Control Architecture for new 27 Storage Tanks, Cold Area

Transcription

Control Architecture for new 27 Storage Tanks, Cold Area
Cerveceria Nacional Dominicana
•Project description
•Why we chose that path?
•Our experience during:
•Part acquisition
•Design
•Installation
•Support
•Commissioning
•Final Results
Fieldbus Educational Seminar
San Juan, Puerto Rico – Oct. 11, 2007
Project description
The Project consisted in the replacement of 27, 40 years old carbon steel tanks,
for new 27 Stainless Steel Storage tanks. Capacity of each tank is 836 Bl. Used as
beer storage prior to the secondary filtration. Old tanks worked in a cascade type
configuration. New tanks however, were conceive to work in pair given to the
flexibility the plant demanded.
Main Project Leader: Ramon Harvey, CND
Electrical and Control Project Coordinator:
Coordinator Julio Rossis, CND
Project Integration, Design & Programming: ISINSA, local Integration
company led by Adalberto Hernandez
Mechanical Contractor: ENERFAB, in charge of tank manufacturing and
installation.
Electrical & Instrumentation: CND Personnel and Local Contractor
2
© 1999 – 2007 Fieldbus Foundation
Old Carbon Steel Tanks being taken
out of 3rd Floor North Cellar
3
Old Tanks Screen, Train or Cascade
type configuration
4
New Stainless Steel Tanks being
placed in 1st floor North Cellar
5
New Tanks and Valves main screen
6
New Tank Screen, Two
Tanks Configuration
7
Why we chose that path?
We wanted to use Fieldbus/Intelligent devices technology in our plant, but we did
not have the project that fits to our intention. We wanted a segmented area for
our pilot plan, however important enough to make a statement in the production
floor as well as in the managerial level.
We thought this specific project was the perfect fit to sell the idea to the
administration.
Our influences were directed mainly to:
Hardware Reduction: On one transmitter we will have level
measurement as well as temperature readings needed in every
tank.
Savings on installation: Time and money will be saved because
on a single pair of wire many devices can be connected.
Maintenance: The self-test and communication capabilities of the
fieldbus devices help reducing downtime and improving plant
safety. Quicker corrective action can be taken because of the ability
of the device to notify abnormal conditions. Predictive maintenance
philosophy of intelligent devices will increase the availability of the
tanks.

8
How we put the puzzle together:
The main supplier for the control part of the project were:
Allen Bradley: Controller, Linking Device, Cards, etc.
Pepperl & Fuchs: Cables, Repeaters, Segment Protectors, Power
Supplies, etc.
Touchenhagen: Intelligent Valves and ASI connectors
Endress & Hauser: Level and Flow Transmitter
9
How we put the puzzle together (Cont.):
Design: once we agreed upon our needs and boundaries of the project, we presented the design to
our manager. In this stage, we worked very closely with the main suppliers to assure
interoperability of the different devices.
Parts Procurement: most of the suppliers and/or manufacturers were able to offer us excellent
lead times as well as their best option for our specific need. Although we were dealing with a
brand new technology, suppliers had the table set with a good variety of choices.
Installation: Installation of the control system and the different instruments, specifically for the
Fieldbus network, prove to be quite an experience. Because of the numbers of devices, we had
to have more than one H1 Fieldbus segment, however in three floor, 27 tanks and only one
orange cable. {Link to the picture of the cable running thru conduits and different floors}
Support: For a project like this to be successful, specially of the type of a first-timer small pilot
unit, one must have integrators and suppliers working as one in the different stages of the
project. Presentations, seminars, conference calls, etc. were all very important, mainly in the
early conceptualization stage where critical decisions shape the final results.
10
Final Thoughts & Results
Challenges: There are two challenges that we face while taken decision we did:
One is train and educate our technical personnel to support this new
platform.
Second involve production and maintenance in such a way that the
plant obtain the best out of this powerful tool.
The outcome of this effort resulted in a well implemented control system, time and
cost effective, with foundation in the latest technology. For all of us involved
implementing it, a learning experience, a change in doing things and ultimately
an opened door for future projects.
11
Allen Bradley
Allen Bradley Rack with 1756-L63
Control Logix
Flex I/O Modules with 1794-ADN Devicet
Fieldbus Linking Device
12
Pepperl and Fuchs
Segment Protectors
ASI interface PS, Foundation
Fielbus PS, Segment Redundant
Motherboard, etc.
13
Tuchenhagen
Matrix Valve Configuration, etc.
T.VIS®
Control Module
14
Endress & Hauser
Deltabar S FMD78
Level Transmitter
15
Important Notes:
• 1757-FFLD2: Foundation Fieldbus to Ethernet/IP Linking
Device. 4 H1 Ports
• Max. 12 devices recommended per H1 segment
• 1788-EN2DN: Ethernet/IP to DeviceNet Linking Device
Existing Plc’s 5
• 45-50 Devices recommended per DNet Network for optimal
performance
Ethernet/IP
100 Mbs
1756-L63
1756-ENBT
1757-FFLD2
Foundation
Fieldbus H1
ASI Network
1794-ADN
Instrumentación en
Campo
Pumps
ASI Network
Valve
Skids
ProposedControl
Control
Proposed
Architecture
Architecture
NewStorage
StorageTanks
Tanks
New
16
DeviceNet
Pumps
Valve
Skids
Pumps
Valve
Skids
Panel 10CP104
17