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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
RS3 DCS Migration at Warwick Chemicals Selecting & Implementing PlantPAx
Les Waymont Process Engineering Manager, Warwick Chemicals November 2012
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2
Agenda
Conclusions, and Questions
Implementation – the story so far
RS3 migration – selecting a new system
Developing manufacturing processes
Warwick Chemicals – an introduction
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Warwick Chemicals – an introduction
3
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Warwick Chemicals
4
Warwick Chemicals are the worlds largest manufacturer of bleach activators – environment-friendly chemicals that make low temperature washing powders possible. We supply to 60 countries on 5 continents. Every major detergent producer uses our products
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Warwick Chemicals
5
The site occupies about 50 acres, adjacent to docks, in North Wales. The site has an industrial history dating back to at least 1294 (yes, that’s over 700 years)
Warwick Chemicals is a self-contained operation, employing about 170 people in manufacturing, engineering, logistics, R&D, and business support functions.
The factory operates 24/7, with typically 2 short shutdowns per year
Warwick has origins in the 1950’s, making chemicals for textile industries
Warwick acquired the manufacturing site at Mostyn, North Wales site in 1979
For many years, Warwick was wholly owned by the Sequa Corporation in the USA.
Currently owned by Close Brothers Private Equity.
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Warwick Chemicals
6
Warwick Chemicals operate a wide range of chemical processes, including most of the ‘classic’ chemical process ‘unit operations’
Continuous reaction Batch reaction Distillation Evaporation Crystallisation
Filtration Vacuum drying Granulation Milling Sieving Fluid bed drying
Combustion Incineration Waste water treatment Warehousing
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Developing Manufacturing Processes
7
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Process – 2011
8
Storage
Precursor formation
(continuous) First crop product
(batch)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Second crop product (batch)
Formulation (continuous)
Waste treatment
(continuous)
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Control – 2011
9
Storage
Precursor formation
(continuous) First crop product
(batch)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Second crop product (batch)
Formulation (continuous)
Waste treatment
(continuous)
RS3
RS3
RS3
RS3
RS3 / Manual
Allen-Bradley
Delta V
Delta V
Delta V
Total: 6000 digital i/o
2000 analogue i/o
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Process – 2011
10
Storage
Precursor formation
(continuous) First crop product
(batch)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Second crop product (batch)
Formulation (continuous)
Waste treatment
(continuous)
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Process – from 2013
11
Storage
Precursor formation
(continuous) First crop product
(batch / continuous)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Precursor separation
(continuous) Formulation (continuous)
Waste treatment
(continuous)
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Process & Control – the choice
12
Storage
Precursor formation
(continuous) First crop product
(batch / continuous)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Precursor separation
(continuous) Formulation (continuous)
Waste treatment
(continuous)
RS3
RS3
RS3
RS3 / Manual
Allen-Bradley
Delta V
Delta V
Delta V
RS3
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Process & Control – the choice
13
Storage
Precursor formation
(continuous) First crop product
(batch / continuous)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Precursor separation
(continuous) Formulation (continuous)
Waste treatment
(continuous)
?
?
?
?
Allen-Bradley
Delta V
Delta V
Delta V
?
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
RS3 Migration Selecting a new system
14
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
RS3 migration strategy
Strategic issues
Ability to integrate with existing systems Transitional arrangements with existing, redundant systems Integration with existing management systems: MIS, MRP, ERP
Ability to develop and enhance New plants, new processes Additional functionality
Advanced control strategies - on-line optimization Management systems integration – off-line optimization
Solid foundation is paramount
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
RS3 migration strategy
Ongoing / lifetime issues
System evolution Software upgrades Hardware upgrades Hardware obsolescence Customer’s dilemma:
Want cutting edge features - on old, proven, reliable hardware
Operating cost System maintenance Support Reliability / Recovery Operator training
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RS3 migration strategy
Short-term – software reconfiguration
Migration of functionality from RS3 to new system Opportunities:
tidy up ‘organic growth’ code reset design standards
» Operator interface design » alarm management
Risk of incorrect translation Imperfect process descriptions, functional descriptions Failing to capture operational evolution, changing practices
System revalidation
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
RS3 migration strategy
Short-term – operational transition
Sales don’t stop! Continued operation Shutdown opportunities limited, and short Restart MUST be on time
Training operators maintenance technicians Systems / configuration engineers
Capital cost
18
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RS3 migration strategy
19
HMI HMI HMI
controller controller controller controller
i/o i/o i/o i/o i/o i/o i/o i/o
Replace by horizontal slice
Strategy only practical for migration from RS3 to Delta V - BUT all RS3 hardware is effectively obsolete (‘retired’) already, - strategy then becomes ‘replace all at once’
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RS3 migration strategy
20
HMI HMI HMI
controller controller controller controller
i/o i/o i/o i/o i/o i/o i/o i/o
Replace by vertical slice
Strategy viable for all systems, if plant can be subdivided readily
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
RS3 migration strategy
Preferred approach:
Replacement in vertical slices
Select 'low risk' slice initially Stage 1: Waste water treatment - can be manually operated Stage 2: Existing plants using Rockwell PLC hardware
Select more complex phases later
21
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Vendor Selection Process
Produce scope Overall plan, three phases Detailed first phase
Select potential vendors Emerson Rockwell Two other vendors with recent RS3 migration experience
Select by weighted scoring Develop selection criteria
Important system features Important vendor features
22
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Vendor Selection Process
Collect data
Technical discussions with vendors
Site visits to current users Preference to users migrating from RS3
On-site test exercise Neutral in-house technicians
Not involved directly in selection process Not familiar with system configuration Removes in-built bias of engineers selecting system
Feedback on system diagnostic features
Evaluation of bid against scope
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Vendor Selection Process
Scoring criteria
Total Cost of Ownership…
Capital cost
Operating costs 15 year life cycle All support costs for all control systems on site
» Continued support for other vendors hardware, if not replaced Software upgrade costs End-of-life hardware replacement costs
» E.g. PC hardware for HMI
24
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Vendor Selection Process
Scoring criteria
Reliability Expected mtbf
System recovery Expected mttr
Security HMI operating system user privilege control
Key / Password / Key + password
25
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Vendor Selection Process
Scoring criteria
Connectivity, functionality Integration with existing systems
PI data historian Other control systems, if not replaced SIS (existing Hima-Sella safety system)
Ease of changeover
Operator interface Functionality Alarm management
26
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Vendor Selection Process
Scoring criteria
Confidence in future support History of product development / evolution
Technical support availability Location Native language Vendor only?
Ease of configuration
27
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Strengths & Weaknesses
28
Weighted scores Vendor 1 Vendor 2 Vendor 3 Rockwell
Total Cost of Ownership 52 -96 12 36 Reliability 22 15 16 11 System recovery 10 18 18 10 Security 17 20 14 14 Connectivity, functionality 15 15 19 21 Ease of changeover 27 27 27 27 Operator interface 32 46 36 32 Confidence in future support 9 9 3 27 Technical support availability 12 12 4 36 Ease of configuration 15 9 12 9
TOTAL 211 75 161 223
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Strengths & Weaknesses
29
Weighted scores Vendor 1 Vendor 2 Vendor 3 Rockwell
Total Cost of Ownership 52 -96 12 36 Reliability 22 15 16 11 System recovery 10 18 18 10 Security 17 20 14 14 Connectivity, functionality 15 15 19 21 Ease of changeover 27 27 27 27 Operator interface 32 46 36 32 Confidence in future support 9 9 3 27 Technical support availability 12 12 4 36 Ease of configuration 15 9 12 9
TOTAL 211 75 161 223
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Implementation … the story so far
30
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Control – from 2013
31
Storage
Precursor formation
(continuous) First crop product
(batch / continuous)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Precursor separation
(continuous) Formulation (continuous)
Waste treatment
(continuous)
?
?
?
?
Allen-Bradley
Delta V
Delta V
Delta V
?
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Control – from 2013
32
Storage
Precursor formation
(continuous) First crop product
(batch / continuous)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Precursor separation
(continuous) Formulation (continuous)
Waste treatment
(continuous)
Rockwell PlantPAx
Allen-Bradley
Delta V
Delta V
Delta V
Rockwell PlantPAx
Rockwell PlantPAx
Rockwell PlantPAx
Rockwell PlantPAx
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Control – from 2013
33
Storage
Precursor formation
(continuous) First crop product
(batch / continuous)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Precursor separation
(continuous) Formulation (continuous)
Waste treatment
(continuous)
Rockwell PlantPAx
Delta V
Delta V
Delta V
Rockwell PlantPAx
Rockwell PlantPAx
Rockwell PlantPAx
Rockwell PlantPAx Rockwell PlantPAx
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Control – review and commit
Reviewed rationale behind simply replacing RS3 ‘island’ of DeltaV in middle of the main process train Limited potential for overall site integration Operators presented with multiple interfaces Technicians have multiple systems to maintain Multiple spares to hold, multiple service contracts “It’s the other guy’s fault” when interoperability problems arise
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Control – from 2013
35
Storage
Precursor formation
(continuous) First crop product
(batch / continuous)
Storage Product separation (batch / continuous)
By-product separation
(continuous)
Precursor separation
(continuous) Formulation (continuous)
Waste treatment
(continuous)
Rockwell PlantPAx
Rockwell PlantPAx
Rockwell PlantPAx
Rockwell PlantPAx
Rockwell PlantPAx Rockwell PlantPAx
Rockwell PlantPAx
Rockwell PlantPAx
Rockwell PlantPAx
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Control – review and commit
Placed contract with Rockwell Automation in November 2011 Develop functional design specifications for
Waste water treatment: independent, limited i/o, possible to operate manually if necessary… low technical risk.
Product formulation units: underlying logic already in Rockwell hardware – fundamentally, only hmi layer changes
Principal aim – reproduce existing functionality Maintain operators familiarity with process as they adapt to new hmi Limit opportunity for ‘translation errors’ from old to new systems
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1st Phase: Waste water treatment
Commenced November 2011 Software engineering carried out by Rockwell Automation, in
Milton Keynes (UK), commencing November ’11 Develop standard modules for future use on all phases
Based on GEMS modules, with minimal customisation Develop standard operator interface styles, alarm presentation Basis of UI for future phases.
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1st Phase: Waste water treatment
38
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1st Phase: Waste water treatment
39
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1st Phase: Waste water treatment
Project Observations Engineer and technician training carried out April ’12 Operator familiarisation and training carried out May – June ‘12 Production demands moved shutdown to later in summer Migration started mid-August
Hardware cut-over and loop testing: 2 days for 100 digital, 50 analogue i/o Factory testing: intermittent through 7 days (depends on tides!)
Carried out simultaneously with one formulation plant migration Migrated system ‘live’ in August ’12
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1st Phase: Waste water treatment
Project Observations Issues in first 8 weeks…
Interrupted sequences when operators take ownership of valves, and don’t return back to program mode
Difference in interpretation of ‘rate of change of level’ led to missing a water discharge window on two or three occasions
Different hardware characteristics on 4-20 mA loops: Flex I/O raises a fault if input < 4mA Compact I/O (like old RS3 i/o) faults at < 2.5mA
Some reconfiguration of old RS3 system required
Re-routing of data for PI historian database Hardware limits of RS3 meant some low priority data sacrificed short-term
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1st Phase: Waste water treatment
Operator feedback Prefer new-style graphics to old
Less distraction – ‘cleaner’ Alarms immediately obvious Windows interface ‘less clunky’, more familiar
Prefer new alarm handling Better access to alarm history
Prefer new trending Some issues adapting to differences in terminology
‘Operator’ vs ‘Manual’; ‘Cascade’ vs ‘Master / slave’ Some issues adapting to Operator vs Program mode
RS3 distinction is rather blurred
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1st Phase: Waste water treatment
Technician / engineer feedback Technicians more closely involved in system configuration
RS3 historically treated as a black box upstream of I/O cards System is ‘mechanically’ straightforward to work with Diagnostics need improvement:
fault finding usually requires jumping between software tools FactoryTalk View ↔ RSLogix ↔ RSLinx
Configuration tools feel like a collection, not a suite Example: slight differences in structured text syntax between
FactoryTalk View and RSLogix But, configuration is not an everyday activity
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2nd Phase: Product Formulation
Implemented August 2012 Scale: 400 digital i/o, 50 analogue i/o Same time as waste water migration Underlying hardware was Rockwell
Application software reconfigured New, but relatively similar operator interface
Outcome Larger system than waste water, changes are less dramatic Some minor issues with reconfigured application software
Due largely to unreliable site documentation Changes to plant since original FDS Arbitrary values for some timers needed refining
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Other aspects
Training PlantPAx specific configuration training needs development On site, application specific, training could be better structured
Review and develop as further phases added
Data capture – OSI PI Integration required cooperation between
Warwick engineering Warwick IT department Rockwell Emerson (who historically support Warwick’s PI installation)
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Conclusions
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Conclusions
Open evaluation looking at 15 year operating life led to moving Warwick Chemicals site to Rockwell PlantPAx
Implementation phases have run reasonably smoothly so far Final quotations for each phase of work have been almost identical to
original estimates System engineering at each stage has been on time, and in budget Implementation has been delayed where necessary to meet site
operational constraints After migration, it all worked.
Operationally, everyone, so far, can see benefits and further potential
Conversations have begun on how to build on this platform
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Questions
Les Waymont Process Engineering Manager, Warwick Chemicals [Mostyn, Wales, UK] November 2012