cs06 calumet-malisko engineering

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Virtualized PlantPAx Improving Consistency and Throughput

Doug Stanek

Plant Engineer - Calumet

Tim Malyszko

Director of Operations – Malisko Engineering, Inc.

November 2014


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Agenda

Future Expansions

Results / Lessons Learned

Selecting a PlantPAx Solution and System Overview

Project Goals

Introduction


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Who is Calumet?

A leading independent producer of high-quality, specialty hydrocarbon products.

Headquarted in Indianapolis, IN with locations throughout the United States.

Fortune 500 Company!


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Calumet Louisiana Synthetics – Louisiana MO

Produces Polyolester based synthetic lubricants

Refinery facility located in Louisiana, MO

36 Million Lbs./year capacity

Refines fatty acids and alcohols into Polyolester based synthetic lubricants

Batch esterification process


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Products


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Who is Malisko Engineering?

• Experts in manufacturing automation and validation

• Founded in 1994

• Headquartered in St. Louis, Missouri USA

– Historic Laclede’s Landing on the Mississippi Riverfront

• Regional office in Denver, Colorado USA

– Serving the Rocky Mountain region and the west

• Rockwell Automation® Solution Partner for control,

process, & information systems.

• CSIA certified member

Historic Laclede’s Landing St. Louis, MO

Denver, CO Malisko Western Regional Office


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Recognized As Experts


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Agenda

Future Expansions



Project Goals

Introduction


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Project Goals – Phase I Existing Synlubes Facility

Automate a primarily manual operation

Convert manual valves to automatic control

Minimize operator intervention by reducing operator interactions in field by over 200

steps per batch

Automate pressure and temperature control

Manage formulations electronically

Migrate manual batch records to electronic batch records

Improve product consistency

Migrate antiquated tank farm HMI to new system


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Project Goals – Phase II Kettle Expansion

Double production capacity

Add two new fully automated kettles

Automate drumming station

Add a new centralized control room for all operations


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Project Goals – Phase II Kettle Expansion

Add fully automated intermediate and finished product tanks and acid storage tanks, truck and rail car loading stations

Automate loading and custody transfer

Add server redundancy to phase I PlantPAx® components


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Agenda

Future Expansions



Project Goals

Introduction


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Choosing a PlantPAx Solution “Traditional” DCS vs. PlantPAx

Criteria Traditional DCS

Local Support Single Local Solutions

Provider

Local Eco-System consisting

of dozens of local Integrators

and Solution Partners

Scalability Hardware + Additional License

required for additional I/O

No additional licensing

required

Topology

Dedicated Servers. Software

and Hardware Upgrades

Expensive

Virtualization Fully Supported

– Decoupling Hardware from

Software


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System Overview – Phase I Define Control Strategy

Needed to estimate system parameters such as server tags, memory

usage and execution time.

S-88 modeling - define control modules, equipment modules, phases and

unit procedures


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System Overview – Phase I PlantPAx System Characterization

Characterization verifies that the system provides the required

performance


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System Overview – Phase I System Architecture

Single physical server with four virtualized images

FactoryTalk® View server ThinManager® remote desktop server FactoryTalk® Historian FactoryTalk® VantagePoint® & Transaction Manger Two View thin clients

Foundation Fieldbus

Move segments from existing DCS to PlantPAx® Combine 3 segments into 1 segment

“Traditional” I/O used for new field devices

Easier to troubleshoot for plant support No significant cost savings using bus technologies


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System Overview – Phase I System Architecture Continued

VPN connection into system for remote support


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System Overview – Phase I PlantPAx Process Objects

v3.0 PlantPAx process objects used

“Out-of-the-box” PlantPAx AOIs used

“Enhanced” PlantPAx global objects used


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System Overview – Phase I Formulation

All product formulas reside in the program

Formulations can be changed, added and removed from HMI with proper security

Formulations can be modified at start of batch by operators and changes reflected in batch ticket


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System Overview – Phase I Convert Log Sheets

Convert manual data collection to automatic data collection

Emergency events such as power loss now automatically recorded on log sheet


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System Overview – Phase I VantagePoint Reporting

All log sheets available via FactoryTalk VantagePoint


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System Overview – Phase I VantagePoint Reporting

Daily tank farm report ran and printed at 7 AM


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System Overview – Phase I ACP ThinManager® Deployment

Easily manage and deploy

FactoryTalk View clients

Application link locks down the

client so operators can only access

the FactoryTalk View client

application.

Shadow feature gives engineers

the ability to remotely monitor the

process and troubleshoot issues

remotely with the operator.


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System Overview – Phase II System Architecture

Add additional controllers and operator workstations for new process units

and tank farm.

Interface to new IntelliCENTER®

Add redundancy to PlantPAx components

Secondary FactoryTalk View Site Edition server

Redundant domain controllers

Mirrored ACP ThinManger servers


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Agenda

Future Expansions



Project Goals

Introduction


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Immediate Results

Batch consistency All formula parameters reside in the system All operators now run the system the same

Batch cycle time optimization Roll from one step in the batch to the next No longer waiting for the operator to perform the next step before

moving forward


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Immediate Results Continued

Eliminate the “I Think” and turn it into “I Know” All devices historized

Batch records can be pulled from VantagePoint since batch number

one on the system

Identify opportunities to increase capacity beyond initial 4-5%

capacity by eliminating process bottlenecks

Heat cycle tracking Reliable data showing heat cycle and adjustments made during cycle

Optimize heat cycle over the course of a batch

Virtualization allowed us to move and redeploy server images and add

server redundancy with minimal interruption to the process

PID control adjustments can be done completely from PlantPAx faceplate

No need to open Studio 5000® when adjusting PID Control


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Long Term Benefits

Operator comfortable with system before major expansion

Ease of adding additional points to system

No additional licensing required Using prebuilt PlantPAx objects like the dosing AOI simplifies brining

in externally totalized additions into system Tracking additions gives Calumet ability to bill customers accurately

for formulation


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Lessons Learned

Use domain controllers

Even on small systems, managing

security becomes a challenge in a

workgroup environment

Foundation Fieldbus network

design

Verify network topology design

before commissioning

Poor design = poor signal quality &

loss of device communications

Remote support via VPN is a must!


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Agenda

Future Expansions



Project Goals

Introduction


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Future Expansion

Migrate existing Traditional DCS controlling Kettle D to PlantPAx

Foundation Fieldbus, DeviceNet and AS-Interface

Add waste water treatment into PlantPAx system to reduces the risk of

costly need for off-Site process.

Convert existing manual tank farm operations unit-by-unit.


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Questions?

Doug Stanek

Plant Engineer - Calumet

Tim Malyszko

Director of Operations – Malisko Engineering, Inc.

11/15/2015

cs06 calumet-malisko engineering

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