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Process Solutions User Group
Process Solutions User Group Event Guide 2011 Welcome Process Users, On behalf of Rockwell Automation, I would like to thank you for joining us in Chicago, Illinois 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 global process users who are improving their business processes, creating new revenue streams and establishing best practices by implementing the 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 Vice President and General Manager Information Software and Process Business table of contents GENERal Information......................................................................................................................................... 3 Agenda and Speakers......................................................................................................................................... 9 Customer Advisory Board............................................................................................................................. 15 Optional Educational Sessions................................................................................................................. 21 Town Hall Voting Sessions........................................................................................................................... 27 Customer Application Stories..................................................................................................................... 31 PSUG 2012................................................................................................................................................................. 41 A special thank you to our advertisers Panduit...................................................................................................................................................................... 2 Endress + Hauser.................................................................................................................................................. 4 Hardy Instruments............................................................................................................................................. 8 Flir............................................................................................................................................................................. 10 ProSoft.................................................................................................................................................................... 16 Mynah....................................................................................................................................................................... 22 Spectrum Controls........................................................................................................................................... 28 Phoenix Digital.................................................................................................................................................... 30 Pepperl + Fuchs.................................................................................................................................................... 32 2011 -1- MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS Automation Fair PSUG Ad.qxp 8/27/2010 2:36 PM Page 1 Improve Reliability, Security, and Safety Whether the solution is for electrical, networking, or control systems, Panduit is uniquely qualified to understand the complexities of plant-level networks and controls. From monitoring production processes to optimizing pathway design, our Industrial Automation Solutions ease the deployment of industrial networks and automation control systems to enable expansion of operations, increase collaboration, and enhance productivity. Targeted to specific plant needs, Panduit’s Industrial Automation Solutions are comprised of five core groups: • In-Panel: Control Panels, Electrical Panels, MCC • In-Field: On the Machine, In the Process Areas or Outdoors • In-Route: Industrial Pathways and Network Zone Enclosures • In-Room: Control Room, Data Center, Telco Closet • In-Frastructure: Power Distribution, Lighting, HVAC, Security, Safety Visit us in Booth No. 1141 For more information on our solutions, visit us at ww.panduit.com, call us at 800-777-3300 or email us at [email protected]. -2- general information -3- Bringing EtherNet/IP to the process industry. Unlock process potential with EtherNet/IP enabled instruments The world’s first flowmeters for the EtherNet/IP network: Coriolis and Electromagnetic • Seamless integration into Rockwell Automation Integrated Architecture™ and PlantPAx™ Process Automation System, expanding the flow of real-time data across the manufacturing enterprise • With just a few mouse clicks, you have the ability to integrate, configure and commission in minutes, not hours like with other networks Experience the potential! Booth #639 • Measurement information from flowmeters into the control system aid real-time decision making for increased quality and output www.us.endress.com/ethernet Endress+Hauser, Inc 2350 Endress Place Greenwood, IN 46143 [email protected] www.us.endress.com Sales: 888-ENDRESS Service: 800-642-8737 Fax: 317-535-8498 -4- Follow ROKAutomation on Facebook & Twitter. Connect with us on Linkedin. Registration The registration area is located near the Level 1 Concierge desk in McCormick Place West—see Convention Center Map ( ). The registration team will be available to assist you with any conference needs during the following hours: Monday: 7:00 a.m. – 5:00 p.m. Tuesday: 7:00 a.m. – 3:00 p.m. BADGES Badges must be worn to gain entrance to all Process Solutions User Group proceedings—including the Monday night event. If you misplace your badge, please go to Registration ( )to have a new one printed. MONDAY NIGHT networking event The Monday evening event will allow you to network with Rockwell Automation and industry peers while enjoying Chicago's Shedd Aquarium. You must have your PSUG badge. EVENT MEALs Monday Lunch Lunch will only be provided to those that attend the Monday morning Optional Educational Sessions. PSUG officially kicks off at noon. Monday Dinner (7:00 p.m. – 11:00 p.m.) Dinner will be provided at the Monday night event at Shedd Aquarium. Tuesday Breakfast (7:00 a.m. – 7:45 a.m.) Tuesday Lunch (12:15 p.m. – 1:15 p.m.) All PSUG at McCormick Place West will be served in W-196 ( ). Mobile Phones and Pagers As a courtesy to all attendees, please set mobile phones and pagers to silent mode. If you need to take a call during a session, please exit the room quietly. -5- MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS general information GENERAL INFORMATION MEN'S ELEC. ROOM Convention center area MAP WOMEN'S EAST VESTIBULE TELECOM ROOM McCormick Place West Level 1, Main Session, Registration, and Dining STORAGE GARAGE OPERATOR EAST CONCOURSE PSUG / SAFETY REGISTRATION RAMP UP CONCIERGE DESK PARKING FACILITY ENTRY/EXIT UP UP UP W-190A/B AUDIOVISUAL IDF ROOM ELEC. ROOM TELECOM ROOM GARAGE ACCESS ROAD UP DR. MARTIN LUTHER KING JR. DRIVE ES PHON MECHANICAL ROOM OFFICE PSUG OFFICE EAST CONCOURSE OFFICE ATM'S MEN'S PHONES WOMEN'S SERVICE CORRIDOR MEN'S ELEVATOR MACHINE ROOM JANITOR'S CLOSET WOMEN'S VESTIBULE GARAGE ACCESS ROAD W-192A W-191 SERVICE CORRIDOR W-192B Safety EAST CONCOURSE MECH. INTAKE PLENUM W-192C RAMP DOWN W-193A UP SERVICE DOCK UP COMPACTOR DUMPER COMPACTOR DUMPER W-193B IDF ROOM TELECOM ROOM UP ELEC. ROOM UP PW STORAGE W-194A Safety ELEV. LOBBY W-194B Safety SERVICE CORRIDOR W-195 SERVICE CORRIDOR UP Safety UP AUDIOVISUAL IDF ROOM SERVICE CORRIDOR UP GARAGE ACCESS ROAD WOMEN'S JANITOR'S CLOSET SESMLAALIN CR3 RLM P 1ED 2 ERTG TO G EAA PSP IU K R UP TELECOM ROOM SESMLAALIN CR3 RLM P 1ED 2 ERTG TO G EAA PSP IU K R MEN'S SERVICE CORRIDOR W-196 12’ SERVICE CORRIDOR 12’ DINING 12’ 12’ Seating for 540 Total Seating for 1260 TOILET FAMILY JANITOR'S CLOSET WOMEN'S MEN'S 12’ 12’ SERVICE CORRIDOR SERVICE CORRIDOR PREFUNCTION VESTIBULE UP UP UP UP Process Solutions User Group annual meeting - November 14-15 -6- McCormick Place West Level 1, Customer and Educational Sessions CC12 C CC12 B CC12 A CC11 B CC11 A CC10 D CC10 C CC10 B CC10 A ELEC. MEN'S ROOM WOMEN'S VESTIBULE EAST TELECOM ROOM STORAGE GARAGE OPERATOR -7- EAST CONCOURSE MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS general information convention center area mAP BATCH OR CONTINUOUS PROCESS? BOTH? WE HAVE YOUR WEIGHING NEEDS COVERED! 1. STOCK 2. MAKE 3. PACK 4. SHIP BATCH PROCESS Material Feed Controller (by Feed Weight) - HI 1756-WS & 2WS ControlLogix® Weigh Modules, Single and Dual Scale Single slot, weigh scale modules Mounts in Allen-Bradley ControlLogix Programmable Automation Controllers (PACs) local or remote chassis Modules available for other Rockwell Automation systems CONTINUOUS PROCESS Material Feed Controller (by Feed Rate) - HI 1756-FC Feeder Controller Single slot, single feeder loss-in-weight feeder controller module Mounts in Allen-Bradley ControlLogix-based PACs Add On Profile (AOP) simplifies integrations BOTH PROCESSES Advantage® Load Points and IT® Junction Box - Stainless steel IP68 hermetic Matched mv/v, mv/v/ohm C2® electronic calibration JBox can be used with up to four, eight conductor load sensors Increase Throughput • Maximize Uptime • Minimize Waste. Reduce Minimum Stock Limits • Lower Energy Costs. Visit us at Booth #314 during Automation Fair® to see how to further optimize your process. Join our Technical Session - Room 5330B @ 11:00 both days of Automation Fair. PROCESS WEIGHING SOLUTIONS 800-821-5831 • +1-858-278-2900 www.hardyinstruments.com • [email protected] -8- agenda and speakers -9- The Measurement Tools for Success To Help Keep You Running Smoothly FLIR gives you the power of thermal imaging and more to see and assess what other monitoring technologies can’t. Improve Process Efficiency, QA, and Safety with the FLIR A310 Continuous Monitoring Camera • Non-Contact Temperature Measurement & Alarming • Native PLC Connectivity via Ethernet/IP & ModbusTCP • MPEG-4 Streaming Video & PoE • 320 × 240 Thermal Resolution Steel Ladle Integrity Seat Heater Testing Hot Glue Flow Synthetic Textile Process Warehouse Monitoring Reduce Downtime and Hazards with FLIR Handheld Predictive Maintenance Products FLIR E60 320 × 240 Thermal Camera FLIR T640 640 × 480 Thermal Camera Extech PRC 70 Multifunction Process Calculator Extech HDV Video Scope with Flexible Probe Imagery used for illustration purposes only. Visit www.flir.com/psug or call 866.477.3687 for your free Automation Guidebook and to find more FLIR process solutions. AutomationPSUGFairBookAd.indd 1 Quality – Trust – Innovation 8/26/11 3:37 PM - 10 - AGENDA – MONDAY, NOVEMBER 14 Time Topic Room Registration Open Lobby Area 8:00 a.m. Optional Educational Sessions Breakout Rooms 9:00 a.m. Optional Educational Sessions Breakout Rooms 10:00 a.m. Optional Town Hall Voting Sessions Breakout Rooms 12:00 p.m. Official Kickoff of PSUG 2011 Stephen Pulsifer, Global Director Process Marketing Development Main Session (W-190 A/B) 12:10 p.m. Process Customer Advisory Board (CAB) Introductions CAB Members Main Session (W-190 A/B) 12:30 p.m. Information Solutions and Process Business Update John Genovesi, Vice President and General Manager Main Session (W-190 A/B) 1:00 p.m. Keynote Address: "The Evolution of Control Systems" Marty Edwards, Director CSSP Program National Cyber Security Division U.S. Department of Homeland Security Main Session (W-190 A/B) 2:00 p.m. Break Lobby Area 2:15 p.m. PlantPAx: Serving Applications Today and Tomorrow Som Chakraborti, Business Director Process Business Main Session (W-190 A/B) 2:45 p.m. Customer Success Stories Breakout Rooms 3:45 p.m. Customer Success Stories Breakout Rooms 4:45 p.m. Wrap Up/Logistics for Evening Event/Dinner Main Session (W-190 A/B) 7:00 p.m. Shedd Aquarium Networking Event/Dinner - 11 - MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS agenda and Keynotes 7:00 a.m. AGENDA – TUESDAY, NOVEMBER 15 7:00 a.m. Registration Open Breakfast Lobby Area W-190 Dining 8:00 a.m. Welcome Back Stephen Pulsifer Main Session (W-190 A/B) 8:05 a.m. PlantPAx System: What's New and Coming Ben Mansfield, Marketing Manager PlantPAx System Main Session (W-190 A/B) 9:00 a.m. Town Hall Voting Sessions Breakout Rooms 10:00 a.m. Break Lobby Area 10:15 a.m. Town Hall Voting Sessions/ Educational Sessions Breakout Rooms 11:15 a.m. Customer Success Stories Breakout Rooms 12:15 p.m. Lunch W-190 Dining 1:15 p.m. Customer Success Stories Breakout Rooms 2:15 p.m. Customer Success Stories Breakout Rooms 3:15 p.m. Break Lobby Area 3:30 p.m. Customer Success Stories Breakout Rooms 4:30 p.m. Town Hall Voting Results/Contest Winners Process CAB Main Session (W-190 A/B) 4:50 p.m. Wrap Up Stephen Pulsifer Main Session (W-190 A/B) Process Solutions User Group annual meeting - November 14-15 - 12 - speakers In order of appearance: John Genovesi Vice President and General Manager, Information Software and Process Business, Rockwell Automation John Genovesi is Vice President, General Manger of Rockwell Automation's 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 customer’s global productivity initiatives. Genovesi'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. Genovesi 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. Marty Edwards Director , Control Systems Security Program (CSSP), National Cyber Security Division U.S. Department of Homeland Security Marty Edwards is the director of the U.S. Department of Homeland Security’s (DHS) Control Systems Security Program (CSSP). CSSP is part of DHS’s National Cyber Security Division. CSSP works to reduce industrial control system risks within and across all critical infrastructure and key resource sectors by coordinating efforts among federal, state, local and tribal governments, as well as industrial control systems owners, operators and vendors. The Control Systems Security Program also operates the Industrial Control Systems Cyber Emergency Response Team (ICS-CERT). The ICS-CERT responds to and analyzes control systems related incidents, conducts vulnerability and malware analysis, and shares and coordinates vulnerability information and threat analysis through products and alerts. Mr. Edwards has over 20 years of experience and brings a strong industrial control system industry focus to DHS. Before coming to CSSP, Mr. Edwards was a program manager focused on control systems security work at Idaho National Laboratory. Prior to his work at the laboratory, Mr. Edwards held a wide variety of roles in the instrumentation and automation fields, including field service, instrument engineering, control systems engineering and project management. Mr. Edwards has also held various positions in non profit organizations, including Chairman of the Board for one of the automation communities’ largest user group conferences. Mr. Edwards holds a diploma of technology in Process Control and Industrial Automation (Magna cum Laude) from the British Columbia Institute of Technology. - 13 - MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS agenda and Speakers Steve Pulsifer Global Director of 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. speakers 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. ben mansfield marketing Manager, 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, 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. Process Solutions User Group annual meeting - November 14-15 - 14 - Customer Advisory Board - 15 - HMMM... BETTER CALL PROSOFT TECHNOLOGY. When it comes to protocol interfaces and wireless solutions, ProSoft should be your first call. PROFIBUS Wireless Modbus PROFIBUS solutions for most Rockwell Automation® platforms. CIPconnect™ enabled modules offer module configuration, diagnostics and FDT/DTM support over EtherNet/IP. Complete wireless solutions across platforms. ProSoft provides access points, repeaters, wireless in-chassis and stand-alone gateways allowing multiple protocols to talk as one. ProSoft Technology offers a complete breadth of solutions for Modbus, Modbus TCP/IP and Modbus Plus applications. With every ProSoft Technology product, you get industry-leading technical support, over 20 years of network and protocol expertise, and unparalleled customer service. Where Automation ConnectsTM +1-661-716-5100 www.prosoft-technology.com/solutions ASIA PACIFIC | AFRICA | EUROPE | MIDDLE EAST | L ATIN AMERICA | NORTH AMERICA - 16 - 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! ARCHER DANIELS MIDLAND BOB WETTER, DIRECTOR OF INSTRUMENT, ELECTRICAL ANd COMPUTER ENGINEERING Bob Wetter has been working with process automation and power distribution for over 30 years—the last 28 years with ADM. He has responsibility for the automation and power distribution for ADM’s 230 processing facilities around the world. At ADM, safety is job one. For power distribution, ADM has implemented a variety of standards to improve the safety for people working on and around electrical distribution equipment. On the automation side, his responsibility includes the design and implementation of control systems for all of ADM’s major processes. As almost all of ADM’s processing facilities deal with potential hazards such as ethanol, hexane, and hydrogen, there is a high level of interest in making ADM’s control system as safe as possible. Colorado Springs Utilities (CSU) Jay Hardison Jay has over 28 years of experience in the areas of electrical, instrumentation, and automation in the water and wastewater industry. Jay first entered the industry working for an automation integrator after college. 10 of the last 26 years at CSU Jay has been a project manager for many projects including a new 20 MGD greenfield wastewater treatment plant and currently managing a new 50 MGD water treatment plant project. NADINE ARENS, Consultant, Process Dynamics and Control Group Nadine Arens is a Consultant in the Process Dynamics and Control Group in DuET. After graduating from the University of Houston, she joined the DuPont field engineering program and implemented new Bailey INFI-90 process control systems in DPC plants for 10 years. She then transferred to the Kalrez® business for 7 years as Quality Manager and Six Sigma Black Belt. In 2008, she moved to the DuET Process Dynamics & Control group as a consultant. Her expertise includes batch control, dynamic modeling and operator training stations. Nadine is the System Manager for ABB Bailey INFI-90 system at the Corporate Integration and Testing Center. Since joining PD&C, Nadine has been involved in implementing projects in TDC3000, ABB Bailey INFI-90, Rockwell RSLogix and Siemens PCS7. Gerrie Process Group Gary McKenzie, Process Control Specialist Gary McKenzie has been working with automated control systems for over 16 years with Gerrie Electric, a Rockwell Automation Distributor. Gary spent the first several years of his career as a Distributor Automation Specialist supporting Allen-Bradley control systems of all varieties. He now manages the Process Control Group within Gerrie Electric, a group that is completely dedicated to designing and deploying automated control systems within process applications using Rockwell Automation technologies. He has worked with process systems across many industries including steel, food and beverage, pharmaceutical and water/waste water treatment. Over the last 7 years, Gary has been involved on several projects replacing large legacy DCS systems, requiring the design of both the control system and migration strategies. INDUSTRIAL FURNACE COMPANY MICHAEL HILTON, DIRECTOR OF ELECTRICAL AND INSTRUMENTION Michael began his career in the electrical field nearly 25 years ago in the military. During that time, he designed and deployed the first wireless network to be used in a combat area. After the military, he worked in the machine tool industry designing “cutting edge” control systems for the automotive industry. In his current role, he works in the waste water, mining, and oil and gas industries using Multi-Hearth and Fluidized Bed Furnace control systems to produce products in a “clean and green” manner. Recently, these projects included heat recovery systems to produce clean power and reduce fuel consumption. These projects utilize most of the Rockwell Automation product line, including both software and hardware interfacing to Fieldbus technology. He has experience with Rockwell Automation Advanced Process Control function blocks and has also worked with - 17 - MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS customer Advisory Board DUPONT ELECTRICAL AND COMMUNICATIONS GROUP MEET THE CUSTOMER ADVISORY BOARD Pavilion solutions. JNE AUTOMATION DARREN TWYFORD, CONTROL SYSTEM SPECIALIST Darren Twyford has been working in the Process Automation field for nearly 15 years in the consulting engineering arena. His experience has been primarily in the metals industry, providing electrical, instrumentation and automation solutions for the iron and steel industry worldwide. Recent projects also include DCS migration into the Rockwell platform. With his previous work experience, Darren is currently providing process control systems from concept to design to commissioning and start up. With exposure to varied control system platforms and manufacturers, Darren has gained critical insight into today’s demanding process requirements and how to achieve sustainable automation. Kimberly-Clark Corporation Bob Kilas, Electrical AND Controls Technical Leader Bob has over 30+ years of experience in electrical and controls engineering. He began his career as an Instrument and Controls Engineer in power generation (right at the time of Three Mile Island). He then worked as a site Instrument and Controls Engineer at a petrochemical facility. Over the last 25+ years Bob has been working at Kimberly-Clark primarily supporting the tissue business. He has held various positions within Kimberly-Clark including an Electrical and Controls Engineer, a Project Electrical and Controls Engineer, a Project Leader, a Site Engineering and Maintenance Manager, a Staff Engineering Manager, and currently an Electrical and Controls Technical Leader. Bob is responsible for developing electrical and controls strategies and setting technical direction regarding the use of electrical and controls technologies. He is also responsible for driving the development and use of engineering best practices and standards. Kraft Foods North America bob pegHer, Staff Engineer – Electrical/Process Controls Bob has over 25 years of experience in electrical engineering and process controls design, primarily as a consultant to the steel, automation, and consumer packaged goods industries. Since 1993, he has been with Nabisco (now Kraft) working as a Supervisory Process Controls Engineer, Plant Electrical Engineer, and Process and Packaging Group Design Leader. Bob currently supports the Kraft Foods North America Snacks Sector as a staff engineer at the Technology Center in East Hanover, NJ. Bob is responsible for all aspects of electrical engineering and process controls design for large capital execution projects. His focus is on developing and maintaining corporate engineering standards, project execution methodologies, safety related control systems, batching systems, and production line integration strategies. Bob helps to maintain and strengthen relationships with Rockwell Automation (Kraft's Strategic Automation Partner), key Rockwell Automation solution providers, systems integrators, and OEMs. Pacific Gas and Electric (PG&E), Diablo Canyon Power Plant (DCPP) Kris D. Jentzsch, Project Engineer – Project Services, Instrumentation and Controls Obsolescence Management (ICOM) Kris was born and raised in Salt Lake City, Utah, and spent over 8 years with the U.S. Navy Nuclear Power Program. He joined PG&E in 1991 at DCPP, performing concept, design, testing, implementation and maintaining of control systems to replace obsolete systems for Liquid and Gaseous Waste Systems, Diesel Generator monitoring, Plant Process monitoring and Reactor Protection. He holds a B.S. in Nuclear Engineering Technology (Excelsior College), a B.S. in Mechatronics Engineering (Mechanical Engineering Core) and a M.S. in Mechatronics Engineering (Electrical Engineering Core) from CalPoly University, San Luis Obispo, California. Pfizer, Inc. Jim LaBonty, Director – PGE Process Automation Jim LaBonty draws on over 30 years of process automation and process control experience aiding Pfizer’s Global Engineering division’s process automation engineering team. Jim contributes engineering leadership to automation engineering technical direction, scope and engineering support for Pfizer specialty care, biotech, pharmaceutical, consumer, animal health and nutrition, 79 global manufacturing sites, authoring overarching automation strategy for each manufacturing division and overseeing global capital projects within these manufacturing sites. Jim also significantly contributes to the Pfizer global Automation Community of Practice—a virtual team of Pfizer’s highly skilled automation professionals that focus and leverage their collaborative energies and skills across Pfizer. This global network team leverages APQC formal community of practice (CoP) principals to provide the framework to collectively work together developing company-wide automation best practices; automation standards; automation guidelines and common unified applications; and harmonized verification and documentation approaches. The central engineering team also performs technical site and project design reviews of manufacturing automation system architectures (MES scope thru automation control systems). Jim holds a B.S. in Chemical Process Solutions User Group annual meeting - November 14-15 - 18 - MEET THE CUSTOMER ADVISORY BOARD Engineering from University of Maine at Orono, a B.S in Electrical Engineering from the Rochester Institute of Technology, as well as a M.S. in Management (Executive M.B.A.) from Purdue University. Pharmaceutical Manufacturer* Don Geers, Senior Process Controls Engineer Don Geers has been working in the Process Controls field for over 30 years as an end user, systems integrator, and back to an end user. His experience has been across a wide variety of industries including chemical, food, and pharmaceutical processes. He has been heavily involved with design, installation, and startup of process automation solutions with emphasis on electrical, instrumentation, and computer controls. Integration with various DCS control systems as well as thePlantPAx process automation system have given him experience in a wide variety of control devices. Don’s primary focus is maintaining and enhancing the process control system within his facility. Don has an Electronics Engineering degree as well as a Level III Certified Control System Technician with the International Society of Automation. *Unnamed due to corporate policy . PREMIER SYSTEM INTEGRATORS LARRY GRATE, P.E., ACCOUNT DELIVERY MANAGER, DECATUR BUSINESS UNIT ProctEr & Gamble, Inc. PAT DOLLARD, PROCESS CONTROL SECTION LEAD Pat Dollard began working in the digital systems labs at Procter and Gamble in 1979, using “powerful” 64KB real-time computers for batch control. He has continued to work on, and lead, Process Control projects for various divisions within P&G, such as food and beverage, health care and beauty care. Currently, Pat leads both the Process Control Section and the Manufacturing Applied Information Technology Section in P&G’s Corporate Engineering. He earned a B.S. in Chemical Engineering from the University of California, Santa Barbara. Shell Global Solution Trung Nguyen, project engineer Trung Nguyen is an electrical engineer with 25 years experience in applied industrial automation. He has worked on projects in many industries such as pharmaceutical, biotech, chemical, metallurgy, petro-chemical and pulp and paper. These projects have allowed him to gain concrete experience in project lifecycle implementation for industrial control systems such as DCS, PLC/ HMI, SCADA, Batch, Data Historian, MES, ERP Integration and networking for industrial applications. He always updates his technical abilities that are complemented by his organizational skills, which are assets in his roles as automation technical lead within the Shell Global Solution organization. - 19 - MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS customer Advisory Board Larry joined PREMIER in 2007 and is responsible for system architecture and design, as well as account management for projects completed out of its Decatur, AL location. As a Co-Op student many years ago, Larry had the unique opportunity to see the migration from single loop controllers and hard-wired relay logic, to PLC-based control and then several DCS implementations in a few short years. Larry has over 20 years of experience in automation and controls, with both DCS and PLC-based systems. He has completed several projects migrating legacy DCS solutions to Logix-based solutions, as well as multiple new installations using object based coding principles and the PlantPAx library. Larry has done various projects using the Advance Process Control blocks in Rockwell solutions as well as similar functions in DCS systems. Larry has experience in pulp and paper, food and beverage, metals, and automation industries. Larry has a B.S. in Engineering from Mercer University in Macon Georgia, and his PE license in control systems. Worried about profits disappearing into thin air? Upgrade your legacy DCS to PlantPAx. There is a cost to doing nothing with your aging DCS system and the dedicated resources needed to support it. Mitigate your risk. Protect your future with the flexibility of the PlantPAx™ Process Automation System. Learn more at Discover.RockwellAutomation.com/Go/DCSMigration. - 20 - Copyright © 2011 Rockwell Automation, Inc. All Rights Reserved. AD RS2255-R1P PlantPAx is a registered trademark of Rockwell Automation, Inc. optional educational sessions - 21 - - 22 - optional EDUCATIONal SESSIONS These are optional sessions and free to all attendees. You can receive Professional Development Hours (PDH) and the corresponding documentation. These optional Educational Sessions are being offered to provide technical information to attendees. The topics were derived from suggestions made by the PSUG Customer Advisory Board. Monday Time 8:00 a.m. 9:00 a.m. CC10A ED-01 PlantPAx System Overview ED-09 Improving Safety and Reliability with High Performance HMIs CC10B ED-02 Using the Process Library Room CC11A ED-05 Turning Process Data into Production Intelligence ED-13 Historian: Overview Strategies for Collecting and Analyzing Data CC11B ED-06 Process Networks and Security ED-14 Process Safety Systems for Critical Control CC12A ED-07 Automation Lifecycle ED-15 Advanced Process Control: Optimizing Your Process Operation CC12B ED-08 Introduction to FactoryTalk PharmaSuite and CPG Suite ED-16 Alarm Management Best Practices CC10C CC10D tuesday Time Room 10:15 a.m. CC10C ED-17 An Introduction to PID Performance Metrics: What Does it All Mean CC10D ED-18 Building the Virtual Plant for PlantPAx Based on Simulation Software CC11A ED-19 Three Simple Steps to SCADA System Security CC11B ED-02 Using the Process Library CC12A ED-05 Turning Process Data into Production Intelligence CC12B ED-04 The PlantPAx System with VM-Ware Ready Software - 23 - MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS optional educational SEssions ED-03 Integrating Devices into Process Control Systems ED-04 The PlantPAx System with VM-Ware Ready Software ED-10 PlantPAx Design Considerations Using Architecture and Sizing Tools ED-11 Process and Power Control: Driving Continuous Improvements ED-12 Implementing PlantPAx Logix Batch and Sequence Manager optional EDUCATIONal SESSIONS ED-01 PlantPAx System Overview Presenter: Jason Wright Gain a comprehensive perspective on the capabilities of the PlantPAx system including system high availability. 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 designs. ED-02 Using the PlantPAx Process Library and Engineering Tools Presenters: Dale Reed and Russ Brandes Reduce your process application development efforts through the use of process library objects and the Logix View Utility, an engineering workstation software that helps reduce configuration time of Logix controllers and HMI applications. The session defines the operation of key objects, explains the technology behind them and demonstrates deployment in a process system. ED-03 Improve Design and Installation Flexibility through Field Device Networks and System Integration Presenter: Brian Root Simplify the connection of smart process instrumentation via EtherNet/IP, HART, Foundation Fieldbus, and ProfiPA through the device integrations tools and documents available with PlantPAx. You’ll see how to implement Process Library objects for instrumentation and gain valuable insight into the ROI associatd with easy device integration for our strategic partners such as Endress + Hauser. ED-04 Constructing a PlantPAx System with VM-Ready Software Presenter: Tony Baker Virtualization is a software technology that is rapidly transforming the enterprise information landscape and fundamentally changing the way hardware is allocated. The technology dynamically allocates servers and other hardware resources when and where they are needed enabling you to run multiple software applications on a single server. Learn about the VMware-ready software products that have been added to the PlantPAx system to help leverage the benefits of virtualization. ED-05 Turning Process Data into Production Intelligence Presenters: Matt Giordano and George Peters 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. ED-06 Process Networks and Security Presenters: Brad Hegrat and Pete Morell Learn about the commonalities between your current process configurations and IT infrastructures and the compelling reasons for change. Gain insight into the design principles necessary to secure your ICS, DCS and SCADA infrastructure for the future. ED-07 Identify, Mitigate and Eliminate the Risks of Process Automation Obsolescence Presenter: Lonnie Morris As process automation systems approach the end of their expected life, the availability of parts and resources become more difficult to obtain, until the point one or both are exhausted. Learn how to proactively manage your automation system lifecycle to maximize uptime, prioritize migrations, and bridge to new technology. Process Solutions User Group annual meeting - November 14-15 - 24 - optional EDUCATIONal SESSIONS ED-08 Introduction to FactoryTalk PharmaSuite and CPG Suite Presenters: Michael Gay and Steve Lichon This session provides a basic introduction discussing the general functionality, technology and value propositions behind FactoryTalk CPGSuite for the food, beverage and consumer packaged goods industries and, FactoryTalk PharmaSuite tailored for the needs of the pharma and biotech industries. ED-09 Improving Safety and Reliability with High Performance HMIs Presenter: Mike Carrigan, Vice President, PAS For over thirty years, 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 Human-Machine Interfaces (HMIs) increases the situational awareness of your operators, resulting in safer and more reliable operations. This session shall include: History of HMI’s in the Processing Industry, benefits to implementing High Performance HMIs, Methods and technologies to design and implement High Performance HMIs ED-10 PlantPAx Design Considerations Using Architecture and Sizing Tools Presenter: Alex Cherpakov Gain an understanding of the PlantPAx core system architecture, hardware, software and performance boundaries. You’ll learn about system sizing rules derived from our process system characterization and how those are applied when defining a PlantPAx system. Learn how to use the Process System Estimator (PSE) within the Integrated Architecture Builder (IAB) to size a PlantPAx system for an application. ED-11 Process and Power Control: Driving Continuous Improvement ED-12 Implementing PlantPAx Logix Batch and Sequence Manager Presenter: John Parraga 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 in 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. You can start small and easily scale into a comprehensive software solution without costly reengineering and testing. ED-13 Historian: Overview Strategies for Collecting and Analyzing Process Data Presenter: Jan Pingel A distributed historian strategy produces strong advantages. Learn how FactoryTalk Historian delivers a scalable, modular, synchronized methodology for collecting, maintaining and analyzing process data at each level of production operations. ED-14 PlantPAx Process Safety System for Critical Control Presenter: Allan Rentcome Learn how the PlantPAx high availability and redundant capabilities will help you with the process safety requirements and technology to further protect process assets, people and the environment. You’ll explore the broad range of scalable solutions possible using PlantPAx. - 25 - MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS optional educational SEssions Presenter: Sergio Gama Learn how the integration of motor control devices to the process control system leverages your investment in automation to support a continuous improvement strategy for your plant. Maximize your asset availability, improve time to market, enable an energy management strategy, and protect your personnel and assets when you combine PlantPAx with Allen-Bradley motor control devices across EtherNet/IP. optional EDUCATIONal SESSIONS ED-15 Advanced Process Control: Improving Yield and Throughput Presenter: Ric Snyder To remain competitive today, process manufacturers must ensure they are getting maximum utilization of their existing assets before initiating costly capacity expansion projects. PlantPAx Advanced Process Control portfolio provides a comprehensive suite of tools and applications to assist our customers in improving product yield and process throughput, from model-based regulatory control blocks to Model Predictive Control and Optimization applications for difficult to control process units. ED-16 Alarm Management Best Practices Presenter: Jason Wright Do you or your customers have an ineffective alarm system that plant operators tend to ignore? Have you heard about ISA-18.2 or EEMUA-191 and wonder what they entail? This session will introduce you to the current industry direction related to alarming and elaborate on some of the best practices and performance benchmarks being recommended. It’s perfect for anyone concerned with solving challenging alarm management issues. ED-17 What Does It All Mean: An Introduction to PID Performance Metricss Presenter: Bob Rice, Vice President, Control Station Real-time monitoring to identify under-performing PID control loops has become an integral part of preventative maintenance. Among others, the rising costs of energy and production inputs are driving forces. While many software solutions display performance metrics, it is important to understand the purpose and limitations of these performance assessment techniques. This session will review performance measures from simple statistics to complicated model-based performance criteria. By understanding the underlying concepts of the various techniques, participants will gain an understanding of the proper use of performance criteria. An evaluation of techniques with tips and suggestions will be provided. ED-18 Building the Virtual Plant Using Simulation Software Presenter: Martin Berutti, President and COO, Mynah Operations managers at process plants have greater challenges than ever before. Worker safety, environmental stewardship, process uptime, and conservation of plant resources have been common goals for plant operations for the last several decades. However, today additional challenges are stretching the limits of plant operations making the job of running a process plant more difficult than any other time in history. Operations managers that use Rockwell Automation's PlantPAx have a powerful tool available to combat these challenges. The Virtual Plant based on MiMiC Simulation Software is an enabling technology that allows process plants to address these issues and other operational challenges. ED-19 Three Simple Steps to SCADA Systems Security Presenters: Gilbert Kwan, Automation Solutions Engineer, Harris Group Gabe Shones, Senior Automation Engineer, Harris Group Today, utilities are asked to do more with less and decreased operational budgets while government regulations have increased. These demands have forced utilities to automate and integrate their operations to collect more process information from their facilities so that they can make supportable smart decisions. SCADA vendor technology has responded by reducing the cost of hardware and software, while improving performance and providing open integration tools. As a result, organizations have been transitioning from proprietary systems to less expensive, standardized technologies and common networking protocols used by the Internet. This presentation will help utilities understand SCADA security and apply three simple steps that can help secure a SCADA system today. Process Solutions User Group annual meeting - November 14-15 - 26 - town hall voting sessions town hall voting sessions - 27 - Ladies and gentlemen, children of all ages: welcome to the Fair! After the PSUG meeting, join Spectrum Controls for some good old fashioned fun and games! Tuesday November 15, 5:30pm, Regency Ballroom Hyatt Regency Chicago, West Tower 151 E Wacker Dr, Chicago Process Solutions for OEMs, Machine Builders and Systems Integrators Analog+HART I/O: The building blocks for your enterprise HART device network. Using your existing device management software, our modules enable management of HART instruments on POINT I/O™, CompactLogix™, and legacy PLCs. Universal Analog: A complete family of Universal analog input modules for 1769, 1756, 1746, 1762 & 1794 platforms, and coming soon on Micro800! Mix thermocouple, RTD, voltage, current or resistance on one module. PLC Remote Access: WebPort allows you to remotely access and control PACs/PLCs via the Internet or on-board modem. Monitor systems, get reporting on exception, and visualize data using a web interface. The perfect remote monitoring solution! NEW! HART for POINT I/O 425-746-9481 | www.spectrumcontrols.com | Automation Fair Booth 101 - 28 - To wn Hall V oting 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 Room CC11A Monday, 10:00 a.m. Tuesday 9:00 a.m. 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 Room CC10D Monday, 10:00 a.m. Tuesday 9:00 a.m. 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 Safety and Critical Control Room CC11B Monday, 10:00 a.m. Tuesday 9:00 a.m. PlantPax Process Safety and Critical Control is the combination of products from Rockwell Automation and ICS Triplex, a Rockwell Automation company. The PlantPAx system supports expanded process safety offerings that provide high levels of availability of safety in process critical control applications. PlantPAx System Core Room CC10A Monday, 10:00 a.m. Tuesday 9:00 a.m. and 10:15 a.m. The PlantPAx core system consists of the components required to engineer and maintain a process system. This includes system servers, workstations and controllers. The core system also includes interfaces to field devices, including I/O modules, linking devices and bridges, as well as the network infrastructure. PlantPAx Process Information Room CC11A PlantPAx System Tools and Utilities Room CC10B Monday, 10:00 a.m. Tuesday 9:00 a.m. and 10:15 a.m. The PlantPAx solution includes additional tools that can be used to develop your process application, in conjunction with the standard Integrated Architecture™ tools such as RSLogix 5000, Process System Estimator, Process Library and IAB. PlantPAx Device integration and Asset Management Room CC10C Monday, 10:00 a.m. Tuesday 9:00 a.m. The PlantPAx system allows for integration of field device components such as interfaces, instruments, actuators, drives, and field devices. This includes EtherNet/IP, DeviceNet, HART, FOUNDATION Fieldbus, and PROFIBUS PA. - 29 - MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS town hall voting sessions Monday, 10:00 a.m. Tuesday 9:00 a.m. 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. In Chassis, Redundant, Self Healing, Drop & Add Modules The Hard Way The Easy Way Huge Installation Savings...No Operational Downtime Transparent “Plug-and-Play” Integration Multi-Drop Ethernet Communication Ultra-High Speed Healing Time Simple “One Size Fits All” Cable Architecture Multiple Vendor Software / Hardware Compatibility Low Risk Legacy System Migration ULTRA-HIGH SPEED, REDUNDANT, FAULT TOLERANT, SELF HEALING FIBER OPTIC COMMUNICATION NETWORKS For ROCKWELL AUTOMATION/ ALLEN-BRADLEY Ethernet, EtherNet/IP, ControlNet®, Data Highway Plus, Remote I/O, DH-485, DF1, Modbus, Modbus Plus, and RS-232/485 Communication - 30 - Phoenix Digital 7650 East Evans Rd. Bldg. A Scottsdale. AZ 85260 Email: [email protected] Phone: +1 (480) 483-7393 Fax: +1 (480) 483-7391 e-mail: [email protected] customer apPlication sessions customer presentations - 31 - are you confident With the protection provided in your plant? We’ve got you covered no matter what kind of protection you need. Pepperl+Fuchs has long been associated with intrinsic safety and explosion protection technology in the chemical and oil & gas markets. Coupled with this expertise are new generation fieldbus products, wireless HART equipment, innovative corrosion monitoring techniques, rugged purge/pressurization systems, and a powerful ability to combine all of our solutions into customized packages. Get protection you can depend on. Pepperl+Fuchs is protecting your process. n World-leading supplier of intrinsic safety interface devices n Complete solutions designed to customer specifications n UL508A and UL698A accreditation for custom cabinets n Global support, worldwide manufacturing, unparalleled service n Advanced diagnostic accessories for fieldbus installations Pepperl+Fuchs, Inc. Twinsburg, Ohio 330.486.0002 www.pepperl-fuchs.com - 32 - CUSTOMER APPLICATION sessions Agenda This year's presenters represent companies from many different countries and industries. Each presentation addresses different applications, critical issues, best practices and solution benefits. Monday Tuesday Time Room 2:45 p.m. 3:45 p.m. 11:15 a.m. 1:15 p.m. 2:15 p.m. 3:30 p.m. CC10A CS-21 Johns Manville CS-02 Applikon Biotech CS-20 Industrial Furnace CS-24 London, Ontario Regional Water Supply CS-13 Engineering Unlimited CS-10 DuPont CC10B CS-23 Momentive Specialty Chemicals CS-10 DuPont CS-03 Automated Control Concepts CS-08 Cynar, PLC CS-01 AMC Medicion y Control CC10C CS-24 London, Ontario Regional Water Supply CS-15 FPD Power Development CS-26 Sementes Selecta S.A. CS-06 BSBios/Intecnial CS-21 Johns Manville CS-17 FPD Power Development CC10D CS-04 Bachelor Controls CS-05 Bama Companies CS-04 Bachelor Controls CS-13 Engineering Unlimited CS-12 ECS Solutions CS-02 Applikon Biotech CC11A CS-19 Huhtamaki CS-26 Sementes Selecta S.A. CS 01 AMC Medicion y Control CS-17 Grantek Systems Integration CS-19 Huhtamaki CS 14 EZSoft CC11B CS-08 Cynar, PLC CS-07 Carvajal Pulpa y Papel CS-11 Eastman Chemical CS-05 Bama Companies CS-27 Unilever CS-06 BSBios/Intecnial CC12A CS-14 EZSoft CS-16 Grantek Systems Integration CS-18 Holcim Cement CS-24 Momentive Specialty Chemicals CS-11 Eastman Chemical CS-25 SAFCO Engineering CC12B CS-22 Malisko Engineering CS-25 SAFCO Engineering CS-12 ECS Solutions CS-09 Dr. Reddy's CS-03 Automated Control Concepts CS-09 Dr. Reddy's CC12C CS-20 Industrial Furnace CS-27 Unilever CS-22 Malisko Engineering CS-18 Holcim Cement customer Application Sessions - 33 - CS-07 Carvajal Pulpa y Papel CUSTOMER APPLICATION sessions CS-01 AMC Medicion y Control Oil and Gas Digital Monitoring and Control System for Offshore Platforms Presenter: Alfredo M. Cardenas, Automation Director AMC implemented a PlantPAx system with Foundation Fieldbus technology in a low consumption system on an offshore platform. Learn how the full system integration (DMCS and SIS) provided optimized commissioning and startup , easy maintenance through standardized libraries and configuration tools and increased operational efficiencies. CS-02 Applikon Biotech Life Sciences/OEM Standarizing on PlantPAx System for Advanced Bioreactor Systems Presenters: Lawrence Forman, Director of Project Management Pete Vranesich, Service Engineer Applikon Biotechnology is a world leader in developing and supplying advanced bioreactor systems from laboratory scale to production scale. This session will discuss Applikon’s new multi-reactor control system designs to standardize on a commercially available controller platform (Logix) and superior physical design for Applikon’s iControl series of bioreactors. CS-03 Automated Control Concepts Life Sciences Implementation of a PlantPAx System in a Regulated Industry Presenter: Victor Ronchetti, Senior Vice President and Technical Director Projects for regulated environments always involve substantial challenges. In designing and implementing a new bioprocess manufacturing facility, ACC strategically used available tools and technology to implement, commission, and qualify the PlantPAx system more efficiently. FactoryTalk AssetCentre was used to maintain control of the software from over 15 different vendors, including skid builders, greatly reducing the time required for coordination during commissioning. CS-04 Bachelor Controls Food and Beverage Making World-Class Bourbon with PlantPAx Presenter: Jerry Leuthold, Project Manager Kentucky produces 95 percent of the world’s bourbon and the industry is expanding faster than any time since prohibition. A new Wild Turkey green field distillery has the latest in modern technology and will double capacity. Learn why the PlantPAx system was selected over an Emerson Delta V system, the objectives of the project management team, and the benefits that PlantPAx provided. CS-05 Bama Companies Food and Beverage Upgading Existing Batch Process to PlantPAx System and FactoryTalk Batch Presenter: Sean Nichols, Control Engineer The Bama Companies replaced their current control system with the PlantPAx process automation system. Learn about the challenges that faced them prior to replacement, the criteria in selecting the new system and the structured process necessary for migrating. With ongoing involvement of key stakeholders, Bama was able to successfully implement the new, flexible system with controlled risk. Process Solutions User Group annual meeting - November 14-15 - 34 - CUSTOMER APPLICATION sessions CS-06 BSBIos/Intecnial Biodiesel/OEM PlantPAx Distributed Control System for Greenfield Soybean Processing Plant Presenter: Marcelo Cantele, Director, Intecnial A new greenfield Soybean Processing Plant selected PlantPAx for complete process control and asset management was engineered and implemented by INTECNIAL, a company level OEM. The system includes a complete distributed system with six PACs, 1.000+ I/O, 200+ HART instruments distributed in redundant ControlNet network and 300 intelligent motor control connected in DeviceNet. Learn how the PlantPAx integrated system allowed the customer to implement start-up in phases and in a very short amount of time. CS-07 Carvajal Pulpa y Papel Pulp and Paper PlantPAx and SIS Solution for a Recovery Boiler at Pulp Plant Presenter: Mario Lopez, Engineering and Project Manager and Jorge Quesada, Automation Manager This session will detail the Colombian paper producer, Carvajal Pulpa y Papel, was facing difficulties in meeting process safety compliance and regulations such as NFPA 85 and 86 and Boiler Advisory Committee (BLRBAC) for its recovery boiler. Their legacy systems were ineffective and posed a challenge in solving their issues. This session with detail the process they followed to choose and implement a PlantPAx system that exceeded their requirements for high availability, tight integration with their power solutions, and provided one integrated control platform for their generation area. CS-08 Cynar, Plc Diesel/Sustainability Rockwell Automation Helping Cynar Convert End of Life Plastic Into Diesel Presenter: Michael Murray, Chief Executive Officer The Cynar technology is a system that converts a variety of waste plastics into low sulphur hydrocarbon fuels. The technology incorporates liquefaction, pyrolysis and distillation. Learn how Cynar supported the commercialization of this technology by leveraging local Rockwell Automation resources and the PlantPAx system with the end result being a fully packaged, modularized skid which can be easily transported and integrated within an existing plant. CS-09 Dr. Reddy's Life Sciences Process Automation Challenges in Generic API Plants in India Presenter: Ramachandra Pandian, Director and Head/Central Engineering - CTO Multi-product API facilities are very complex in nature and have their own dynamics. There are various stages and numerous steps in manufacturing one API. Designing, commissioning and qualifying a complete process automation system is always a challenge. Moving from a complete manual operation to a very high level of automation was also challenging. Our journey started eighteen months ago. We succeeded because of strong teamwork in the design space and stong in-house project support capabilities in the manufacturing space. Our process and safety requirements were superbly matched by technical solutions provided by the world's best automation corporations. CS-10 Dupont Performance Coatings Specialty Chemicals - 35 - MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS customer Application Sessions A Process Control System Prototype for Acrylic Polymerization Reactors Presenter: Harry Gianakis, Principal Investigator Across DuPont Performance Coatings (DPC) manufacturing sites, process control assets are aging, while limited resources are available to support their replacement. Control software configuration is the most complex and expensive step in the installation of new control systems. This session will discuss how deployment of selected control system prototypes can simplify installation, reduce cost and deliver additional benefits. We worked with Rockwell Automation engineers to develop a new process automation system for a Pilot Polymerization Facility. The PlantPAx system was initially set-up at the Corporate Integration and Testing Center and was interfaced to a DuPont™ TMODS™ model of the facility. This setup was used for control system check-out, recipe testing and operating procedure development well before the facility was constructed. An operator training simulation tool is being developed using the same simulation model of the facility, emulated controllers, virtual images of the servers and a virtual process control network. CUSTOMER APPLICATION Sessions CS-11 Eastman Chemical Chemical Cybersecurity within the Chemical Sector Presenter: Mark Heard, Systems Associate In an environment of growing cyber threats, a chemical plant is not safe unless it is secure. The Chemical Sector, in partnership with U.S. Department of Homeland Security, published a Roadmap to Secure Control Systems in the Chemical Sector. A public-private working group formed focused on the implementation of the Roadmap. This session will describe the collaborative efforts underway in the working group, the progress made and resources available to support the goals. CS-12 ECS Solutions, Inc. Food and Beverage Making ISA-S-88 Control Systems More Affordable Presenter: Randy Otto, Vice President ECS Solutions has developed software which delivers a high-feature control system at or below the cost of a simple recipe system, making ISA S-88 (batch) control systems much more affordable. ECS will present a highly successful project recently completed. With this software ECS started production trials on a 60 unit FactoryTalk Batch system only 11 weeks after purchase order and at 25% lower cost than a traditional recipe system. Customer ROI exceeded expectations by $1M (US) annually. CS-13 Engineering Unlimited Food And Beverage Food Grade Oil Production Facility Utilizes PlantPAx to Improve Operations Presenter: Paul Sprattler, Director of Engineering Discover how PlantPAx was utilized throughout this grain crushing oil production facility to deliver operational effectiveness and increased maintenance benefits. Project scope included plant utilities—boilers, steam heating, cooling, HVAC and more. Discussion will cover advantages of programming with PlantPAx objects, efficiencies gained from component feedback, and business improvements gained through operational reporting. CS-14 EZSoft, Inc Wastewater/Life Sciences Using Production Intelligence for Wastewater Pre-Treatment Complianace Presenter: Martin Fallon, Vice President – Sales New regulatory standards required a drug manufacturer to keep better records and better control of its wastewater pre-treatment operations. They deployed FactoryTalk Historian SE and FactoryTalk VantagePoint to gain greater visibility into its pre-treatment process, meet excursion responses and reporting regulations, and improve discharge accuracy. The solution will be able to be expanded to other operations in their facility. CS-15 FPD Power Development Power Generation New Power Generation Facility Uses PlantPAx to Meet Reliability Goals Presenter: Jeff Gale, Executive Vice President FPD Power implemented a PlantPAx system for a new power generation facility, helping NorthWest Energy prepare for changes to renewable power usage requirements. NERC CIP regulations associated with blackstart facilities change frequently and require additional security measures. This session will demonstrate how the redundant PlantPAx system allows the facility to operate as a 150 Megawatt facility with blackstart capabilities and provides the necessary flexibility to meet these changing requirements. FPD partnered with Rockwell Automation, HiProm, ProSoft and Cisco to deliver a system that meets the demands of NorthWest Energy. Process Solutions User Group annual meeting - November 14-15 - 36 - CUSTOMER APPLICATION sessions CS-16 Grantek Systems Integration, Inc. Water/Wastewater Pump Optimization Using FactoryTalk VantagePoint Presenter: Rick Hargreaves, Sales Manager Energy cost savings are very topical today. Using Rockwell’s FactoryTalk VantagePoint and Grantek’s Pump Optimization plug-in module, users can quickly benchmark how optimized their pumping assets are at the moment and also enjoy the benefits of continuous optimization data. Once installed, reports are accessible via FTVP. This presentation will show users what the plug-in is all about, see samples of real-time optimization reports and trends and understand where best to focus their cost saving strategies. CS-17 Grantek Systems Integration, Inc. Food and Beverage/Specialty Chemical Maximizing Process Efficiency Using Golden Batch Analysis Presenter: Michael Lohmeyer, Regional Sales Manager Many batches are processed with limited or no visibility to adherence to process parameters until after the batch is completed. Learn how your operators can know, visually, graphically, and empirically, how the current batch is progressing compared to a perfect or golden batch. And since this information is displayed to your operators in real time, they will be enabled to make appropriate adjustments to process parameters before the process drifts outside an acceptable limit. In this session Grantek Systems will demonstrate the Golden Batch planning board, they will also demonstrate a Current Batch vs. Golden Batch comparison in real-time. CS-18 Holcim Cement Mining/Cement Network Infrastructure in a Large Process Control System Presenter: Kenny Martin, Senior Process Programmer In order to design and maintain a stable, secure control system, special attention must be given to the network and automation engineers must rely on skills traditionally reserved for IT departments. This presentation describes many of the challenges and lessons learned during the commissioning and startup of the control system at the Holcim Ste Genevieve plant and specifically looks at the importance of strong network infrastructure to a achieve a stable, secure, control system. CS-19 Huhtamaki, Inc. Consumer Goods Process Automation Lifecycle Management Presenter: Stewart Whitlow, Manager, Manufacturing Systems Process automation system migration remains a major issue for end users as they deal with an increased older installed base. In terms of sustainability, older systems can significantly hamper efforts to reduce maintenance costs, improve power management, provide appropriate documents and traceability for regulatory requirements, and much more. The IT-related infrastructure of modern process automation systems also presents many lifecycle management issues of its own. This session is designed to show end users how they can develop a cost effective lifecycle management strategy that addresses the need for sustainability in manufacturing at the same time. MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS customer Application Sessions - 37 - CUSTOMER APPLICATION Sessions CS-20 Industrial furnace Company Mining/Power Leveraging PlantPAx Technology to Survive and Thrive in a Dynamic Business Environment Presenter: Mike Hilton, Director - Technical Industrial Furnace implemented a PlantPAx system with industrial controls, CENTERLINE motor control centers, and varied network connectivity, including ControlNet, DeviceNet and Foundation Fieldbus to bring a brownfield calcinations plant online as a fast track project. The project utilized FactoryTalk Asset Center and RSFieldbus to engineer, install and maintain 800 instruments on Foundation Fieldbus. In addition, it utilized Advanced Process blocks to control large dead-band natural gas process burner loops saving large amounts of fuel and reducing deployment time. CS-21 Johns Manville Building/Construction Roofing Material Manufacturer Migrates Aging DCS to the PlantPAx Process Automation System Presenter: Bos Howard, Electrical Process Control Engineer Johns Manville, a leading manufacturer of premium-quality roofing and roof insulation material, was facing increased downtime, costs and limited diagnostic capabilities due to its aging DCS equipment. They standardized on one system—PlantPAx—to control their process, drives, motion and visualization needs. To understand how the new system works, the staff also performed the installation on their own using pre-built faceplates, permissives and interlocks to meet their specifications. This session will detail their decision to upgrade their process automation system to increase production line reliability and throughput, create reusable applications that could be applied to multiple production lines and, at the same time, reduce maintenance and training costs. CS-22 Malisko Engineering, Inc. Food and Beverage PlantPAx Virtualized System Reduces Capital and Maintenance Costs Presenter: Steve Malyszko, President and Steve Schneebeli, Lead Systems Engineer Malisko Engineering recently deployed a PlantPAx system to replace a high-maintenance legacy control system at a major U.S. food manufacturer. The legacy system was semi-automatic, required constant operator interaction and ran on an obsolete HMI/Controller platform. This session will demonstrate how Malisko saved the client capital and maintenance costs by using redundant virtualized servers, thin client HMIs and PlantPAx to provide fully automatic batch controls with Phase Manager, CIP sequencing, local and remote alarm notification, historical data archiving, secure VPN remote access and a framework for a multi-plant FactoryTalk VantagePoint roll-out. CS-23 Momentive Specialty Chemicals Speciality Chemical Honeywell DCS Conversion at Chemical Plant Presenter: Rob Wood, Global Process Controls Engineering Manager Momentive is a global leader in specialty chemicals and resins and serves the forest products, building and general industrial industries. Learn how Momentive, with the help of Rockwell Automation, converted their legacy Honeywell DCS system to a PlantPAx system to meet their project objectives and business goals. cs-24 Regional Water Supply, London, Ontario Water/Wastewater SCADA System Upgrade of a Major Water Distribution System Presenter: John Walker, Operations Manager A complete retrofit of the main water treatment SCADA systems for the City of London and surrounding municipalities was undertaken to replace old equipment and enhance functionality and reliability. The new system includes controllers and distributed I/O, operator interface, dual SCADA servers, a historical plant data RS SQL database, and SCADA document management systems. Project requirements equated to actual implementation will be discussed including lessons learned. Process Solutions User Group annual meeting - November 14-15 - 38 - CUSTOMER APPLICATION sessions CS-25 SAFCO Engineering, S.R.L. Oil and Gas A Fire and Gas Integrated Solution for Middle East Refinery Plant Presenters: Luca Germani, Managing Director, Gianbattista Zago, Sales and Business Development Director SAFCO, a system integrator and leader in fire and gas solutions for the Oil and Gas industry, is working on the design, supply and commissioning of a fire and gas system for a large Middle East refinery. The system is based upon a PlantPAx integrated solution composed of ControlLogix PACs in redundant configuration and fault tolerant servers with FactoryTalk View SE—all connected via a redundant Ethernet network. The refinery requested that a SAFCO-LIB addressable fire panel be fully integrated into the PlantPAx system in order to guarantee total protection of the plant. CS-26 Sementes Selecta S.A. Biodiesel PlantPAx Process Control System for Soybean Processing Plant Presenter: Jales G. Tavares Jr., Utilities and Maintenance Manager Sementex Selecta, one of the main soya bean product producers in Brazil, selected PlantPAx as its plant process automation system for their new soybean plant. The system includes a complete distributed sytem with: 11 controllers; 1,200+ IO; 800 HART instruments distributed in a redundant ControlNet network; 900 intelligent motor controls connected in DeviceNet. In addition, it included 2 redundant operation servers with 10 operator workstations, an engineering workstatin, field local PanelView and Asset Management server with calibration management and process device configuration. The application was engineered and implemented by IASTECH, a Process Solution Provider. This session will discuss the selection process and detail the system and its implementation. CS-27 Unilever HPC Consumer Goods Legacy DCS Migration: Justification and Phased Migration Presenter: Steve Berkos, Senior Controls Engineer, DCS Migration Project Manager The DCS migration justification and vendor selection process began in 2008 and experienced several time interruptions. In 2010, Unilever completed their packaging line upgrade and could finally begin the long awaited phased migration of their legacy Provox DCS. The Unilever team was able to get senior management buy-in by identifying the operational risk of the existing infrastructure. The PlantPAx low risk phased migration was selected unanimously by the Unilever team. This session will detail the justification process and the different phases of this three-year migration plan. - 39 - MCCORMICK PLACE WEST -- CHICAGO, ILLINOIS Process control. Why stop there? PlantPAx delivers integrated power, safety and process control in one system. With one system you have the needed intelligence to: • Manage your energy consumption and asset performance • Protect your environment, equipment and people • Optimize your daiuly processes and production requirements One system does it all. PlantPAx from Rockwell Automation. To learn more, visit: http://oilandgas.rockwellautomation.com/ Copyright © 2011 Rockwell Automation, Inc. All Rights Reserved. AD RS2233-R1P PlantPAx is a trademark of Rockwell Automation, Inc. - 40 - process solutions users group 2012 - 41 - Save the Date... PROCESS SOLUTIONS USER GROUP 2012 ANNUAL MEETING November 5 and 6 Philadelphia, PA 2012 For more information or early registration contact: Marilyn Muscenti [email protected] 1.440.646.4087 - 42 - Extend your process week.... AUTOMATION FAIR 2012 November 7 and 8 Philadelphia, PA For more information about our process automation solutions, please visit: http://www.rockwellautomation.com/solutions/process/ 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. PlantPAx, Integrated Architecture, Listen. Think. Solve, Total Cost to Design, Develop and Deliver, and PartnerNetwork are trademarks of Rockwell Automation, Inc. All other trademarks and registered trademarks are properites of their respective companies.. October 2011 Copyright ©2011 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
