simcoa system platform looking forward, looking...
TRANSCRIPT
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SIMCOA Operations
SIMCOA System Platform
Looking Forward, Looking Back
Mike Chivers
Electrical Engineer
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Simcoa Operations
Only Silicon Smelter in Australia
Commissioned 1989
Owned by Shin-Etsu Chemical (Japan)
160km south from Perth
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Simcoa Operations - Site
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Silicon Process
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Simcoa Operations
24h 7d Operation
10h 5d Maintenance + Shift Roster
1 Process Engineer
1.5 Electrical Engineers
1 Mechanical Engineer
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Plant Control System (2005)
7 x GE Series 6 PLCs
11 x ABB MOD300 Controllers
6 x ABB MOD 300 Consoles
1 x Citect HMI
3 x GE Series 6 Programmers
1 x MOD300 Configuration Node
1 x MOD300 History Node
1 x Serial DDE Link to Laptop (Hist Data)
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Plant Control System (2005) - Issues
Reliability
Spares
Technical Support
Troubleshooting (Double Handling)
Engineering Efficiency
Expandability
Many HMI Pages / Colours
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Plant Control System (2005) - Arch
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Plant Control System (2005) - Scale
610 Analog I/O
3,100 Digital I/O
12,255 Rungs PLC Ladder
2,890 DCS Loops
1,550 DCS Devices
40,000 DCS TCL Lines
121 Graphic Pages
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2005 Upgrade Project Assessment
Many One-One Between DCS and
System Platform
System Platform Customisable
Single Controller Architecture Advantage
Capital Cost vs Risk & Efficiency
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2005 Upgrade Design - Philosophy
Redundancy
Combined DCS HMI/Controller Upgrade
Terminal Services
Redesign HMI Graphics
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2005 Upgrade Design - Software
MS Windows Server 2003 (+ CALs)
Wonderware Application Server (25K I/O, 5
platform)
Wonderware InTouch TS View (10 user,
redundancy)
Wonderware Historian (5K tags)
Wonderware ActiveFactory (10 user)
GE GES OPC Server
Moxa SNMP OPC Server
GE Proficy Machine Edition – Logic Developer
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2005 Upgrade Design – Plant Model
Hierarchical Function-Based Model
Plant / Area
Process / Line
Function
Sequence / Loop
Std Logic
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2005 Upgrade Design – Plant Model
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2005 Upgrade Design - HMI
Tag-Based PLC Access (OPC/Symbolic)
Review / Apply HMI Standards (also
Consider Colour Blindness)
Consolidation of Graphics
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2005 Upgrade - Design
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2005 Upgrade – System Platform
I/O Point Count: 9,107
Instanced Object Count: 3,119
Object Templates: 117
Historian Tag Count: 3,725
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Implementation – Issues
Alarm Descriptions
Fetch Alarm Functionality
Priority Based Alarm Sound
Didn’t Leverage Containment
Alarm Management vs User/Logon
Too Many Templates
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Furnace 3 Expansion (completed 2013)
Additional (3rd) Furnace & Grinding Plant
1 x New PLC, 1 x Expanded PLC
1 x Safety PLC (Triconex TriGP)
5 x New Operator Stations
2 x Server Upgrades (Win 2008 Svr)
Historian Upgrade (5K to 12K Tags)
NAS for 10y+ History Online
Widescreen Conversion (1920x1200)
Archestra Graphics (new Symbols)
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2013 Expansion – System Platform
I/O Point Count: 13,714 (9,107)
Object Count: 4,894 (3,119)
Object Templates: 176 (117)
Historian Tag Count: 5,698 (3,725)
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Wonderware Upgrades
Various Upgrades (in-house)
Beware Hidden Functionality Changes
Migrating SmartSymbols (on-going)
Various Continuous Improvements
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Performance – System Platform
Engine Scan Period: 0.5s
Readback of Write: <1.0s
HMI Page Change: <2.0s
HMI Page Update: 0.5s
Retrieve 24h Trend <4.0s
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Utilisation (Typical)
Ethernet Network: 2%
App Server CPU: 30% (2005)
5% (2012)
Terminal Server CPU: 10%
Historian CPU: 20%
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Engineering Efficiency
Substantial Improvement in Engineering
Efficiency
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Reliability
Downtime:
1 x Network Failure (config error)
2 x PLC Failure (prog, h/w fail)
No Significant Impact:
3 x Historian Failure (mem leak)
2 x PLC Hardware
5 x Operator Console Hardware
Numerous Operator Console Software
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Lessons – System Platform
Adaptability – Painless Correction
Invest Time in the Model!
Set Standards
Experience Adds Value
Full Benefit Not Realised (Brownfields)
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Lessons – Other
HMI Pages:
Many & Simple to Few & Busy
ActiveFactory Web and Excel
Tools in Hands of Users
Eliminated Old Data Bottlenecks
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Support Tips
System Architecture Diagram
Servers & Roles
Network Connections (VLANs)
Clients
Controllers
Serial Comm Links
Locations
Network Addresses
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Support Tips
Software Record
Server Specs (CPU, RAM)
Installed Software per Server
Versions
Licence Install Locations
Archive on Update (History)
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Future Plans
Improved Alarm Descriptions
Alarm Inhibiting
Rollout Generic Object Alarm Status
Migrate $AnalogDevice to $UserDefined
Migrate to Archestra Graphics
Online Version Upgrades
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Wishlist
Historian Summary Config in IDE
Log Operator Actions by RDP Client
Better Alarm&Event DB Performance
Enumerated UDAs
Hist Client Display Enum Label (not Int)
Method to Integrate IDE Security with Alarm Query (Ack Permission)
Optional Contained Name for Object in Area & Alarm Properties for Containers
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The End
Thanks!