anglo american platinum standardizes on plantpax hybrid process solution at their precious metal...
DESCRIPTION
The legacy control system at Anglo American Platinum's Precious Metal Refiners, the world's leading primary producer of platinum group metals, was becoming increasingly difficult to support and to access benefits from improved control technologies. Leveraging its longstanding relationship with Rockwell Automation, the company is in the process of upgrading to a hybrid process solution to standardize its batch and continuous processes. The ISA88-structured PlantPAx solution has improved maintenance and troubleshooting, and helps the company comply with strict international process control standards for starting and aborting batches.TRANSCRIPT
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
Tweet About It Using #PSUG
ISA88 Structured Process Solution Batch, Continuous and Hybrid Processes
Hermanus du Preez
Control Technology Specialist
November 2014
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Hermanus du Preez
Qualification : B.Eng (Process Control Engineer)
Current Position : Control Technology Specialist
15 years Automation and Control experience -> Mining & Petrochem
Responsible for ALL Regulatory and Advanced Process Control Projects
and Strategies at Anglo Platinum Precious Metal Refinery (PMR)
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Agenda
Structure, Key Features, Issues and Solutions
Anglo American Platinum Overview
Why the NEED to Upgrade?
Solution Options & Why Rockwell Automation?
Project Implementation
Project Outcome
Benefits and Realization
Conclusion
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Anglo American Platinum
World’s largest producer of primary platinum
Produces about 40% of all newly mined platinum in the
world each year.
Mining and Process (Concentrators, Smelters and
Refineries) Division
Precious Metal Refinery based in Rustenburg, South Africa
In 2012 produced 2,336,148 Platinum ounces
Products
Catalytic converters, Fuel Cells, Jewellery and various
other industrial applications
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Platinum Process Overview
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
PMR Area Overview
Different PGM are processed in different Bays, consisting of several Areas, including a Tank Farm and Site Utilities
Each Area consists of several Units, with it’s respective Equipment Phases and Equipment Modules
Approximately 70 Areas, with a total 395 Units, which have similarities, but are ALL Unique
Process Area
Areas
Units
Phases
Equipment
Control Modules
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Why the NEED to Upgrade?
Specialized skills required to maintain custom sequence manager -> Ex-Support
Proprietary driver out-of-date. Could not upgrade -> EN2T does not work!
Long start-up delays (1-2 hrs) -> Entire tag database has to be loaded first
All code in Logix configure in Continuous Tasks -> No prioritization
Limited upgrade potential due to timeslice constraints.
2x Resources required to support different systems and structures
SCADA On-Line edits not possible.
SEQ
Citect
APC Custom Build Sequence Manager
C++ Based
20x L64 Rockwell Control Logix
Proprietary API Driver
Legacy System
200k Tags
~ 20000 I/O
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Solution Options - General
WANTED:
Vertical (Single Vendor) solution
Commercial Off-the-Shelf (COTS)
Vendor Support, Experience, Knowledge and Responsiveness
Cost Effective (Minimal downtime)
Rapid Development
OPTIONS CONSIDERED:
DCS Vendor
3x Costs
Difficult to RIP and REPLACE due to existing Fibre Backbone and ControlNet Infrastructure.
Strict Access Control on existing Running plant
Rockwell Automation
Existing ControlLogix installed based
PLC flexible with DCS power -> Plant PAx & Rockwell Mining Solution
Costs.
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Solution Options – Rockwell Automation
FT Batch
No need for Recipe Management ->
Limited plant recipe changes
Ideal for “Pure” Batch process. Not
an ideal fit for Continuous or Hybrid
processes
Controllogix
Process Solutions (Plant PAx)
LBSM
(Logix Batch & Sequence Manager)
Process Objects / RAMS
(Rockwell Automation Mining Solution)
System too large/complex ISA88 objects (CM, EM & EP) flexibility
Ideal for OEM solution, continues process
startup/shutdown
Well defined libraries
Matured and well supported and
documented.
Met most of the User Requirement
specifications (Out-of-the-box) and
Rockwell flexible to meet additional
requirements.
Off-the-shelf features like Ownership,
Reporting, Propagation
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation End State System Architecture
FT Directory Server
Domain Controllers
X45 Clients
Operator Clients
Terminal Servers (2 or more) • FT View SE Clients x 25
x40 L75 - CLX
CNet
Flex Flex Flex
FT Historian Server
Managed Ethernet Switch for Control System Network (CSN) – Ctlr Communications
FT AssetCentre Server
Engineering Workstation (14)
• FT View Studio • RSLogix 5000
Redunadant Servers
x2 HMI Server
x10 Data Servers
Primary Servers x2 HMI Server x10 Data Servers
Commercial Access Network
Managed Ethernet Switch for Control System Network (CSN) – Ctlr Communications
FT Gateway Server
Lab Systems
APC Server
Legacy System
Firewall
OPC
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation ISA88 Implementation / Structure
ControlLogix
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Equipment Phase Structure
Equipment Phases designed to perform single Process Function
Chemical Addition, Transfer Out, Sampling
Process Capability
Basic Control
EM’s Basic Control
CM’s
Mode Permissives Command/Status
Unit Interface
Cm
d. In
terf
ace
Equipment Interface Conceptual Grouping of Equipment Designed for process capability
Module (object)
100% Re-Usable
Customizable
Human Requests
Report/Parameters
EP_GEN
Coordination Control Sequencing of Devices
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Equipment Module Structure
Equipment Modules designed to Run Continuous and Perform State Specific Action
Agitate (Stop and Start Agitator Based on Level)
Equipment Grouping
Equipment Control
CM’s Basic Control
CM’s
Mode Permissives Command/Status
Unit Interface
Cm
d. In
terf
ace
Coordination Control Sequencing of Devices
Device/Equip. Interface Conceptual Grouping of Equipment
Module (object)
100% Re-Usable
Customizable
Human Requests
Report/Parameters
EM_GEN
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Unit Procedure Reactor Model
Project Implementation S88 Grouping – Reactor Example
~ 400 Unit Procedures -> Rapid development achieved by using EP and EM Libraries
F
F
F
Unit
Reactor
Reagent 3
Reagent 2
Reagent 1
FM4100
FM4110
FM4120
CV4100
CV4110
CV4120
CV4900
CV4010
M4020
DMW
To
Filler
JX4910
M4100
M4110
M4120
FT
4100
FT
4110
FT
4120
LS4010
CV4020
CV4030
TT4020
AV4020
TIC402
0
Steam
Condensate
Equipment Phase Flow Meter Addition
Equipment Phase Flow Meter Addition
Equipment Phase Flow Meter Addition
Equipment Phase Transfer Out
Equipment Module Agitator
Equipment Module Temperature Control
Equipment Phase Wash
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Any Questions…?
http://xkcd.com
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Scada Overview
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Key Features – Unit/Area Propagation
Mode Management for group of equipment
Alarm Management for group of equipment
Aggregate Status for group of equipment
Mechanism for Defining Global Interlocks & Permissives for group of equipment
By assigning a module to a group, the ability to propagate exits
Down UP
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Key Features – Unit/Area Propagation
Multiple Area Button Bar
• Each button (Area 1 – 5) on the button bar represents an Area
• Each button (Area 1 – 5) links to an Area Menu window.
• Selecting a button on the Area Menu will open the associated (Unit) overview screen
• The Multiple Area Button Bar and a sample Area Menu are shown in the figure below:
Ownership
• Equipment Grouping / Propagation
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Key Features - Interlocking
Interlocks
First-Up Indication - Standard
Last 10 Events – Additional Functionality
Individual / Maintenance Bypass Options – Additional Functionality
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Key Features – Batch Reports
Batch Reporting
Operator Visibility and Tracking on HMI
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Key Features - Routing
Complex Routing
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Key Features - Parameters & Reports
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Key Features - Parameters & Reports
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Key Features - Parameters & Reports
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Any Questions…?
http://xkcd.com
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Issues and Solutions
Complex Routing and Sharing of equipment.
Legacy System operators had free reign to decide which equipment should be used and by which procedure.
Not scheduling the sharing of equipment caused additional delays.
Flexible block development and Ownership property allowed
us to create a unique routing block to schedule and manage
shared equipment
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Issues and Solutions
Limited downtime available (8hrs a month)
Shutdowns are scheduled Process testing limited. Hot-commissioning after field instrumentation has been tested.
Online Edits allow for Quick Changes with Change
Management Procedures in place
Brown Fields Plant (25 years old)
Not all templates developed are ‘cut’ and ‘paste’. Different areas with similar equipment are operated differently due to available field instrumentation
Require customised libraries
Code Generation
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Issues and Solutions – Code Generator
Rapid Development and quick modifications achieved for Equipment Phases and Equipment Modules
Equipment Modules Equipment Phases
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Implementation Issues and Solutions
Defining S88 Libraries
Upgrade done in stages from area to area Different areas have different S88 philosophies which could
complicate standard library development, which only gets defined with repeatability.
Approx. 400 similar, but Unique Unit Procedures -> standardization is achieved on EP and EM level.
Repeatability and maintaining philosophies led to rapid code generation and deployment
Equipment Module vs Equipment Phase Implementation Example : Agitator
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Outcomes Benefits and Realization
Stricter control over batches
Realistic model/capacity of process Live reporting of delays (Operator response time, Sampling,
Availability of equipment) Active tracking / reporting of consumables / reagents
Improved fault finding at operator level -> reduced downtime
More visibility and reporting into process at operator level
95% of all changes (Maintenance, Configuration, Alarms, etc.)can be done
directly from Scada, with the exception of forcing I/O.
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Project Outcomes Benefits and Realization
Fast-Tracking Project Implementation
Team of 5 x Rockwell Engineers and 4x Anglo Platinum Engineers
Initial Area -> 6 months from design to commissioning
Second Area -> 2 x Size of Initial -> 3 months
Third Area -> 4 x Size of Initial -> 3 months
Documented Process Flow Charts
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Conclusion
ISA 88 Allowed Modular Design
Rockwell Automation’s PlantPAx and Mining Solution supported custom
S88 philosophy implemented
Generating S88 libraries initially takes longer, but ramp-up code
generation realized as soon as libraries are repeatable.
S88 Structures / Philosophies
Define the purpose / objective of S88 structures and “STICK-TO-IT”
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
Tweet About It Using #PSUG
Questions
Name – Hermanus du Preez
Title – Control Technology Specialist
Date -- November 2014