rockwell automation: dcs platform migration, pulp & paper industry
TRANSCRIPT
Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
CS17: Multiple Concurrent Legacy Migrations Achieved with a PlantPAx® DCS Platform
Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
Agenda
Benefits
Project Details
Solution Selection Criteria
Project Challenge
Company Profile
Next Steps
Q/A
Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
Company ProfileBackground
Founded in 1996 Employ over 40 Process Control Engineers & E/I Technicians Control System Services - Design, build, configure, test, install, checkout and startup, of
control system hardware and software. Operational IT Services - Design, build, configure, and install of network and data center
systems. Data Historian Services - Historian configuration, installation, reporting, and data
visualization. Cyber Security Services - Risk assessment, network analysis, system design, installation
and support. 24/7 Monitoring and maintenance support services for all areas of industrial control
system platforms.
Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
Company ProfileBackground
Over two decades of expertise in the following industries: Pulp & Paper Specialty Chemicals Food & Beverage Life Science Municipal Utilities
Platform independent solutions with experience in a majority of legacy and current technology offerings.
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Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
Agenda
Benefits
Project Details
Solution Selection Criteria
Project Challenge
Company Profile
Next Steps
Q/A
Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
Project ChallengeProject Overview
Paper Industry End User Customer Conversion of multiple legacy DCS platforms and PLC/5 Hardware Two major automation platform upgrades during project lifecycle
Recovery Boiler Paper Machine
Project Constraints Recovery
Project execution period during facility annual outage, lasting 6 days. Paper Machine
Major machine redesign / rebuild concurrently executed with DCS platform upgrade Common utility systems used in areas outside of machine rebuild Staged commissioning and trial runs for operations
Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
Project ChallengeDCS Replacement Driving Factors
Technical Factors Spare parts unavailability Diminishing technical knowledge of multiple platforms in both areas Desire to leverage HART data from capable transmitters
Business Factors Cost of mature technology Reduced life-cycle costs Increase business intelligence Major capital investment in reconfiguration of facility
Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
Project ChallengeExisting Platforms
Paper Machine DCS System – ABB 800xA
14 x ABB MOD300 SC Controllers 2 x ABB 800xA PM866 Controllers 2,350 I/O (TRIO & S800)
PLC System – AB 2 x AB PLC/5 Controllers 5 x 1771 I/O racks
HMI - 800xA (Process Portal A) QCS System – ABB
Recovery Boiler DCS System - Siemens APACS
1 x ACMx APACS Controller 375 APACS I/O
PLC System - AB 1 x AB PLC/5 Controller HMI - Proficy iFIX 4.0 10 x 1771 I/O racks
Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
Project ChallengeDelivered Platforms
Paper Machine System 2 redundant PASS system server applications 29 x Operator Clients (mixture of physical and virtual) FactoryTalk Historian, VantagePoint, & AssetCentre 6 x 1756-L75 PACs 19 x 1756 (ControlLogix) I/O racks via Ethernet DLR 2 x 1734 (PointIO) I/O racks via Ethernet DLR 5 x 1771 (PLC5) I/O racks via DHRIO
Integration of ABB ACS800 VF Drives via Ethernet Integration of Rockwell E300 Overload Relays via REP Protocol
Ring Quality Control System from Valmet consisting of:
1 new dry end scanner 1 new single point wet end scanner Integration to Rockwell via Ethernet I/P
Recovery Boiler System 1 redundant PASS system server application 8 x Operator Clients (mixture of physical and virtual) FactoryTalk Historian FactoryTalk VantagePoint FactoryTalk AssetCentre 1 x 1756-L75 PAC w/ Redundancy 4 x 1756 (ControlLogix) I/O racks via Ethernet DLR 2 x 1794 (Flex) I/O racks via Ethernet DLR 10 x 1771 (PLC5) I/O racks via DHRIO
Integration of ABB ACS800 VF Drives via Ethernet Integration of 5KV Powerflex 7000 VF Drive via Ethernet Integration of second recovery boiler controls into HMI layer
1 x ACMx APACS Controller 1 x AB PLC/5 Controller
Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.
Thank You!
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