Process Solutions User Group (PSUG)

Process Solutions User Group (PSUG)
George R. Brown Convention Center | Houston, TX | November 11-12, 2013
For more information about our process solutions, please visit: www.rockwellautomation.com/go/process
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November 2013
Copyright ©2013 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
TABLE OF CONTENTS
Process Solutions User Group 2013
Welcome Attendees,
Over the course of the next two days, you are going hear a lot about trends and technology. From
the requirements of the information-driven enterprise, to the growing number of technologies
available to improve your business, the Process Solutions User Group (PSUG) will deliver informative
learning opportunities about technologies and best practices to grow your business.
Table of Contents
3
Agenda
However, I’m most excited about the opportunity you have to interact with your
9
Convention Center Maps
peers and Rockwell Automation industry experts. It’s truly the people that make
11
Speakers and Customer Advisory Board
this event great and offer you the chance to gather ideas about how to improve
15
Educational Sessions and Hands-On Labs
your business processes, create new revenue streams and creatively solve your
19
Round Table and Town Hall Voting Sessions
business challenges. Technologies are important, but it’s the people and ideas
23
Customer Application Sessions
31
Process Solutions User Group (PSUG) 2014
that are leading us to an exciting future.
There are many unique venues at this event including education sessions, customer presentations,
hands-on labs and opportunities to give direct feedback on the future developments of the
PlantPAx process automation system. I encourage you to participate to gain the most from your
experience. In addition, please tap any Rockwell Automation representative on the shoulder and
engage us in helping you solve your daily challenges.
A Special Thank You To Our Advertisers
2
8
ProSoft Technology
Hardy Process Solutions
20Endress+Hauser
Enjoy your time in Houston!
Sincerely,
Please visit the booths of HART Communication Foundation,
FDT Group, ODVA, Fieldbus Foundation and MIMOSA
during this event.
John A. Genovesi
Vice President and General Manager
Information Software and Process Business
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
1
AGENDA
AGENDA
MONDAY | NOVEMBER 11, 2013
Process Solutions User Group 2013
Breakout Rooms
7:00 AM
Room 330A
Educational Sessions
Educational, Round Table and
Town Hall Sessions
10:00 AM
10:30 AM
Room 340A
ED14: Skid Integration to
Plant-Wide Control Systems
ED11: Human Factors
in the Process Industry Why Good Design Matters
ED16: Leveraging
Information in
a PlantPAx System
ED09: Advanced System
Engineering Utilizing
the PlantPAx Sequencer
ROUND TABLE
Production Intelligence
TOWN HALL VOC
Design & Implement
PSUG Official Kickoff
11:00 AM
"Integrating Control, Power, Safety and Information" - Som Chakraborti, Director, Process Business
Keynote Address
"The Internet of Things: Balancing Big Data and Security" - Rick Esker, Senior Director, Industry Solutions
12:15 PM
PSUG Overview - Jason Wright, Marketing Manager, Process Business
12:30 PM
Lunch Grand Ballroom B/C
2:30 PM
Room 360B/E
Room 360A/D
Room 360C/F
ED08: PlantPAx Field
Device Networks and
System Integration
ED06: Adding Adaptive
Mobile Computing to
Your Facility Floor
ED04: PlantPAx
Virtual Templates
ED01: Introduction
to the PlantPAx System
ED07: Process Safety
Application Development
with AADvance
ROUND TABLE
System Security
TOWN HALL VOC
Operate & Maintain
ED02: Using the
PlantPAx Libraries
ED05: Defining a
PlantPAx System for
Optimal Performance
Opening Remarks - Stephen Pulsifer, Market Development Director, Process
"The Information Driven Enterprise" - John Genovesi, Vice President and General Manager, Information
1:30 PM
Room 350D
Break
10:40 AM
11:30 AM
Room 340B
PSUG Registration is open throughout the day
Registration Opens
8:00 AM
9:00 AM
Room 330B
Customer Applications
Customer Applications
Software and Process Business
Group, CISCO
G-CON
(Life Sciences)
Lauren Engineering
& Constructors
(Power)
Ecopetrol
(Oil & Gas)
PCI and
City of Fremont
(Power)
Zilor
(Chemical)
Shell Canada
(Oil & Gas)
Sirio Sistemi Elettronci SpA
(Oil & Gas)
Tunning
(Mining)
Electro Controles
del Noroeste SA de CV
(Chemical)
PEMEX
(Oil & Gas)
Alicorp SAA
(Food & Beverage)
PERENCO
(Oil & Gas)
Matrix Technologies
(Food & Beverage)
Stone Technologies
and Ameren Corp
(Power)
Kimberly Clark
(CPG)
DTE Energy and
Innovative Controls
(Power)
Break
3:30 PM
3:45 PM
Customer Applications
Emerald Performance
Materials
(Chemical)
Hatch Consulting
(Mining)
ESCO Automation
(Chemical)
Celec
Electroguayas
(Power)
EnergyWorks
(Power)
Champion Technologies
and Phillips 66
(Oil & Gas)
Optimation
(Chemical)
Mallinckrodt
(Life Sciences)
4:45 PM
Customer Applications
Champion Technologies
and RAIN CII
(Power)
Chevron Phillips
Chemicals
(Chemical)
China National Offshore
Oil Corp
(Oil & Gas)
E-Technologies
(CPG)
_
Malisko Engineering
and Noosa Yoghurt
(Food & Beverage)
Energy Control Techology
(Oil & Gas)
Industrial Automation
Group
(Food & Beverage)
5:45 PM
Bus Transportation to Houston Museum of National Science (HMNS)1
6:15 PM
Cocktails, Hors d'oeuvres, Dinner at HMNS
Educational
Round Table
Theater B
Customer Applications
Town Hall Voting
1
Bus transportation will continuously loop from museum to convention center area
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
5
AGENDA
TUESDAY | NOVEMBER 12, 2013
Process Solutions User Group 2013
Breakout Rooms
Room 330A
Breakout
Rooms
7:00 AM
7:00 AM
8:00 AM
8:00 AM
9:00 AM
9:00 AM
10:00 AM
Room 330A
Breakfast
Grand Ballroom B/C
Educational, Round Table
and Town Hall
Sessions
Educational,
Round
Table
Process
Safety
Lab
and Town Hall Sessions
Process Safety Lab
Educational, Round Table
and Town Hall
Sessions
Educational,
Round
Table
Safety
Lab
andProcess
Town Hall
Sessions
Process Safety Lab
Keynote Address
10:15 AM
11:15 AM
Keynote Address
11:15 AM
Customer Applications
ED10: Optimizing Process
Efficiency
ED10:Plant
Optimizing
Process
Plant Efficiency
12:15 PM
12:15 PM
1:15 PM
Customer Applications
1:15 PM
Customer Applications
2:15 PM
Customer Applications
2:15 PM
3:15 PM
Customer Applications
Room 350D
Room 360A/D
Room 360B/E
Room 360C/F
Room 371E
Room 330B
Room 340A
Room 340B
Room 350D
Room 360A/D
Room 360B/E
Room 360C/F
Room 371E
TOWN HALL VOC
Design
& Implemention
TOWN
HALL VOC
Design & Implemention
ED12: Layer of
Protection
Analysis
ED12: Layer
of
(LOPA)
Protection Analysis
ED15: Leveraging ISA S88 for
Batch,
ED15:Automating
Leveraging ISA
S88 for
Continuous
or
Discrete
Operations
Automating Batch,
ROUND TABLE
PlantPAx
Libraries
ROUND TABLE
PlantPAx Libraries
TOWN HALL VOC
Operate
& Maintain
TOWN HALL
VOC
Operate & Maintain
ROUND TABLE
Alarm
Management
ROUND
TABLE
Alarm Management
TOWN HALL VOC
Operate
& Maintain
TOWN HALL
VOC
Operate & Maintain
Matrix Technologies
(Food & Beverage)
Matrix Technologies
(Food & Beverage)
Energy Control
Technology
Energy
Control
(Oil & Gas)
Technology
(Oil & Gas)
E-Technologies
(CPG)
E-Technologies
(CPG)
PERENCO
(Oil & Gas)
PERENCO
(Oil & Gas)
DTE Energy and
Innovative
DTE EnergyControls
and
(Power)
Innovative Controls
(Power)
Shell Canada
(Oil & Gas)
Shell Canada
(Oil & Gas)
Malisko Engineering
and Noosa
Yoghur
Malisko
Engineering
(Food & Beverage)
and Noosa Yoghur
(Food Automation
& Beverage)
ESCO
Kimberly Clark
(CPG)
Kimberly Clark
(CPG)
Sirio Sistemi
Elettronci
SpA
Sirio Sistemi
(Oil & Gas)
Elettronci SpA
(Oil & Gas)
ROUND TABLE
Batch
Management
ROUND
TABLE
Batch Management
TOWN HALL VOC
Design
& Implemention
TOWN
HALL VOC
Design & Implemention
ED03: Monitoring PID
Controller
Performance
ED03: Monitoring
PID
Controller Performance
(LOPA)
ED11: Human Factors
inED11:
the Process
HumanIndustry
Factors Why
Good
Design
Matters
in the Process Industry
-
ED13: Integrating Intelligent
Motor
Control Devices
ED13:
Integrating
Intelligent
Into
PlantPAx
Motor Control
Devices
Why Good Design Matters
Into PlantPAx
Continuous or Discrete Operations
ED06: Adding Adaptive
Mobile
Computing
to
ED06:
Adding
Adaptive
Your
Facility
Floor
Mobile Computing to
LAB:
Configuring
LAB:
an AADvance
Configuring
Process
an AADvance
Safety
Solution
Process
Safety Solution
Your Facility Floor
Break
"Harnessing the Power of Your Instrumentation, HMIs and Information"
Todd Lucey, the
General
Manager
Endress + Hauser;
Lisaand
Garrison,
NA Managing Director - Acuite;
"Harnessing
Power
of Your -Instrumentation,
HMIs
Information"
Barry Johnson, Director of sales - Information Software - Rockwell Automation
Todd Lucey, General Manager - Endress + Hauser; Lisa Garrison, NA Managing Director - Acuite;
Mallinckrodt
China National
Celec Electroguayas
(Life Sciences)
(Power)
Offshore
Oil
Corp
Mallinckrodt
China National
Celec Electroguayas
(Oil
&
Gas)
(Life Sciences)
(Power)
Offshore Oil Corp
(Oil
&
Gas)
Lunch Grand Ballroom B/C
Barry Johnson, Director of sales - Information Software - Rockwell Automation
Champion Technologies
Chevron Phillips
Industrial
and Technologies
RAIN CII
Chemicals
Automation
Group
Champion
Chevron Phillips
Industrial
(Chemical)
(Power)
(Food & Beverage)
and RAIN CII
Chemicals
Automation Group
(Chemical)
(Power)
(Food & Beverage)
Lunch
Grand Ballroom B/C
Ecopetrol
(Oil & Gas)
Ecopetrol
(Oil & Gas)
Zilor
(Chemical)
Zilor
(Chemical)
Optimation
(Chemical)
Optimation
(Chemical)
PEMEX
(Oil & Gas)
PEMEX
(Oil & Gas)
Emerald Performance
Materials
Emerald
Performance
(Chemical)
Materials
(Chemical)
EnergyWorks
(Power)
EnergyWorks
(Power)
Break
3:15 PM
3:30 PM
Customer Applications
3:30 PM
Customer Applications
Break
Alicorp SAA
(Food & Beverage)
Alicorp SAA
(Food & Beverage)
4:30 PM
Educational
Room 340B
Breakfast Grand Ballroom B/C
ED01: Introduction to
ROUND TABLE
the
PlantPAx
System
Field
Device Management
ED01: Introduction to
ROUND
TABLE
the PlantPAx System
Field Device Management
Customer Applications
Educational
Room 340A
Break
10:00 AM
10:15 AM
4:30 PM
Room 330B
G-CON
(Life Sciences)
G-CON
(Life Sciences)
Town Hall Voting Results and PSUG WrapUp
Round Table
Round Table
Theater B
Theater B
Town Hall Voting Results
and PSUG WrapUp
Customer Applications
Customer Applications
Town Hall Voting
Town Hall Voting
Electro Controles del
Noroeste
SA de CV
Electro
Controles
del
(Chemical)
Noroeste SA de CV
(Chemical)
Hatch Consulting
(Mining)
Hatch Consulting
(Mining)
Champion Technologies
and Phillips
66
Champion
Technologies
(Oil & Gas)
and Phillips 66
(Oil & Gas)
Stone Technologies
and
Ameren
Stone
Technologies
(Power)
and Ameren
(Power)
Lauren Engineering
& Constructors
Lauren
Engineering
(Power)
& Constructors
(Power)
Tunning
(Mining)
Tunning
(Mining)
_
_
(Chemical)
ESCO Automation
(Chemical)
PCI and
CityPCI
of Fremont
and
(Power)
City of Fremont
(Power)
_
_
_
_
_
_
_
_
Lab
Lab
Invitation Only: SI/SP Meeting
Room 360C/F
Invitation Only: SI/SP Meeting
Room 360C/F
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
7
Process Solutions User Group 2013
PSUG
General Session
PSUG Meals
LEVEL 3
B
A
B
B 332 E
B 342 E
D
A
D
C
General C
A Assembly
Theater
320
Hall A
B
B
B
330
340
A
Badged Entrance
Hall B
C
F
B 352
E
A D
C
GrandBallroom
A D
LEVEL 1
F
C
F
A
C F
B 310 E
RUSK STREET
C
Exhibit Floor
A
Registration and
Main Entrance
Hall C
F
C
F
B 362 E
D
A
C
F
C
B 361 E
A D
C F
B 350 E
C F
B 360 E
A D
D
F
B 372 E
A
B 351 E
A D
A
C
D
F
B 371 E
A
D
C
382
B
A
C
381
B
A
C
F
B 370 E
A
D
380
A C
Hotel Shuttles
Drop off/Pickup
Hall D
Hall E
POLK STREET
A
322
AVENIDADE LAS AMERICAS
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
9
Is Your DCS Straining To Provide
Information From Your Critical Assets?
Maximize asset availability, harness energy consumption, and protect
valuable assets with the PlantPAx™ process automation system.
It delivers true plant-wide control – including power and motor control –
and easily integrates with your devices to deliver superior performance.
PlantPAx. It’s More Than a DCS.
Learn more at
www.rockwellautomation.com/go/process
PlantPAx is a trademark of Rockwell Automation, Inc. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. AD2013-10-EN
SPEAKERS AND
CUSTOMER ADVISORY BOARD
SPEAKERS
Process Solutions User Group 2013
Stephen E. Pulsifer | Global Director, Process Market Development, Rockwell Automation
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.
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.
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.
Richard Esker | Senior Director, Industry Solutions Group-EcoSystems | Industrial Automation
and Connected Real Estate Domain Leader, CISCO
Mr. Esker has over 30 years of experience in the Telecommunications and Technology Industry with responsibilities in Sales,
Business Development, Engineering, Alliances and Global Accounts including tenure at Wang Laboratories and PictureTel.
Mr. Esker has been with Cisco for more than 15 years. His roles have included Senior Management positions in Sales, Strategic
Alliances and now Industry Solutions Ecosystems. Mr. Esker has held responsibility for Cisco’s Strategic Alliances strategy creation
and operation for Mobile Service Providers, Mobile Devices and currently is responsible for Cisco’s Alliances and Ecosystems in
Industrial Automation and Connected Real Estate. Mr. Esker holds a Bachelors Degree with triple majors in Mathematics,
Economics and Physics and a Masters Degree in Mathematical Economics and Quantum Methods.
Todd Lucey | General Manager , Endress+Hauser Sales Center USA
Vice President of the Board for the Measurement Control Automation Association (MCAA)
Todd Lucey, General Manager of Endress+Hauser Sales Center USA, joined the company in 1993 as a Pressure Product Manager.
He has a B.S. in Chemical Engineering from the University of Minnesota and has held numerous product, industry, marketing,
support, and sales responsibilities. He is Vice President of the Board for the Measurement Control Automation Association (MCAA).
Lisa Garrison | Managing Director for Acuitē North America
Lisa Garrison is one of the founders of Acuitē and currently serves as a managing director for Acuitē North America. Lisa
pioneered advanced process control graphics and has been a leader in developing and applying the principles and methods for
creating state of the art user interfaces for process control operators
As a Human Factors expert, Lisa has provided specialized HMI training and consulting for major corporations worldwide.
As a result clients have seen increases in operations performance, product usability, and have won awards for technological
excellence and innovation. Lisa began her diverse career as a flight control engineer at Johnson space center in Houston, TX. This
experience initiated a commitment to safety, reliability and human factors. Her experience in the process control industry started
at Exxon working as a Human Factors Engineer and later working for Honeywell to develop Abnormal Situation Management
(ASM) as a service business.
Lisa holds a BS in Aerospace Engineering from Texas A&M and MSc in Industrial Engineering (Human Factors) from University of
Houston. She has been a full member of the Human Factors and Ergonomics Society for over 15 years. In 2000, Lisa started her
own consulting company to focus on both research and applied aspects of human-systems integration issues in complex, high
technology industries. With the support of clients and a talented group of colleagues, Acuitē has been at the forefront for high
performance operator graphics for over a decade.
Barry Johnson | Director of Sales, Information Software, Rockwell Automation
Jason Wright | Marketing Manager, PlantPAx System
Jason Wright (“JP”) has nearly 20 years of experience in the Process Control Industry having worked and played leadership
roles at an independent control system integrator, large DCS control system provider, process control consulting firm, and a
biotechechnology manufacturing end user. Currently, JP is the Marketing Manager for the PlantPAx Process Automation System,
responsible for driving the future of the product portfolio to meet the needs of its process industry clients. JP holds a Bachelor
of Science degree in Systems and Control Engineering from Case Western Reserve University and a Master of Business
Administration from Kent State University.
Barry joined Rockwell in 2006 and is responsible for growing market share of the company’s comprehensive information and
process optimization software solutions. Barry and his team work with our customers to solve operational challenges by applying
Manufacturing Operations Management and Process Optimization software solutions.
Barry has over 15 years of experience in automation and Information solutions, in global direct as well as local channel
businesses. He has held positions of increasing responsibility in sales, sales leadership, and business development with
experience in strategic planning and sales execution. Barry has a B.S. in Mechanical Engineering from University of
Wisconsin - Madison.
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
13
Process Solutions User Group 2013
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
Bob Kilas
Electrical & Controls
Technical Leader
Kimberly-Clark
Corporation
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
Trung Nguyen
Project Engineer
Shell Global
Solution
Darren Twyford
Control System
Specialist
JNE Automation
EDUCATIONAL SESSIONS
AND HANDS-ON LABS
EDUCATIONAL SESSIONS AND HANDS-ON LABS
Process Solutions User Group 2013
EDUCATIONAL SESSIONS
AND HANDS-ON LABS
These sessions, offered to provide technical information,
are free to all attendees. You can receive Professional
Development Hours (PDH) and the corresponding
documentation.
ED01: Introduction to the PlantPAx System
Jason Wright, Marketing Manager, PlantPAx System
Introduction to the PlantPAx system for those looking to gain a
basic understanding. After attending this session, you will be able to
define the PlantPAx System and understand how it provides all the
capabilities you expect from a DCS - and more.
ED02: Using the PlantPAx Libraries (2 Hours)
Dale Reed, Senior Project Engineer, PlantPAx
Systems Engineering
The PlantPAx Libraries are key ingredients for project
implementation. This session shows how to obtain, install, and
use the PlantPAx Library of Process Objects. It will demonstrate
the operation of common objects such as modes and alarms,
reviews the functions of all library objects, shows what’s new in
the 3.0 release of the library, and demonstrates library tools for
speeding application development. You will walk away with the
knowledge and resources to create your process skid or application
more effectively.
ED03: Monitoring PID Controller Performance
Bob Rice, PhD., Vice President-Engineering,
Control Station, Inc.
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
and methods for PID Controller Tuning.
ED04: PlantPAx Virtual Templates
Greg Hood, Product Manager, PlantPAx System
Virtualization allows users to realize infrastructure cost savings by
reducing the amount of required hardware to operate a facility.
The technology dynamically allocates resources when and where
they are needed enabling multiple software applications to run on
a single server. This session discusses how to properly design and
implement a PlantPAx system infrastructure that will support
virtualization technology. Users will leverage the sizing rules and
configurations derived from our process system characterization
efforts with virtualization. A basic understanding of virtualization
concepts is necessary.
ED05: Defining a New PlantPAx System for
Optimal Performance
Alexander Cherpakov, Manager, Process System Engineering
Learn how to select the appropriate PlantPAx system architecture
based on project requirements. This session will present the latest
system sizing and architecture rules derived and tested in our
process system characterization lab. Learn how to use the sizing
tools to help fine tune loading and performance of your system.
ED06: Adding Adaptive Mobile Computing to
Your Factory Floor
Matt Crandell, CEO, Automation Control Products
Imagine a brand new factory floor computing system that allows
you to view your existing Windows applications from iPhones,
iPads and Android devices. Imagine this same system delivering
applications and information to you based upon your skill set,
proximity to a process, or ability to handle an event such as an alarm.
Now envision adding this functionality to your existing factory floor
computing systems with no impact on production. You’ve just
entered the world of Adaptive Mobile Computing with “Relevance” –
the latest client management software for the factory floor brought
to you by the developers of ThinManager. Join us at this session and
experience this “Relevance” through a live demonstration depicting
the factory of the future.
ED07: Process Safety Application Development
with AADvance
Pete Skipp, ISA S84 SIS Fundamentals Specialist
Learn the steps required to implement an AADvance Process Safety
application to meet National and International Functional Safety
Standards. This session explores each step of the Process Safety
lifecycle and discusses the key areas required to define, design,
deploy and maintain a Process Safety application using
AADvance technology.
ED08: Improve Design and Installation Flexibility through
PlantPAx Field Device Networks and System Integration
Yuri Zelenkov, Product Manager, Control &
Visualization Business
Simplify the integration of smart field devices via HART,
WirelessHART, FOUNDATION Fieldbus, Profi-PA, and EtherNet/IP by
learning about the broad portfolio of connectivity options available
with the PlantPAx system. Explore the connectivity options and
see the latest in accredited fieldbus solutions, wireless connectivity
and the use of Ethernet devices in the field that can help you save
integration time and improve productivity.
ED09: Advanced System Engineering Utilizing the
PlantPAx Sequencer
Bruce Lightle, Global Process Technical Consultant,
PlantPAx System
Learn about the new PlantPAx Sequencer Object. PlantPAx
Sequencer Object manages devices (valves, pumps, loops)
following user configured procedures and is ideal for CIP skids,
equipment start-up and shut-down strategies, or some batch
processes. In this session, we will discuss where PlantPAx
Sequencer Object can be employed and how PlantPAx
Sequencer Object operates.
ED10: Optimizing Process Plant Efficiency
Maina Macharia, Product Manager, Pavilion Technology
Process Industries are under tremendous pressure to be efficient
in response to the global rise of energy and material costs.
Plant managers are looking at their process operation and
implementing model predictive control technology (MPC) as
an alternative for multi-million dollar plant equipment projects.
MPC technology improves the regulation of the plant by predicting
real-time product qualities and integrating the impact of all
variables controlling the process units. This results in an increase
in raw material yield, lower energy usage and more optimal
production rates – a net effect of higher plant efficiencies in the
range of 5-10%. Learn how MPC technology is implemented and
see a demonstration of the technology on a natural gas liquids
(NGL) fractionation unit.
ED11: Human Factors in the Process Industry –
Why Good Design Matters
Lisa Garrison, North America Managing Director, Acuite
This session will provide participants with an introduction to Human
Factor Engineering in the Process Control Industry. Specifically we
will cover the principles and foundations of effective user interface
(HMI) design. Operator graphics are both vulnerable and an
untapped opportunity. Well-designed graphics will enable the
operators to not just run the plant but run the plant well. The
scientific principles for that are the basis for many of the current HMI
recommendations to be discussed. This will assist participants in
making educated decisions for their particular process and industry.
ED12: Layer of Protection Analysis (LOPA) and
Common Mistakes
Paul Gruhn, PE, Global Process Safety Consultant
Layer of protection analysis (LOPA) is a semi-quantitative method
of determining/selecting the safety integrity level (SIL) of a safety
instrumented function (SIF). The method avoids some of the pitfalls
associated with older and simpler subjective, qualitative techniques.
As a result, LOPA has become the preferred SIL selection technique
with most organizations. However, there are a number of
misunderstandings and potential misuses of this method.
This session will review the methodology, along with some of
the more common errors that seem to be occurring.
ED13: Integrating Intelligent Motor Control Devices
into the PlantPAx System
Stefan Zak, Area Manager, Power Control Systems
A detailed overview of the workflow for the integration of devices
in CENTERLINE Motor Control Centers to PlantPAx systems.
This demonstration will provide a tangible illustration of the
advantages of Allen-Bradley Intelligent Motor Control technology
and the benefits delivered through the life cycle of the
industrial facility.
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
17
Process Solutions User Group 2013
EDUCATIONAL SESSIONS AND
HANDS-ON LABS CONT.
ED14: Skid Equipment Integration to Plant-wide Control
Systems: Strategies and Solutions for OEMs
Greg Turner, Business Manager, Process OEMs
This session will address the common challenges, and describe best
practices that can be adopted to reduce design effort, minimize
cost, and shorten commissioning time through pre-FAT testing
while using established or emerging standards for system design.
Our domain expert will explain how to apply modular control
concepts to achieve optimum integration of skid equipment with
the plant-wide control system, minimizing one of the major cost
elements of any process skid project.
ED15: Leveraging ISA S88 for Automating Batch,
Continuous or Discrete Operations
John Parraga, Product Manager, PlantPAx System
Batch, continuous and discrete processes can all benefit from
utilizing a modular/flexible approach to defining, executing and
tracking standard operating procedures, whether the process
activities are performed by operator actions or by the automation
control system. Leverage the PlantPAx Sequencing offerings and
ISA S88 to create a modular design that enables all areas of your
plant to adapt to market changes as well as improve your
existing processes.
ED16: Leveraging Information in a PlantPAx System
Scott Sandler, Product Manager, PlantPAx System
Increase the value of PlantPAx with Production Intelligence
capabilities. Perform root cause analysis using advanced trending
capabilities to overlay alarms and operator actions on process data.
Monitor your alarm system performance using the new library of
Alarm Management Reports. Find problems before they happen;
using PlantPAx Library Reports. Become familiar with the decision
support tools that can help reduce variability and drive a more
optimized process.
LAB1: Introduction to Configuring an AADvance
Process Safety Solution (2 Hours)
The AADvance solution is a truly distributed, scalable architecture
comprised of a hardware controller and a software environment
that allows you to apply different levels of module redundancy as
required by specific parts of your application. It offers a high level
of flexibility from small quantity I/O to large systems, non-safety
to SIL 3, and fail-safe to multiple fault tolerant. This two-hour session
will show you how to select, configure and deploy a flexible
architecture using the AADvance Process Safety solution.
1
Note: If you missed the early-bird online registration, you can still sign up for
any remaining seats once you arrive at PSUG
ROUND TABLE AND
TOWN HALL VOTING SESSIONS
Process Solutions User Group 2013
TOWN HALL VOTING SESSIONS
Town Hall Voting sessions are your opportunity to shape the
future of the PlantPAx system. These Town Hall Voting Sessions
are a prime opportunity to give your input into the evolution
of the PlantPAx process automation system capabilities.
Rockwell Automation business and product managers will listen,
respond and consider your input for the development roadmap.
Sessions Available:
• PlantPAx System Design and Implementation
• PlantPAx System Operate and Maintain
ROUND TABLE DISCUSSIONS
Round Table Discussions are an opportunity to discuss, learn and
share information on process automation topics with a panel of
experts and your peers. These one-hour Round Table Discussions
will be open forums where you can ask questions and share
best practices.
Areas of focus:
• Optimization Through Production Intelligence
• System Security
• PlantPAx Libraries
• Field Device Management
• Alarm Management
• Batch Management
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
21
Communication is Key.
Are Your Disparate Control Systems Talking?
The PlantPAx™ process automation system offers one platform for true plant-wide control
– including process, discrete, power, safety and information. Utilizing EtherNet/IP
as its backbone, it delivers increased communication and real-time information to
optimize processes, performance, maintenance and profitability. Now you’re talking.
CUSTOMER APPLICATION SESSIONS
PlantPAx. It’s More Than a DCS.
Learn more at
www.rockwellautomation.com/go/process
PlantPAx is a trademark of Rockwell Automation, Inc. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. AD2013-11-EN
23
an
CUSTOMER APPLICATION SESSIONS
Process Solutions User Group 2013
CUSTOMER APPLICATION SESSIONS
This year’s presenters represent companies from many
different countries and industries. Each presentation
addresses different applications, critical issues, best
practices and solution benefits.
Alicorp SAA and IASTECH
“Peru Biscuit Plant Undergoes Major Process and Batch
Control Modernization Efforts Using PlantPAx”
Presenters: Luis Roberto Castillo Campos, Project Manager –
Automation Development and Rafael Pezzella Chiea,
Automation Manager
Alicorp is one of the biggest consumer product companies
in Peru and continues to steadily grow. When it came to
modernizing the process control systems at their biscuit facility
they chose the PlantPAx system, but knew they would only
have a limited time to implement it and keep up with demand.
See how Alicorp and system integrator, IASTech, were able to
develop, test and simulate the PlantPAx process automation
system in action, even before they needed to shutdown the
plant for actual implementation. This provided for a smooth
transition to the new system with minimal interruptions to
normal production schedules.
Celec Electroguayas
“Upgrading a Power Generation Plant with the
PlantPAx System”
Presenters: Carlos Julio Balda, BU Manager and Mauricio Molina,
Instrumentation & Control Specialist - Edison Sosa
CELEC Electroguayas, a thermoelectric generation company
which provides services to Ecuador’s electrical network,
operates two steam generators and one gas generator. This
session will discuss the steps taken to upgrade its boilers and
turbo-generator controls including combustion control (CCS);
burner management system (BMS); and master fuel trip (MFT).
Additionally, it will include a discussion on improvements to the
turbine control system (TCS) and control & monitoring system.
Champion Technology and Phillips 66
”Phillips 66 Gulf Coast Lube Oil Plant Replaces
Siemens PCS7 System with PlantPAx and Integrates
Plant Production to Its ERP System”
Presenter: Scott Thompson, Project Engineering Manager
This session will discuss the rationale and criteria for selecting
and standardizing on the PlantPAx system at Phillips 66.
Additionally, we’ll outline the benefits realized by Phillips 66
in the areas of production, quality and efficiency since
migrating to the PlantPAx system.
Champion Technology and RAIN CII
“Installation and Automation of Waste Heat Recovery
Steam Generation (HRSG) for Commercial Power
Generation at RAIN CII”
Presenter: Brad Jordan, Business Manager
Discover how RAIN CII implemented a 34.6MW HRSG
cogeneration system using flue gas from two kilns that were
previously not recovering gas. We’ll also discuss how Champion
Technology was able to integrate the bag house, chemical
treatment, sand filter skids and continuous monitoring system –
all supplied by multiple vendors – into the PlantPAx system
for added benefits. From fiber optic Ethernet and redundant
ControlNet to operator stations and redundant HMI servers,
learn how PlantPAx is helping RAIN CII remain power
independent with the capability to sell power to the utilities.
Chevron Phillips Chemicals
“Using Advanced Process Control Technology on a Gas
Phase Polyethylene Reactor “
Presenter: Robert Freeman, DCS Technician
The polyethylene industry faces many challenges – rising
energy costs, limited resources – that are impacting operations.
As a result, improvements in reactor process control, response
time, and productivity have major impact to a company’s
success. We’ll discuss the implementation of advanced process
control, from inception to execution, and provide details on
the benefits it provided to improve efficiencies and overall
plant profitability.
China National Offshore Oil Corporation
”It’s More than DCS for Offshore
Production - PlantPAx”
Presenter: Huang ShunPing, Technical Manager
Implementing and making sure that an offshore platform
is running at its utmost efficiency without endangering
personnel, assets or the environment is always challenging.
Learn how CNOOC overcomes that challenge by leveraging
the flexibility of the PlantPAx system and the AADvance
Fault Tolerant system to achieve a SIL 3 Emergency Shutdown
Device(ESD) and Fire & Gas(F&G) safety system for offshore
O&G production.
DTE Energy and Innovative Controls
“Utilizing Virtualization to Improve Sustainability
Goals in Energy Facility”
Presenters: Chris Hardy, Electrical Engineer and Rick Wright,
Principal Analyst
Detroit–based DTE Energy is committed to balancing its social,
economic and environmental responsibilities while providing
reliable, affordable energy. DTE is in the process of converting
their Stockton, CA coal plant to an environment friendly woody
biomass. Learn how Innovative Controls, a Rockwell Automation
Recognized System Integrator, was able to implement a robust
and redundant HMI solution for the process control room. We’ll
provide details on the utilization of VMware vSphere, Factory
Talk View, and Wyse Thin Clients to create an engineered
solution that has proven to be highly reliable and fault tolerant.
Ecopetrol and Montajes Morelco
“Implementing Emergency Shutdown at a Refined
Product Pipeline Utilizing AADvance Technology”
Presenters: Rafael Mesa, Profesional de Proyectos VIT and
Javier Cabal, Functional Safety Engineer
Electro Controles del Noroeste, S.A. de C.V.
“Migration from PlantScape to the PlantPAx System”
Presenter: Joe Palazuelos, Branch Manager
Solvay Fluor Mexico, S.A. de C.V manufacturers industrial
inorganic chemicals. It needed to migrate its legacy PlantScape
system to PlantPAx and turned to ECN, a Rockwell Automation
Process Solution Provider, to handle the project. Discussion
will center on the details of the project including needed
engineering and connection of HART instrumentation and
FactoryTalk AssetCentre. In addition, we detail the PlantPAx
library modifications that were instituted to help increase
operator efficiencies. As a result of this migration, Solvay enjoys
increased production and higher velocity communication.
Emerald Performance Materials
“Maximize Your Return on Your Legacy DCS Migration
Through Phased Migration and Incremental/Limited
Investments”
Presenter: Thomas Bilkie, Electrical Engineer
Emerald Performance Materials, LLC produces and markets
technologically advanced specialty chemicals for a broad range
of food and industrial applications. At its Akron facility, the
focus is on rubber anti-oxidants and accelerators, latex and
adhesives. As demand grows for increased process control and
automation, Emerald was faced with a legacy control system at
its limit for expandability and parts and support sustainability,
in addition to its inability to address increased automation and
expansion. Through a series of scheduled phases, the project
team – consisting of Emerald, Rockwell, Rexel (distributor) and
Rovisys (Process Solution Provider) – were able to successfully
deploy a PlantPAx system under budget and with minimal
impact to production. This session will discuss the project in
its entirety and highlight the benefits achieved, including
optimization of manpower usage and scheduling.
Colombia’s oil production has been growing steadily over the
past five years. As a result of this growth Ecopetrol has started
a major upgrade of the transportation infrastructure within the
country. Part of this plan was upgrading the Pozos-Colorados
Galán Pipeline 500Km which transports refined products in
the northern coast of Colombia. This session will discuss the
project, including the installation of 42 sectioning valves in
order to control spills and avoid disasters. We’ll highlight how
an ESD using AADvance technology and an automatic
sectioning algorithm was the solution developed to control
the sectioning valves.
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
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CUSTOMER APPLICATION SESSIONS
Process Solutions User Group 2013
CUSTOMER APPLICATION SESSIONS CONT.
Energy Control Technologies, Inc.
“Fully Redundant Integrated Turbomachinery Control
on a Two Section Propylene Refrigeration Compressor
in a Petrochemical Plant”
Presenter: Greg Johnson, Director Product Development
Energy Control Technology (ECT) implemented a fully
redundant PlantPAx system, including analog output
redundancy, and achieved cost reductions of 50% over
proprietary hardware systems due to lower project costs,
shorter commissioning time, and mean time to repair.
These results were achieved with ECT’s TurboPAC advanced
turbo-machinery control system implemented on the PlantPAx
system. Learn why the customer selected the PlantPAx system
with Add-On Instruction capabilities over a proprietary turbomachinery control system. Redundant management system
displays will be presented with control system functionality for
compressor surge and capacity control and protection.
EnergyWorks
“Concurrent Engineering in a Production-Scale Energy
Production and Nutrient Recovery System”
Presenter: Jeff Noland, Director of Electrical/I&C Engineering
The PlantPAx Library of Process Objects , incorporated with
historian software, mitigates risk and provides integration
efficiencies in developing a first-of-a-kind industrial process
on a large scale. This session will discuss the integration of the
PlantPAx system with Schweitzer Engineering Laboratories’
protective relay equipment to deliver direct transfer trip,
facility protection, and power factor correction systems at
a new energy production and nutrient recovery facility.
ESCO Automation
“DuPont Replaces Competitor’s Batching Software
with the Batch Management Capabilities of the
PlantPAx System”
Presenters: Tom Miller, Director of Business Development
and Brad Sefcik, Senior Engineer
The SDP Expansion Project was the first implementation of
PlantPAx batch management software for the DuPont facility
in Fort Madison, IA. It laid the framework for a future facilitywide conversion based on the DuPont corporate standard.
The project involved expanding ink production at the facility
by duplicating an existing line currently utilizing WonderWare
with a new line that deploys the PlantPAx capabilties. The new
system was more robust, scalable, and responsive. It created a
more intuitive batch-to-operator interface and will be more
easily maintained than the previous system. Additionally, it
created new batch reporting capabilities that were not
previously possible.
E-Technologies Group
“Justification & Execution of a Multi-Phased Honeywell
Migration to the PlantPAx System”
Presenter: Steve Veldhuis, Principal
Many manufacturers with aging DCS systems struggle
with the justification and complexity of converting to a new
automation platform. E-Technologies, a Rockwell Automation
Solution Provider specializing in migrations, will review a multiphased Honeywell migration to the PlantPAx system. They will
highlight both migration decision-making and execution of
phased migrations, tailored to individual manufacturers’
equipment. Key design considerations will be discussed along
with the lessons learned from an experienced DCS migration
partner. Technical enablers, approaches for migrating and the
advantages of the PlantPAx system architecture – optimizing
performance, maintain operational continuity, and achieving
planned economic returns will be reviewed.
G-CON
”Flexible Bio-Manufacturing Utilizing the
PlantPAx System”
Presenter: Barry Holtz, President
The bio-manufacturing industry is experiencing many challenges
including reduced capex, the need for rapid transition between
product development and commercialization, and flexible
and reusable facilities. To answer these challenges, G-CON has
developed flexible, modular, clean-room pods. The early
integration of automation and facility design as part of QbD
development of pharma processes is now a critical step in
product and process development. Using the PlantPAx system,
these pods are easily moved, easily integrated, and ready-to-use
upon delivery. This session will explore why G-CON chose a
scalable, redundant PlantPAx system , the benefits it offers
including historian capabilities, energy savings, improved
operator interface, and integration ease with building
management systems. Join us as we discuss the “smart”
process choice.
Hatch Consulting
“Mine-Wide Integrated Process and
Power Solution for a Greenfield Nickel Mine”
Presenter: Josh Lilley, Process Manager
Hatch Consulting designed, managed and installed a
mine-wide integrated process and power solution for a
greenfield nickel mine. You’ll learn how this fully integrated
underground mining solution utilized the PlantPAx process
automation system, intelligent motor control, and low and
medium voltage VFDs to realize budget and project goals.
Industrial Automation and Diageo
“Improving Manufacturing Capacity, Quality and
Reliability Using the PlantPAx System in a Virtual
Environment”
Presenters: Niniv Tamimi, Program Manager and
Thomas Maulsby, Process Engineer
Diageo was able to increase the capacity of their Plainfield
production by adding new receiving and batching capabilities
along with integrating their existing assets into the new system
with a minimal amount of downtime. The PlantPAx system core,
Process Information and Batch Management provided Diageo
with improved batch capabilities and control based on the
S88 batch model as well as batch information management.
Diageo realized reduced integration / start up costs as well as
plant wide optimization by leveraging Integrated Architecture
capabilities. FactoryTalk VantagePoint provided the portal to
access the reporting and generated all the additional reports.
High system availability was achieved by leveraging a
virtualized and redundant server configuration (Rockwell
native redundancy and/or VMware Fault Tolerance). Learn
why helped this process solution was selected and how it
increase the throughput and quality at this Diageo facility.
Kimberly Clark
“Migration of Honeywell TDC/PLC5 System on a Tissue
Machine to the PlantPAx Architecture”
Presenter: Bob Kilas, Engineering Technical Leader
Kimberly Clark elected to replace the Honeywell TDC3000
control system and the companion PLC5 systems with the
PlantPAx system. The scope included replacing the TDC I/O,
control code and HMI screens and converting existing logic.
All servers were virtualized. Attendees will learn about the two
phases employed in the migration, the challenges encountered,
and best practices to employ when contemplating a
migration project.
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
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CUSTOMER APPLICATION SESSIONS
Process Solutions User Group 2013
CUSTOMER APPLICATION SESSIONS CONT.
Lauren Engineers & Constructors, Inc.
“Designing, Building, and Commissioning India’s First
Full-Scale Concentrated Solar Power Plant Using
the PlantPAx System”
Presenter: Ron Johnson, Executive Vice President
The Godawari Green Energy Project, a 50 MW concentrated
solar power (CSP) plant, is the first full scale CSP plant to be
commissioned in India. It is part of the Jawaharlal Nehru
National Solar Mission, which plans to deploy 20,000 MW of
grid connected solar power by 2022. The PlantPAx system
controls the solar field and power generating equipment.
This presentation will focus on the design integration,
procurement and delivery of materials to the remote area of
India, construction, and commissioning. Design concepts will
be reviewed and experience in integration and commissioning
of the controls will be highlighted.
Malisko Engineering and Noosa Yoghurt
“The PlantPAx Flavor-Advanced Automation System
Implementation helps All-Natural Aussie Style Yoghurt
Become a Consumer Favorite”
Presenter: Dan Malyszko, Director of Operations – Denver
Noosa Yoghurt, the wildly-popular Australian-style yoghurt,
recently became available nationwide for the first time after
completing the commissioning of a greenfield processing
facility located at Morning Fresh Dairy in Bellvue, Colorado.
The new facility helped propel the company to year-over-year
revenue growth of 260%. Plans have already been announced
for an expansion. Malisko Engineering designed and deployed
a PlantPAx Process Automation System to integrate all of
the yoghurt plant’s utilities, CIP, and process systems. The
PlantPAx platform provided the customer with a scalable
system architecture with defined system elements, each with
a set of specific responsibilities and detailed specifications.
The legacy processing facility was an all-manual operation
with no established automation infrastructure. To evolve the
dairy into a ‘world class’ facility it was imperative to deliver
a characterized control system that ensured efficient
development and commissioning on a very aggressive
project timeline to meet high consumer market demands.
Mallinckrodt
“Pharmaceutical Legacy Control System Upgrade Project
Utilizing the PlantPAx System”
Presenter: Don Geers, Sr. Maintenance Engineer
This session details the legacy control system upgrade project
and the set of custom validated S88-based modules which
were integrated into the new PlantPAx system. The new system
included batch management, historian and production
reporting capabilities to replace hand-written batch reports.
Existing field I/O architectures remained intact to minimize
downtime during cutover and existing operational interfaces
were leveraged to maintain operational efficiencies. All software
was installed on Mallinckrodt’s existing VMware virtual
infrastructure with Wyse thin client terminals, reducing the
maintenance of approximately 15 computers. This project
was the collaboration of Mallinckrodt, system integrators,
distributors and the Rockwell Automation Solutions team.
Matrix Technologies
”Kalsec Inc. Takes a Leap from Manual Operations to a
Fully Automated New Plant Tightly Integrated with their
Business System”
Presenter: Divya Prakash, Director of MES Implementation
Kalsec Inc. produces Natural Colors, Natural Flavor Extracts,
Antioxidants and Nutritional Ingredients for the food, beverage
and pharmaceutical industries. Kalsec recently made a giant
leap to move from manual operations to a new fully automated
plant tightly integrated with their business system. There are
many challenges when building a new production facility.
Process technology is important but it is only one piece in the
puzzle. It was vital to consider all aspects of the project –
networking, data modeling, process technology selection,
recipe definition, operator training and support strategy. Matrix
Technologies, Inc., a Rockwell Automation Process Solution
Provider, delivered a solution incorporating the PlantPAx system
with FT Batch in addition to real-time information integration
with their iRen business system. This session will describe the
many considerations Kalsec Inc. went through when they chose
Matrix Technologies, Inc. to be their Engineering Procurement
& Construction Management (EPC) resource in building the
new plant. Learn about the entire project and how Kalsec Inc.
transitioned its operations from a manual process to a
recipe-driven automated one.
Optimation and Novomer, Inc.
“Designing a Pilot System for Process Experimentation
and Future Scale-Up”
Presenters: Mike Triassi, Business Development Manager;
Marcia Pohl, Principal Engineer and Anatole Pleten,
Research Technician.
PERENCO
“Reduction of Operational Expenditure in
Onshore/Offshore Oil Production”
Presenter: Laurent Mollard, Senior Engineer
The PlantPAx system with Factory Talk Batch, Historian and
VantagePoint was used to create a laboratory reactor to
experiment with formulations for catalysts. The key to
successfully characterizing the process relies on the accuracy
and flexibility of changing chemical doses, temperatures and
pressures, coupled with the insight gained on the impact of
these changes. Learn why the PlantPAx system was selected
for this project and the advantages gained from its libraries,
recipes and controller phases which are designed to be
reusable on a full scale installation.
Perenco, an independent oil and gas company with onshore and
offshore capabilities, has standardized on Rockwell Automation
solutions. This session will show how the integrated process /
safety / power solution from Rockwell Automation helped
them reduce their OPEX in their production facilities in Gabon,
Congo, Cameroon, Tunisia, United Kingdom and Peru through
reduction of operator presence in offshore locations, rationalized
maintenance costs and improved production data analysis.
We’ll discuss the utilization of Rockwell Automation solutions
for a variety of functions: process control, process safety, power
plant management, power distribution and load shedding,
vibration analysis, motor controls through medium and low
PCI and City of Fremont
“PlantPAx System Drives Waste to Energy Plant”
Presenter: Hassan Ajami, General Manager
voltage drives, with local and remote control using wireless
or satellite communications. In addition, through consistent
implementation between facilities, operators and
maintenance engineers are able to move from country
to country without any trouble.
The City of Fremont, MI was looking for a method to dispose
of farm waste. With the help of PCI, a system integrator and
industrial automation firm that specializes in process control,
they created a plant that converts the waste to biogas that is
used to drive a generator to put power on the grid. Using PCI’s
ingenuity and the PlantPAx process automation solution,
learn how the City of Fremont is generating power from farm
waste and creating a green, sustainable solution to its problem.
PEMEX
“SDMC, SF&G and ESD Systems Migration
at Offshore Platform”
Presenters: Arturo Lara Gomez, Maintenance Supervisor
and Manuel Reyes Pena, Maintenance Supervisor
Challenged with unexpected shutdowns, system reliability
and security concerns related to their legacy systems, PEMEX
undertook a phased migration to upgrade its SDMC, SF & G
and ESD systems. This session will elaborate on each of the
upgrades including content on hardware, wiring, networks
and timelines. It will take the audience from design, install
and wiring to testing and documentation. Finally, it will
discuss the benefits realized since installation.
Shell Canada
“Shell Converts Montreal East Refinery to a
Terminal Controlled By PlantPAx”
Presenter: Tan-Trung Nguyen, Project Engineer
After 75 years of operation in Montreal East, Shell has
decided to close the refinery but retain part of the site as a
terminal to maintain the distribution of finished products to
customers. The conversion project needed to be executed
flawlessly since the distribution network could not afford an
interruption to supply for the Quebec market. The existing
DCS at the refinery was abandoned for a new PlantPAx
system for the terminal. We’ll discuss the project planning
by Shell project engineers with support by local system
integrators and provide information on the fully automated
terminal to offload finished products from ships, manage
the inventory of storage tanks and the distribution of
products to truck loading ramps.
PROCESS SOLUTIONS USER GROUP PSUG 2013 | HOUSTON, TX
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Process Solutions User Group 2013
CUSTOMER APPLICATION SESSIONS CONT.
Tunning
Sirio Sistemi Elettronci S.p.A.
“Integrated Control & Safety System
for Crude Oil Transfer Pipeline”
Presenters: Claudio Jara, General Manager and
Jose Opazo, Control Engineer
Presenters: Bruno Zanotti, Technical Director and
Cristiano Tatini, Commercial Director
Sirio Sistemi Elettronici S.p.A. operates in the field of
industrial control solutions and undertakes the design,
software development, production and commissioning
of control & supervisory systems for the Oil & Gas and
Power Generation Industries. SSE is currently supplying an
integrated control and safety system for crude oil transfer
pipeline based on the PlantPAx system. The proposed
solution utilizes both ControlLogix and AADvance controllers
in redundant configuration for PCS, ESD and F&G functions.
Attendees will learn how this solution helped guarantee total
control and protection of the plant including full integration
of all installed components over a single platform, avoiding
miscommunication between Safety Instrumented Systems
(SIS) and Process Control Systems (PCS).
Stone Technologies and Ameren Corporation
“Landfill Gas Plant using PlantPAx for
Energy Production”
Presenters: Mark DeYoung, Principal Engineer and
Mike Whitmore, Plant Superintendent
This session will provide a process overview of how landfill
gas is processed and converted into electricity, as well as
describing how the PlantPAx system is used to integrate
disparate control systems into a common control platform
that can be controlled from a central control room or from a
remote location during “lights out” generation. The PlantPAx
system and FactoryTalk Historian are used for master
control and historical monitoring of over 25 sub-systems
while directly controlling many other subsystems. The
PlantPAx control system provided all of the functionality of a
traditional power plant DCS system at a much lower cost.
“Solutions from Rockwell Automation Improve
Electrical and Control Systems in Mining Application”
The Los Colorados Iron Ore Mine in Chile needed to upgrade
its mill and powerhouse. It turned to Recognized System
Integrator, Tunning, for their expertise in control and
electrical systems. You’ll learn about the supply and startup
of the systems, use of low voltage motor control centers
and medium voltage VFDs, and how integration of the
systems was achieved utilizing the EtherNet/IP network.
In addition, you’ll see how third-party equipment was
integrated using Modbus, Modbus TCP and
Profibus-DP networks.
Process
Solutions
User Group
2014
November 17-18
Anaheim, CA
http://psug.rockwellautomation.com
Zilor
“Production Optimization in a Sugar
Crystallization Plant”
Presenters: Edilson Casanova, Automation Specialist and
Leandro Martinelli, Process Engineer
Significant economic benefits for sugar factories can be
realized through the utilization of new control technologies
that leverage existing instrumentation. Model Predictive
Control technology is a key tool to help optimize equipment
performance to realize those benefits. This case study will
discuss MPC technology, its ability to reduce process
variability, and the challenges faced at Zilor, a manufacturer
that transforms sugarcane into food and clean energy. In
particular we’ll discuss key plant variables – supersaturation
degrees, consistency, liquor purity and the Brix – and their
role in variability reduction. We highlight the benefits from
implemented MPC, including a 50% reduction in Brix
variability and a 3% increase in sugar production.
Extend Your Stay!
Automation
Fair® 2014
November 19-20
Anaheim, CA
Anaheim Convention Center