saint-gobain builds for the future with plantpax and production intelligence

Copyright © 2014 Rockwell Automation, Inc. All rights reserved.

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Saint-Gobain Builds for the Future with PlantPAx and Production Intelligence.

Nick Thompson – Plant Superintendent

Larry Grate – Account Delivery Manager

Date – 11/14/2014

AGENDA

Who is Saint-Gobain and PREMIER

Business Justification

Migration Strategy to PlantPAxTM

Leverage Production Intelligence

Solution

Results and Look Forward

Questions and Answers

ADFORS OVERVIEW

Saint-Gobain, the World Leader in sustainable habitat and

construction markets, designs, manufactures and distributes

BUILDING AND HIGH-PERFORMANCE MATERIALS, providing

innovative solutions to the challenges of growth, energy efficiency,

and environmental protection.

Saint-Gobain manufactures the following materials:

Flat Glass

Ceramic Materials

Abrasives

Performance Plastics

Saint-Gobain ADFORS

Exterior Wall Insulation (VERTEX)

Wall Coverings (NOVELIO)

Joint Tape (FibaTape)

Bonded glass for thermal insulation and asphalt toppings (NewYorkWire,GlasGrid).

PREMIER OVERVIEW

For more info . . .

Visit PREMIER’s website at www.premier-system.com

Founded in 1991

Privately Owned

100+ Employees

CSIA Certified (6 Years)

Corporate Office Located in Smyrna, TN

Regional Operations in S.E. U.S.

Smyrna, TN

Decatur, AL

Cincinnati, OH

PREMIER OVERVIEW

Rockwell Solution Partner

Rockwell Control Solution Partner

Rockwell Information Solution Partner

Rockwell Process Solution Partner

Competencies

PLC/DCS Programming and Configuration

HMI Development

MES Solutions

Legacy PLC/DCS Retrofits

Coordinated Drives Solutions

For more info . . .

Visit PREMIER’s website at www.premier-system.com

Information

PREMIER OVERVIEW

Industries

Automotive

Chemical

Consumer Products

Food & Beverage

Metals

Pulp & Paper

Power

For more info . . .

Visit PREMIER’s website at www.premier-system.com

BUSINESS JUSTIFICATION

Lost our internal ProcessLogixTM Champion

Have a small PlantPAx system in place for resin blending.

This in conjunction with ProcessLogix being based on 1756 I/O made the best

solution easy to choose.

Had experienced the advantages of built in directed diagnostics.

Liked the ability to find trained resources on Rockwell solutions.

ProcessLogix server stability was becoming a problem.

Unsupported hardware/software (Windows 2000)

BUSINESS JUSTIFICATION

Project justification was on Cost Avoidance.

If a failure occurred the MTTR would be significant, increasing production

costs.

On power outages we were having a difficult time recovering due to issues

with the ProcessLogix servers.

When process improvements were implemented the labor cost for

ProcessLogix integration would be higher than PlantPAx.

MIGRATION STRATEGY

Had existing solution in place for Resin, wanted to build on it.

Had an infrastructure that was expanded multiple times

without a well thought out strategy.

Had legacy code that needed to be cleaned up.

Needed to install the upgrade on a short outage.

Operators were already familiar with the Resin system

faceplates and control.

ORIGINAL INFRASTRUCTURE

Saint-Gobain

Process Network Diagram

Lab Office

Process Control Network X.X.X.0/24

X2

Process

MCN

X3

Business to

ASA

X.X.X.X

Business Network

Process Network Copper

MODE

STACKSPEEDDUPLXSTATMASTRRPSSYST

1 2 3 4 5 6 7 8 9 10 11 12

1X

2X

11X

12X

13 14 15 16 17 18 19 20 21 22 23 24

13X

14X

23X

24X

Catalyst 3750 SERIES

1 2

North

MCC

South

MCC

Control

Room

Operator

Console #1

Operator

Console #2

ProcessLogix

Server

Line Drives

Former

Former

RTO

RTO

Panelview

Resin

PULPER

PULPER

RSView32

Line Drives

Winder

Wrapper

Wrapper PV

Process Network Fiber

ProcessLogix

Processor

Resin HMI

Server

Maintenance

Winder

RSView32

FINAL INFRASTRUCTURE

Saint-Gobain

Process Network Diagram

Lab Office

Process Control Network X.X.X.0/24VMWare ESXi

USRUSAPP2

X.X.X.17

USRUSVAPPDC2

Win 2008 Server R2

sp1

X.X.X.12

X2

Process MCN

X3

Business to

ASA

X.X.X.X

USRUSVAPPDC1

Win 2008 Server R2

sp1

X.X.X.11

VMWare ESXiUSRUSAPP1

X.X.X.19

USRUSVAPPHMI1

Win 2008 Server R2

sp1

X.X.X.13

Business Network

Process Network Copper

Domain

Controller

HMI Server

#1

USRUSVAPPHIST

Win 2008 Server R2

sp1

X.X.X.15

MODE

STACKSPEEDDUPLXSTATMASTRRPSSYST

1 2 3 4 5 6 7 8 9 10 11 12

1X

2X

11X

12X

13 14 15 16 17 18 19 20 21 22 23 24

13X

14X

23X

24X

Catalyst 3750 SERIES

1 2

USRUSVAPPHMI2

Win 2008 Server R2

sp1

X.X.X.14

USRUSVAPPASSET

Win 2008 Server R2

sp1

X.X.X.16

USRUSVAPVP

Win 2008 Server R2

sp1

X.X.X.17

Historian

Vantage

Point Server

USRUSVAPPFTD

Win 2008 Server R2

sp1

X.X.X.16

North

MCC

Domain

Controller

HMI Server

#2

AssetCentre

Factory Talk

Directory and

Activation

Server

South

MCC

Control

Room

Operator

Console #1

Operator

Console #2

Fiber Ring Level 2

Fiber Ring Level 1

Engineering

StationLine Drives Former

Former

RTO

RTO PV

Resin

PULPER

PULPER

Line Drives

Winder

Wrapper

Wrapper PV

Wrapper

Process Network Fiber

LEGACY CODE MIGRATION

Integrator documented all existing loops.

Reviewed code list with production for equipment that was out of

service or provided poor performance.

Converted existing code and tuning values.

Some sequences were eliminated due to better tools in PlantPAx.

Consolidated multiple HMI platforms from other systems into the

new Factory Talk® View SE system.

Pulper RSView32 System.

Line Drive RSView32 System.

Multiple PanewView Plus Applications.

NEEDED TO INSTALL ON A SHORT OUTAGE

Initially targeted a 24 hour production down.

Integrator put together a thorough test plan for critical loops

at startup.

Actual outage was 36 hours due to other maintenance.

Startup went extremely well.

We did have a path back to the ProcessLogix system if we had a

catastrophic problem.

We moved two ControlNet racks to Ethernet due to failing ControlNet

cables installed crossing the machine in the basement.

We did have access to the ProcessLogix code if needed to verify

operation.

OPERATOR FAMILIARITY

Operators were already comfortable with the HMI due to the

existing Resin PlantPAx implementation.

Operator training on the HMI was minimal, screens mimicked

the existing ProcessLogix using familiar faceplates.

OPERATOR FAMILIARITY

OPERATOR FAMILIARITY

LEVERAGING PRODUCTION INTELLIGENCE

Chose to use Factory Talk Historian as a replacement for the

ProcessLogix Historian.

Chose to use Factory Talk VantagePoint to provide production

intelligence to operations management.

Chose to use Factory Talk AssetCentre for Disaster recovery

and backup.

Chose to use ACP Thin Manager for HMI clients and

engineering station.

LEVERAGING FACTORY TALK HISTORIAN

Used to create trends relating critical process values for a

quick overview of production quality.

Used to create ad hock reporting to troubleshoot process

problems as they arise.

Used to create required environmental reporting.

Working on production dashboards for critical KPIs.

THICK STOCK VS LEVEL

AD HOC

ENVIRONMENTAL REPORTING

Repository for plant-wide control of asset programs.

Automated disaster recovery on critical process assets.

FactoryTalk AssetCentre DIRECTORY

FactoryTalk AssetCentre AUDIT LOGS

THIN MANAGER

Tool for managing HMIs across the facility.

Provides for remote shadowing of operator screens for

troubleshooting and diagnostics.

Makes terminal replacement simple.

Simplifies the use of Terminal Services for Factory Talk View

HMI servers.

THIN MANAGER TREE

THIN MANAGER SHADOW

SOLUTION

Live Demo of Graphics

MAIN OVERVIEW

LINE DRIVES CONVERTED PV DISPLAY

DIAGNOSTIC EXAMPLES

RESULTS AND PATH FORWARD

KPI Screens in FactoryTalk VantagePoint

Converting balance of plant to Ethernet

Automated Reporting of Production

Additional Process Improvements

Copyright © 2014 Rockwell Automation, Inc. All rights reserved.

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QUESTIONS

Please email us for additional information.

nick.thompson@saint-gobain.com or

larry.grate@premier-system.com

ANY QUESTIONS?

Please email us for additional information.

nick.thompson@saint-gobain.com or larry.grate@premier-system.com