plantpax in abocol expansion & upgrade project · abocol production processes 7 nitric acid ....

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

PlantPAx in Abocol Expansion & Upgrade Project

Lina María Guevara Marín A&C Process Engineer November 5-6, 2012

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Agenda

Conclusions

Plant PAx Solution and Results

PlantPAx Expansion & Upgrade Project

ABOCOL – Infrastructure and Production Processes

ABOCOL – Our History


Abocol - Our History

3

Abocol was founded in 1960 (52 Years).

Abocol is a company engaged in the import, production, marketing and export of fertilizers and industrial products. Its productive infrastructure is located in Colombia (Main operation in Cartagena), and has direct operations in 6 countries and exports to over 35 countries around the world.

Activity: Fertilizers, Ammonia, Nitric Acid and Ammonium Nitrate Production

Main Customers: Agricultural chain and mining sector

Employees: 780


Abocol – Our History

4

Abocol, with 52 years serving Colombia’s and the world’s industrial products and fertilizer markets, is a company that offers a complete product portfolio that includes NPK compound fertilizers, calcium nitrate, blends, liquid and foliar fertilizers, as well as industrial products such as ammonia, nitric acid (56% concentration), and ammonium nitrate (83% concentration).


Abocol Infrastructure

5

Infrastructure: Production Plants and Port

Blends Plant 120k t/y

Cartagena

Buenaventura

Main operations in Cartagena Blending facilities and Warehouses in Buga (close Buenaventura port) Branches in Bogota and other cities


Abocol Production Processes

6


Abocol production Processes

7

NITRIC ACID



8

NPK FERTILIZER COMPLEX



9

CALCIUM NITRATE


NPK-NICA Architecture Before

10


Challenges…

Control system expansion needs leveraging robust architecture, redundant philosophy for supervision and control and scalable solution. Process requirements in terms of performance improvement was a must.

HMI performance needs for improvement in terms of availability. Frequent communication issues motivating evaluation of actual Wonderware system.

Control system working prior projects implementation started showing issues in terms of performance, speed, communication failures and supervision difficulties.

NPK and NICA1 plants were depending just from one application server, generating high risk and vulnerability for operation uptime.

11


Challenges…

Expansion needs for 1 new calcium nitrate plant adding important amount of IO, going to be integrated with the rest of the plant.

Implementation for a process system with complete integration of Analog, Discrete and Motor Control including history and plant supervision, easy to maintain for Abocol personnel everything focused in a Cost/Benefit solution.

Standardization for Automation inside the plant was a MUST targeting partner definition with clear strategies for post sales support including spare parts management (local availability), training and local/remote engineering support.

12


NPK-NICA Final Architecture

13


NPK-NICA Architecture Final

14


Plant PAx Solution and Results Two HMI redundant servers were installed for each NICA and NPK plant

migrating from Wonderware to FactoryTalk View. Additionally at hardware level redundant controllers with EthernetIP and ControlNet communications implemented. High availability and robust process solution in place.

System implemented has improved availability, increasing up time operation and performance in terms of operation. Communication issues got rid of and network performance was significantly improved.

Robust and scalable solution was implemented, generating base structure and standardization for complete control solution including process, Intelligent Motor Control, discrete control and visualization.

Final complete integration with control equipment already in place.

15


NAP2 Architecture Before

16


Challenges… Obsolete DCS installed base migration needs, preserving regulatory

control functionality, changing complete platform for system operation at process level.

Vulnerability for DCS system in terms of availability and process up time. Replacement must be scalable, highly uptime support and information enabled structure. Network performance was significantly improved

Historical information was a weakness having in mind obsolete DCS capabilities. The new system must have complete support for historical process and analysis.

To reduce risks in terms of obsolete products selecting the right platform with strong support , decreasing downtime operations due to lack of spare parts.

17


Challenges…

Expansion needs for 1 new nitric acid plant adding important amount of IO, going to be integrated with the rest of the plant.

Implementation for a process system with complete integration of Analog, Discrete and Motor Control including history and plant supervision, easy to maintain for Abocol personnel everything focused in a Cost/Benefit solution.

Standardization for Automation inside the plant was a MUST targeting partner definition with clear strategies for post sales support including spare parts management (local availability), training and local/remote engineering support.

18


NAP2 Architecture Final

19


Plant PAx Solution and Results

Successful DCS migration from Yokogawa to Plant PAx according to project time frame, accomplishing life cycle project and production timing.

Robust platform implementation with redundant philosophy at Control/HMI levels. Significant improvement in terms of system scalability for next expansion projects inside the plant.

Significant risk mitigation in terms of system availability achieved. Plant has been running keeping high up time for production, getting rid of concerns for down time with obsolete platforms.

Complete automation system was standardized, leveraging high local availability for spare parts, improved local engineering support and helping to lower inventory levels for the plant (production cost reduction).

20


Why Rockwell as a Partner

Initial installed based of Allen Bradley PLCs, showing great performance and availability.

Excellent support of Rockwell Automation and its distributor, solutions providers and integrators in Colombia. Support strategy differentiates Rockwell from the rest of Automation providers.

Important Cost/Benefit relationship in terms of automation project results (TCO)

Plant PAx value proposal, getting rid of initial PLC conception showing capabilities for process applications (formerly DCS inside plants)

21


Conclusions

Rockwell Automation architecture, PlantPAx, ensures an scalable, flexible and reliable solution for fertilizers infrastructure.

PlantPAx enables us to have process information available to all corporate levels, beyond the control rooms.

Rockwell Automation has consistently demonstrated efficient strategy in terms of support, enough capable to respond to our schedule requirements, complexity and quality. Delivery time for parts, local availability and engineering support has been differentiating Rockwell, motivating strong relationship like strategic partners.

22


Next Steps

Complete Automation installed base standardization to Rockwell Automation including Process, Motor Control, Information Solutions and Industrial Control.

Complete migration from SLC-500 installed base to PlantPAx.

Information solutions level implementation, enhancing data analysis, reporting and integration with enterprise management system.

23


Questions

Lina María Guevara Marín A&C Process Engineer November 5-6, 2012

plantpax in abocol expansion & upgrade project · abocol production processes 7 nitric acid ....

Documents