle times, consistency
and quality of their 21 unit batch operation without upsetting
its existing investment in Rockwell Automation technology.
They worked with Automated Control Concepts, a Rockwell
Automation Solution Partner, to implement a new batch and recipe
management system on top of the existing RSView32 architecture.
The solution included new PowerFlex® VFDs, FactoryTalk Batch and
eProcedure® and Formulation Manager. PhaseManager was also
implemented to bring an S88 structure to the system. The
completed system provided Kozy Shack with genealogy to
allow for quick analysis of batches. This session will discuss the
implementation of the system and, the benefits it provided to consistency, cycle times, time to market, training and, more importantly,
the tremendous reduction in batching errors.
NRG Energy, Inc., and QA Support, LP
“Environmental Compliance Monitoring and
Reporting Built on the Rockwell Automation Platform”
Presenters: Ray E. Fain, Jr., Vice President, Data Systems,
Patrick Yough, Environmental Supervisor and Perry Galloway,
Senior Environmental Specialist
Enterprise-wide environmental compliance monitoring and
reporting is a challenging task. Many resources are employed to
provide accurate and timely data to corporate managers from
emission sources measuring multiple pollutants with different types
of vintages of data collection and reporting systems. QA Advantage
solutions are built on the Rockwell Automation platform and are
currently in service delivering real-time data from approximately
400 sources (along with regulatory reporting) to the enterprise
level in many nationwide power generation utilities. FactoryTalk
VantagePoint® EMI is utilized to aggregate data reports and trends
on demand from numerous disparate sources directly to the
decision makers. In addition, QA Advantage leverages FactoryTalk
View SE, Transaction Manager and CompactLogix™ in the total
solution. Learn how this process has provided measurable returns
in accuracy, resource reductions, and timely business decisions
through the ease of data presentation and reporting.
PEMEX Exploracion & Produccion and ISI Solutions
“Implementation of PlantPAx for Process Control System,
ESD and F & G System”
Presenters: Giussepe Zanetti, Project Manager
and Alejandro Lupianez, Account Manager
PEMEX Exploration and Production continually looks for new and
flexible ways to improve the crude oil production in Mexico.
Process automation systems are very important for continuous
improvement in standardization, flexibility and process
information. At its Poza Rica facility, PEMEX had the challenge of
getting information from all areas of the plant – refocusing its
efforts on process improvement, instead of seeking to integrate
multiple disparate control systems. PEMEX selected the PlantPAx
system to avoid miscommunication in Safety Instrumented Systems
(SIS), and Basic Process Control System (BPCS), as well as OEM
equipment. The new system utilized common tools, helped
reduce engineering, commissioning and start-up time, and
allowed PEMEX to maximize the use of technologies such
as Foundation Fieldbus.
27
Petroamazonas, E.P.
“Oil and Gas Company Optimizes Its Upstream Production
Using PlantPAx Convergence and Virtualization Capabilities”
Presenter: Gonzalo Maldonado, IT Infrastructure Supervisor
As a crude upstream facility, Petroamazonas had the challenge to
automate their process given its constant growth and change
conditions. The PlantPAx system currently controls the central
production facility with over 100K tags and helps run the daily
150K barrels in an efficient way. The current solution includes
all of the automation pyramid levels and takes advantage of
virtualization techniques for its software platform.
Polytron, Inc.
“Batch Emulation – Return Beyond Startup”
Presenter: Scott Richards, P.E., PMP, Project Manager
A global beverage manufacturer had developed and test marketed
a new product. They engaged Polytron to create a new automated
batching system to support their national rollout of the new
product. Polytron and Rockwell Automation teamed up to design
the system using the Rockwell Automation process control platform
with ControlNet, remote I/O racks, and FactoryTalk Batch with
Material Track and eProcedure as a recipe manager. Polytron applied
its PolySim emulation technology as a core part of the project
allowing a full FAT with the client prior to the completion of
construction. The use of emulation modeling allowed the client
to cut two weeks from the start-up schedule. Years later, the
beverage manufacturer updated all its servers and software
converting from RSBatch™ v.5 to FactoryTalk Batch v.10.0. Polytron
again applied emulation to verify the model, uncovering
anomalies that would have led to downtime. Learn how emulation
helps manufacturers achieve major cost savings by reducing the
impact at startup and sets the stage for outstanding returns in the
years to come for subsequent system changes. A look at the total
lifecycle costs shows how quickly emulation pays for itself.
Ripon Cogen, LLC and Maverick Technologies, LLC.
“Replacing a Westinghouse WPDF System
Serving as BOP Control System”
Presenters: Jim Groff, Plant Manager and
John Boyd, Business Development
This BOP control system is an interdependent system that involves
all of the related areas within the Ripon Cogen facility including
HRSG control, gas compressor, ammonia plant, chiller and water
treatment. The brownfield project had many challenges: zero
impact to production; limited number of shutdown opportunities;
unreliable or nonexistent documentation; physical space
limitations and competing internal production priorities.
Learn how Rockwell Automation worked with Ripon Cogen to
collaboratively develop a specification that allowed Ripon Cogen to
realize a single architecture, improve support and leverage
operational expertise. Also learn how Maverick Technologies
worked with the client to complete phased implementation installs
and tests using simulation software to prove desired functionality
before changeover of the three redundant control systems.
Scott Springfield Manufacturing, Inc.
“Maximize Plant Safety and Reliability by
Integrating HVAC Equipment with PlantPAx”
Presenter: Patrick Melia, General Manager
HVAC is often undervalued as a critical element to the reliability of
any industrial process. Beyond the specification, installation and
commissioning of the equipment, seamless, and early, integration of
the industrial HVAC and plant-wide control will help maximize plant
safety and reliability. Learn about the benefits and total cost of
ownership of using a common hardware/software platform across
the plant. In addition, understand the importance of an HVAC
system response to a fire or gas event and its criticality to the
overall performance of the plant-wide safety system.
Stone Technologies, Inc.
“Choosing PlantPAx Over DeltaV Provides Benefits
to End User and System Integrator”
With a new production process to bring on line, Stone
Technologies’ client, a supplier of phosphorus chemicals for food,
pharmaceutical, agricultural, and industrial applications, turned to
the PlantPAx system for ease of integration and implementation.
Join us to learn about the entire project and how utilization of
the PlantPAx tools and utilities provided additional benefits to
the customer as well as Stone Technologies as the system integrator.
Stone Technologies implemented the system using the PlantPAx
Library of Process Objects to accomplish the clients goals. Utilizing
twelve of the objects, in most cases exactly as they were provided,
Stone Technologies was able to provide the comparable look, feel,
and functionality of the existing DCS at a fraction of the cost and
time if building it from scratch. The client chose PlantPAx and its
newer technology due to its in-house supportability, readily
available resources for future projects, and lower total cost
of ownership.
Thermo Systems, LLC
“Replacing a Yokogawa DCS System to Improve Efficiencies”
Presenter: Eric Silk, Business Development Manager
Pepco Energy Services (customer) partnered with Thermo Systems,
a Rockwell Automation Solution Partner, to design, build, deploy
and commission a turnkey replacement of its aging Yokogawa DCS
system serving its Atlantic City power plant. Thermo designed
a PlantPAx system and partnered with the Rockwell Automation
Power & Energy Management Solutions Group for delivery of the
boiler control system replacement and transaction management
software. The successful migration included minimum downtime,
ease of service, increased operational efficiency and billing accuracy,
and expansion possibilities moving forward.
Vadxx Energy
“From Pilot to Production: Keys to Effectively
Launching a New Process Plant”
Presenter: Jeremy DeBenedictis, Vice President,
Operations & Engineering
There are many challenges ahead when trying to take a start-up
company from pilot plant to full-scale production. As important
as the process technology is in the process, it is only one aspect.
This session will describe the many considerations Vadxx Energy
went through when they chose Rockwell Automation to be their
Engineering Procurement & Construction Management (EPCM)
developer in building waste to energy plants using the PlantPAx
system. It is vital to consider all aspects of the project – networking,
modeling, scale-up analysis, process technology selection, capital
investment funding, risk mitigation and support strategy. At the end
of this session, you will be able to use the following equation
to solve your selection challenges: 3E = 3S + 4P.
Warwick Chemicals
“Migrating a Legacy Fisher RS3 DCS to Provide
Increased Integration and Expansion Capabilities”
Presenter: Les Waymont, Process Engineering Manager
Warwick Chemicals, the world’s leading provider of bleach
activators for detergents, operates a wide range of chemical
processes, including most of the “classic” chemical process unit
operations. In 2010, Warwick needed to replace their aging Fisher
RS3 DCS with a solution that would offer a solid foundation – one
with the ability to interface to existing plant management systems
while offering the expansion capability to provide advanced control
strategies, management system integration and off-line process
optimization. A User Requirement Spec (URS) was issued to four
vendors and the Rockwell Automation PlantPAx system was selected.
Learn about the scoring criteria developed to evaluate the URS
responses, what items were essential to Warwick, and what
has been implemented in Phases 1 and 2 of the project.
Wood Group
“How Hawaii Electric Light Company (HELCO)
Met Uptime and Reliability Goals with PlantPAx”
Presenters: Clark Weaver, Business Development
and Bud Blankenship, Business Development
Faced with 50% downtime caused by an obsolete proprietary turbine
control system supplied with its turbines, HELCO made the decision
to migrate to the PlantPAx process automation system. Wood Group,
a Rockwell Automation recognized system integrator, upgraded the
entire turbine and accessory controls, then leveraged that customer
success to provide a complete Rockwell Automation solution for the
plant when it was converted from simple cycle to combined
cycle. This session will detail the decision to choose Rockwell
Automation for the turbine retrofit project and explain how the
facility later implemented PlantPAx for total plant-wide control
along with a discussion of the benefits of an open platform
solution vs. a purpose-built/proprietary platform for power
generation applications.
29
Process
Solutions
User Group
2013
2013
November 11-12
Houston, TX
http://psug.rockwellautomation.com
Extend Your Stay!
Automation
Fair® 2013
November 13-14
Houston, TX
George R. Brown
Convention Center

Process Solutions User Group (PSUG)

Transcription

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