buckeye partners: virtualized plantpax system improves risk management

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Buckeye Partners, L.P. Perth Amboy Marine Terminal Virtualized PlantPAx Improves Risk Management

David Cortivo - Senior Engineer, MAVERICK Technologies

John F. Boyd - Technology Leader, MAVERICK Technologies

November 17, 2014


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Agenda

Questions & Answers

Full Utilization PlantPAx DCS and Vantage Point System – New Beginning

Implementation the PlantPAx DCS – Journey

Why PlantPAx– Start

Introduction – Buckeye Oil and Gas Terminal


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Buckeye Partners - Introduction

Who is Buckeye Partners?

Buckeye Partners traces its roots to March, 1886, when The Buckeye Pipe Line

Company was incorporated as a subsidiary of the Standard Oil Company.

From its modest nineteenth century beginning as a local crude gathering subsidiary,

Buckeye in the twentieth century transformed itself into one of the nation's largest

independent common carrier refined products pipelines.


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MAVERICK Technologies - Introduction

Who is MAVERICK?

Broad and deep manufacturing technology specialist focused on delivering value to its clients

Total solutions provider – from the plant floor to the “C” suite

Good people to work with, relationship focused

A global network of more than 1,000 resources and partners

Value driven

Locations

Global Headquarters – Columbia, IL

Additional Locations – Nineteen (20) North American Locations


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Start

Grass Roots for a DCS Platform Selection

The Perth Amboy Refinery is a refinery built in 1920 and was owned and operated by chevron. In 2012

the facility was acquired by Buckeye Partners and a modernization effort to bring the facility into the 21

century as a terminal service provider was born.

Control System Hardware

“State of the Art” hardware, utilizing the latest in Virtual Server applications with remediation concerns at the

heart of the design. Perth received considerable damage during the hurricane Sandy and did not have

remediation ability on site.

Top of the line motor actuated control valves utilizing DeviceNet bus technology.

Remote cabinets with Point I/O™ for cost savings measures

Control System Software

Microsoft desktop and server operating systems, world class historian server, and automatic generation of real-

time/historical reports thru VantagePoint

DCS system easily supported by internal operations and remote support provided by Maverick Technologies 24/7

offerings.

http://en.wikipedia.org/wiki/Refinery


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Journey - Planning

During the DCS Implementation MAVERICK used the project

complete process

Planning with the process needs of Buckeye thru structured collaboration.

Understanding the benefits of a automated facility

Working with the current need and vision for growth

Identifying the key drivers impacting business needs

Developing a tailored solution for the facility

Communication to all trades involved with the expansion effort

Project complete is the combination of Planning, Delivery and

Sustaining Services into one turnkey solution.


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Journey - Software

Software Implementation Process

Discovering the Existing System MAVERICK and Buckeye engineers analyze the existing system and

developed a functional specification

We took a fresh look at existing plant operations and we developed a structure

for the DCS system to integrate with current tank monitoring and vapor

recovery systems.

PlantPAx process objects where selected for the facility and development of

additional functionality commenced

Current RSView 32® operating systems are being migrated into the PlantPAx

DCS system to have a unified plant structure.


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Journey - Software

System Architecture


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Journey - Software

VMware Architecture


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Journey - Software

Software Application Process

Conceptual layout of screen navigation and content for rapid development among all parties

Built working model with standard control code. Standard code also vetted by Rockwell

Automation PlantPAx engineers for proper use and application

Long term simulation network built for operator training and testing applications.

Dynamic simulation model using Mynah Mimic software


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Journey - Software

Software Application Process – Selling a Standard

Built working model with standard control code. Standard code also vetted by Rockwell

Automation PlantPAx engineers for proper use and application.

Initial training and look and feel was presented to operations with a small model built with the

PlantPAx objects. With the defined standard model that PlantPAx brought to the project the

overall reaction to the model was well received.

Basic equipment operations supported without having to design special faceplates or control

code. 90% of the equipment at Buckeye is motor actuated valves which are supported with

PlantPAx.

No need for external databases as device information already housed in the PlantPAx

controllers.

Existing tools prebuilt by Rockwell Automation for rapid configuration of equipment

parameters. Both read and write ability supported.


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Journey - Software

Software Application Process – Virtual Machine Selection

Ability to remote build VM’s without having final server purchased due to the use of the VM

nature.

Cost savings with the use of VM’s as the development network and platform basis. The

exact VM images were directly installed into the plant environment once server structure and

network were in place. Minimal configuration changes had to be made in the transition to

operational.

Remote development teams operating thru the VM’s to keep project security and continuity

intact.

Virtual engineering workstations were built with all design software requirements. This

allowed for minimized software revision issues among configuration PC’s.


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Journey - Software

Software Application Process – Simulation Network

Long--term simulation network built for operator training and testing applications.

Selection of equipment for simulation network. Built on a single pc for mobility.

Emulator used for PLC backbone.

Dynamic simulation model using Mynah Mimic software for I/O tieback.


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New Beginning - PlantPAx

Process Screen - Concept


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New Control Valves


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Process Screen – Big Picture


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Process Screen – All detail and overviews two button clicks with

quick area navigation


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Process Screen – Paper reduction thru HMI and Historian


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Reports – Secure remote live data without need to open the process

control network


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Questions

David Cortivo - Senior Engineer, MAVERICK Technologies

John F. Boyd - Technology Leader, MAVERICK Technologies

November 17, 2014

buckeye partners: virtualized plantpax system improves risk management

Technology

plantpax dcs system

plantpax dcs journey

psug journey planning

buckeye engineers

existing system maverick

utilization plantpax

plantpax process objects

plantpax objects