agenda: rockwell automation solutions & technology for the biofuels industry issues facing the...
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Agenda: Rockwell Automation Solutions & Technology for the Biofuels Industry
• Issues facing the Biofuels Industry• Partnering for Success • Expertise in Europe• Global Supply & Local Capabilities• Delivering Value• Technology and Expertise
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Solutions & Technology for the Biofuels Industry
Presented By:Grant Watkins
Agenda
• Issues facing the Biofuels Industry• Partnering for Success • Global Supply & Local Capabilities• Delivering Value• Technology and Expertise
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Issues facing the Biofuels Industry
• Planning and implementation– Reduce time required for system design and implementation – Lower risks related to plant commissioning
• Process improvement at existing plants– Improve yield – Increase throughput by reducing cycle time
• Reduction of operating costs– Improve maintenance operations– Efficient energy usage– Optimise labour utilisation through training and improved automation– Reduce downtime
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Issues
1/4
Issues customers face
Issues the biofuel industry face:• Pressure to increase operational profits to improve the return on investments and
increase shareholder value:– Increased utility and raw material costs– Tight safety and quality standards– Compliances with new environmental regulations – Pressured to look for alternative raw material– Increasing competition
Solutions we provide:• Process technology for high yields and low operating costs, which are on time with
guaranteed performance and within budget:– Asset optimisation related to process, storage, and utilities utilisation– Saving in consumptions of water, energy and reagents– Reducing wastes applying zero effluent process, dehydration and incineration– Professional and experienced project management
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Issues
2/4
New plant and start up
• When building a new Biofuels plant, any delay in reaching production and designed capacity, seriously affects the viability of your customers investment
• Achieving full production requires a significant investment in electrical equipment and process automation
• Keeping the plant running profitably requires good equipment maintenance procedures and practices, robust process control, and attention to utility usage and electrical demand
• Rockwell Automation has demonstrated a successful track-record in delivering automation solutions that simplify both the design and operation of a Biofuels plant, resulting in energy-efficient systems with maximum availability, commissioned in the shortest possible time
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Issues
3/4
Response
Continuous peak efficiency is essential for any biofuel plant• Reducing engineering and support costs through a single control architecture for process
control & modular packaged plant• Eliminating integration costs through use of “Intelligent Motor Control Centres” • Minimising commissioning through a plant-wide communications architecture• Reducing risk and lowering operational costs by providing “turnkey” modular process skids• Providing connectivity into your customer’s business systems • Maintaining both equipment and personnel safety
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Issues
4/4
Partnering for Success
• Our in-depth understanding of the requirements affecting your industry can help you minimize risk, improve efficiency, reduce process variability and achieve greater profitability
• Rockwell Automation has a successful track record focusing optimisation solutions on the issues you confront
• Rockwell Automation is cooperating with your suppliers and partners in order to get the best solution for you. Strategic Alliances (e.g. with Endress+Hauser) provide you with best of class systems and solutions
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Partnering for Success
1/1
Collaborating to meet your needsPlanning and implementation
Planning and implementationDelivered value of compatibility and interoperability
• Single system for the plant
– Reduces time for instrument and loop configuration– Reduces development time– Reduces training– Reduces risk
Delivered Value: Reduced engineering hoursReduction of project timeline
Delivered Value: Reduced engineering hoursReduction of project timeline
Delivered value of tools and software
• Pre-developed templates for instrument and control loops– Instrument configuration
• Reusable engineering for applications, standard P & I D loop control, standard motor control strategy, standard drive control strategy and standard on/off control (valves)– Reduces development time
Delivered Value: Reduced engineering hoursReduction of project timeline
Delivered Value: Reduced engineering hoursReduction of project timeline
Planning and implementation
Install/troubleshoot hardware quickly
Ethernet/IP
Maintenance Office
Plant Floor
• Continuous operations - add any device online
• Control, configure and collect over the network
• Troubleshooting and production aid - gather any information from any location without programming
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 22/27
IntegratedArchitecture
™
Interoperability testing
• Performance measures jointly established by both companies
• Verified through completion of common test procedures
– Assurance Endress+Hauser field instrument meets Integrated Architecture system interoperability performance
Delivered Value: Ensures a reduced risk solution highlighted by ease of integration and optimum performance
Delivered Value: Ensures a reduced risk solution highlighted by ease of integration and optimum performance
• 50 Endress+Hauser devices tested
Planning and implementation
Example: Sodes Lillebonne -Ethanol Production Plant
BENP Lillebonne Ethanol Plant:– Redundant Fiber Optic Ethernet Network– Redundant ControlLogix with redundant ControlNet card
and power supplies– Redundant Servers and Factory Talk View with 10 operating and
engineering stations– About total 7000 I/Os – 1800 Hart I/Os and approx.
2000 Analog I/O – 200 PowerFlex 700 Drives and SNC FlexStarters
with DeviceNet– Fieldcare Software for Hart device configuration– Cabinets for starters and drives– RSSql and Factory Talk Historian
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Expertise in Europe
2/3
Biofuel Customers in Europe
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Bioetanol de la Mancha– Bioethanol (Alcázar de San Juan – Ciudad Real, Spain),
annual production capacity of 26.000 tonnes
TAGOL - Companhia de Oleaginosas do Tejo, S.A.– Biodiesel (Almada – Lisboa, Portugal)
Tereos– Bioethanol (Lillebone - France), annual production capacity of
820.000 tonnes of corn resulting in 300.000 m3 ethanol
Greenergy International– Biodiesel (Port of Immingham – England),
annual production capacity of 100.000 tonnes
Expertise in Europe
1/3
Expertise in EuropeExample: Biodiesel Plant
Biodiesel Plant (blind story) - ― High Availability: Through redundancy and integrated safety and condition monitoring― Minimised Development, Installation and Start-Up Time: Through integrated multi discipline
control and information solution for discrete, process, batch, motion, drives― Modular and Scalable Process Control Platform: Assures to remain competitive in a
changing environment with the freedom to have the flexibility to integrate changing plant wide operations - making this complex task a simple one
Biodiesel Production Process
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Expertise in Europe
3/3
Serving Europe, Middle East & Africa
Europe, Middle East & Africa:
50+ countries
1000+ professionals executing customer projects
Critical domain expertise & industry knowledge
Leading software, hardware & service solutions
Certified project management
Worldwide delivery
Europe, Middle East & Africa:
50+ countries
1000+ professionals executing customer projects
Critical domain expertise & industry knowledge
Leading software, hardware & service solutions
Certified project management
Worldwide delivery
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Global Supply
2/3
Global Supply & Local Capabilities
• More than 5000 engineers in more than 80 offices worldwide
• Prompt availability and local support, wherever
• Designed to simplify start-up, reduce installed cost and provide plant and production that you need
• Safeguard equipment, increase energy efficiency, streamline production and lower total cost of ownership
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Global Supply
1/3
Delivering Value summary
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
• Integrated discrete, control & power solutions
– Increase reliability with system wide, actionable information
– Improve operational flexibility with proven advanced technologies
• Utility management– Power & Energy Management solutions
to help maximise energy efficiency
• Reliability-centered maintenance– Industry leading condition monitoring– Proactive rotational equipment analysis
• Improve time to market– Design automation tools & templates– Information software products– Integrated Architecture™ system– Proven track record of project management
capabilities– Deployment of tested reusable modular
designs on process systems
• Global life cycle services– Global customer support locally– Consistent, repeatable solutions to reduce
time to market of new projects
• Partners to expand the value of Rockwell Automation solutions
Delivering Value
4/4
Technology and Expertise
• Integrated Architecture• Manufacturing Execution Systems (MES)• Power and Energy Management (PEMS)• Process Technology (Proscon)• Services and Support (MPS + CSM)
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Technology and
Expertise
1/2
Area of expertise
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Site ServicesValidation
Production Facility
Process Modules
Control System
MES
Technology and
Expertise
2/2
Integrated Architecture™
• Real-time information is crucial when making decisions that enhanceproductivity and reduce costs
• Integrated Architecture gives you that kind of responsiveness, as well as the ability to improve operations instantly and facilitate real-time instant reporting to higher level business systems
• Full range of control and information disciplines to help you:– Optimise production– Respond quicker to customer or market demands– Reduce costs faster than before
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
IntegratedArchitecture
™
1/27
Design and ConfigurationIntegrated environments for creating,modeling & programming your productionprocesses
Production Management Real-time coordination across your plant wide production processes
Data ManagementTools & methods to use for collecting, transforming& integrating production information
Quality & Compliance Ensure operational processes and procedures meet standards or specifications
Asset Management Optimises maintenance and plant operations to improve your resource availability
Performance & Visibility Presents a window into the process so you can make better decisions
Production Disciplines
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 2/27
IntegratedArchitecture
™
Core technologies
The Logix Control Platform, the FactoryTalk Integrated Production Management and Performance Suite are linked through a set of core technologies allowing seamless interaction and information flow:
• Logix: multi-disciplined, information enabled and scalable controller family– reducing equipment, training and development costs
• NetLinx: common industrial protocol from plant floor device to IT, improving flexibility and productivity while reducing cost
– Control, Configure, and Collect information and data efficiently• View: a common, fully integrated, scalable visualization strategy across your whole
manufacturing enterprise– Delivering the information you need for more effective decision-making
• FactoryTalk: flexible application development framework, common user interface and industry-standard data models
– Premier integration and interoperability
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 4/27
IntegratedArchitecture
™
Ethanol Production Plant
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Ethanol Plant
5/27
IntegratedArchitecture
™
Conventional Solution - separate systems
Batch(Dedicated Batch
Systems)
Continuous(DCS)
Discrete (PLC)
Safety(Safety Controls)
Different Automation Systems for Different Applications = Lots of Integration Costs & Long-term Maintenance Costs.
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 6/27
IntegratedArchitecture
™
Process(Logix)
Batch(Logix)
Drive(Logix)
Safety(Logix)
Discrete(Logix)
Enterprise(View)
Station/Unit(View)
Machine(View)
Integrated Architecture™ - A Single Solution
Benefit: The Integrated Architecture Simplifies Ordering, Stocking, Training, Development, Interfacing,
Troubleshooting, & Maintenance efforts …. Saving Time & Money!
Control(NetLinx)
Control(FactoryTalk)
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 7/27
IntegratedArchitecture
™
Coaxial/Fo ControlNet couplers
ControlNet redundant coaxial
Redundant supply
Profibus
E/S Flex IO
Redundant supply
DeviceNetControlNet redundant Fo
Primary redundant processor
Secondary redundant processor
Master
Server
Sodes Lillebone (Example) E/S Flex IO Version
Details:– Redundant Controllers (2 supply lines + 2 chassis + 2 processors
+ 6 ControlNet cards+ 4 Ethernet cards + 2 Redundancy modules)– E/S Flex IO with redundant supply lines & ControlNet communication cards– ControlNet redundant coaxial & optic fiber network for E/S management– Ethernet network for centralized control and redundant inter-controller exchanges– Specific communication networks DeviceNet, Hart, Fieldbus Fundation, Modbus, Profibus
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 10/27
IntegratedArchitecture
™
HMI Screens
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 12/27
IntegratedArchitecture
™
Ethanol Plants
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Operator interface screens – one box, one keyboard, one mouse and one operator
13/27
IntegratedArchitecture
™
• Huge selection of I/O– Fully supported remote ControlNet and Ethernet I/O capabilities for distribution
of I/O throughout the plant including adding I/O online– Intrinsically safe I/O for hazardous locations– Ability to easily integrate into Process Field Devices– Can add 1756 I/O online
• Redundancy available with off the shelf product– Controller, HMI, Intrinsically Safe Cabling, Power Supplies, etc
• Deploy and install plants quickly– Network able devices = Ease of installation and troubleshooting
“Huge reduction in wiring time”
Biofuels Plant Control
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 15/27
IntegratedArchitecture
™
Intelligent Motor Control
• Combines leading-edge motor control and protection devices with advanced networking and diagnostic capabilities of Integrated Architecture
• Designed to simplify start-up, reduce installed cost and provide plant and production that you need
• Safeguard equipment, increase energy efficiency, streamline production and lower total cost of ownership
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 16/27
IntegratedArchitecture
™
Cost of a control system
Hardware &software
20%System
configuration
40%
Programdescriptions
40%
•Controllers•Instruments•Network Modules•I/O Modules
•Description of Operation•Drawings•Logic / Rung Comments•Tag Descriptions
•I/O Configuration•Instrument Setup•Network Setup•Task, Programs, Routines•Structures, Tags
80% of the cost of
implementing a
control system is
the program description,
system configuration,
and documentation
Savings
Savings
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 17/27
IntegratedArchitecture
™
System configuration
1. From P&ID diagram 2. To configuration
3. To faceplates and graphical
displays
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 18/27
IntegratedArchitecture
™
Software integrationwith field devices
• Automatic integration of devices into Logix programming
• Filed devices pre-programmed displays
Configuration Wizards
Parameter Monitor and setting list
Spreadsheet View of MCC
Electronic User ManualsField Instruments
Electronic CAD Diagrams
Unit Monitor View
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 20/27
IntegratedArchitecture
™
Process faceplate detail displays
• The main faceplate display links to several detail displays. For example, a PIDE faceplate provides details for:
Instruction StatusInstruction ConfigurationLoop Trend Manual TuningAuto tuning
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 21/27
IntegratedArchitecture
™
Savings through reusable engineering
• Common Definition– Executing the same project multiple times at lower implementation cost with each
iteration• How we put this into practice:
– Leveraging a library of field proven, modular elements that are transportable across various projects and businesses resulting in lowest installed cost
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 23/27
IntegratedArchitecture
™
Data collection (process, alarms, batch)with data historian
• Provides reliable process data collection (no more clipboards!)
– Data collection and storage– Analysis of process parameters– Graphical visualisation
• Makes “data mining” a snap• Additional set of charting tools to
drill into your data– Bar Graph, Grid, Pie Chart, Pareto, etc.
• Historian can also analyze data collected by other applications
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 25/27
IntegratedArchitecture
™
Increase productivity with advanced process control
• 2D graph and 3D graphs with many options including zoom, line, grid density, range, axis, texture, etc
• Simulation mode allows you to watch influence of individual component values
• Value changes appear also in graphs as “path”
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 26/27
IntegratedArchitecture
™
Model predictive control of a reactor
Controller capabilities
2x2 model predictive control Rank PV’s in order of importance Auto-manual switch for each MV Executed in ControlLogix controller Uses standard function block library Improve yield Increase capacity by 10%
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 27/27
IntegratedArchitecture
™
Lower Operational Costs
Lower Total Cost of Ownership
Regulatory & Standards Compliance
Better Information
Faster Decisions
Increased Productivity
Lower Operational Costs
Lower Total Cost of Ownership
Regulatory & Standards Compliance
Better Information
Faster Decisions
Increased Productivity
Integrated Architecture™
One Architecture for Plant Wide Control & Information
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 8/27
IntegratedArchitecture
™
Manufacturing Execution Systems
• Integrated suite of plant wide information software• Easier integration, faster application development• Seamless information-sharing between factory floor and other departments• FactoryTalk and Logix Control Platform are linked through shared communication services
and technologies that allow seamless interaction and technology flow making possible:– Control System Connectivity– Enterprise and Plant System Integration– Human Machine Interface (HMI)– Supervisory Control and Data Acquisition (SCADA)– Manufacturing Execution System (MES)– Asset Management
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Manufacturing
Execution Systems
1/2
Manufacturing Execution Systems
• MES can increase the throughput of your plant by:– Eliminating paperwork– Reducing errors – Maintaining high quality standards
• MES can eliminate resources that are performing unnecessary tasks and help reduce material waste– Tighter automation integration & extended capabilities for production and manufacturing
companies– Latest version provides on-demand manufacturing information to help improve productivity and
reduce time-to-market– Extends capabilities in automation information integration – Offers increased flexibility in state-of-the-art data management and process execution– E.g. software helps simplify the integration of information between resource logistics and order
fulfilment
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Manufacturing
Execution Systems
2/2
Power and Energy Management
• Log usage, demand and production data• Create historical trend reports and charts• Establish consumption baseline and user
defined time of use periods• Assign rate plans to meters or groups of meters• Create and print daily or monthly cost and billing
reports by meter, business group, department, or site
• Create energy budgets and forecasts.• Compare and contrast alternative utility rates; do
“what-if” for other rate structures
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Power and Energy
Management
1/1
Global Applications - PEMS Application Examples
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Power & Energy Management (PEMS) Metal Forming Industrial Combustion Advance Process Control (APC) Coal Handling, Ash Handling, Soot Blower De-Mineralizer Water Treatment Material Handling / Packaging Manufacturing Execution System (MES) Safety Solutions Regulatory Compliance Services Batch Solutions Legacy Conversions
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Process Domain ExpertiseDistillation & Solvent Recovery Systems
• ProsCon’s highly efficient and energy saving Distillation and Solvent Recovery systems help you recover more from your manufacturing process at lower energy consumption
• Assess the viability of distillation and solvent recovery for your application using– Front end studies– Budget development studies– ROI assured through Waste analysis, distillation and recovery simulation, utilising pilot-scale test
facility and simulation• Benefits include
– Accelerated Construction schedule by parallel path activities– Integrated heat recovery reduces steam consumptions and energy costs– Shrinking the volume of disposable waste and decreasing waste treatment costs– Cut haul-away disposal or incineration charges– Conforming to environmental protection standards– Maintaining quality of solvent and Ethanol concentration
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
ProcessTechnology
1/3
Process TechnologyRecover More, Waste Less
• Modular Distillation and Solvent Recovery units incorporate all the hardwareand structural elements your installation requires
– vessels– columns– heat exchangers– pipe work– valves,– instrumentation– steelwork
• Integrated process solutions include control systems designed and built in any platform
• Integration with your wider plant control architecture.• Modules shipped quickly and safely to locations throughout the world
from our dockside facility
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
ProcessTechnology
2/3
Process Technology Modular Solutions
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Build Finish Install
ProcessTechnology
3/3
Feasibility study Counseling and conception of the problem solution Device specifications / calculation Product and functional specifications Control and monitoring concepts Function plans Software implementation Special applications Project management and project realization Commissioning Validation and acceptance Documentation Training Support and maintenance Plant management services
MPS - From Concept to Successful Solution
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
A worldwide support at anytime
Engineering Resource Centers
Major Project Implementation Centers
A worldwide common iPM methodology integrated with our business systems programs and policies.
Global network of domain expertise, industry knowledge, and world-class offerings create an unparalleled solutions in over 80 countries.
Over 1800 engineers with critical domain expertise understand your business and help you to succeed.
Worldwide local support for engineering and maintenance.
Services and SupportSuperior Services & Expertise
• Long-term and reliable support with the immediacy you need• Rockwell Automation’s portfolio of services can meet the challenges
at any stage of the project• Machine diagnostics and optimisation, allowing systems to collect and analyse information
for efficiency measuring• Let us help you optimally manage your assets regardless of the maintenance strategy
employed
PredictivePreventativeCorrective
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Services and Support Condition-Based Maintenance
• A strategic approach to maintenance is essential to minimise downtime
• Rockwell Automation offers a full line of services and support that significantly reduces unplanned downtime by:
– Applying a condition-based maintenance program to your rotating machinery and notifying you of problems before they occur
– Applying a preventative maintenance program to your controls equipment– Training your maintenance department to troubleshoot your controls equipment– Giving you real-time access to our global network of world-class Customer Support
Centres and technical resources– Making sure you have the right parts when you need them to get your machine up
and running quickly
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Transforming maintenance from an expense to a business asset
• Aligning the Resolutions to Your Issues – Using maintenance as a business asset
means correlating financial and productivity issues with Strategic Maintenance resolutions
– Rather than pick a single mode of maintenance, strategic maintenance combines predictive, preventive and reactive methods in an optimal fashion to reach your goals
By implementing a Strategic Approach to Maintenance, companies can reclassify maintenance from an expense to
a competitive differentiator and profit driver.
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 19/27
IntegratedArchitecture
™
Integrated Automation and information solutions using best-in-class
solutions for your company
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