rs3 dcs migration at warwick chemicals - rockwell automation · pdf filesystem maintenance...

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

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


Warwick Chemicals – an introduction

3


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


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.


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


Developing Manufacturing Processes

7


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)


Control – 2011

9

Storage

Precursor formation


(batch)



(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


Process – 2011

10

Storage

Precursor formation


(batch)



(continuous)



Waste treatment

(continuous)


Process – from 2013

11

Storage

Precursor formation


(batch / continuous)



(continuous)

Precursor separation

(continuous) Formulation (continuous)

Waste treatment

(continuous)


Process & Control – the choice

12

Storage

Precursor formation





(continuous)



Waste treatment

(continuous)

RS3

RS3

RS3

RS3 / Manual

Allen-Bradley

Delta V

Delta V

Delta V

RS3


Process & Control – the choice

13

Storage

Precursor formation





(continuous)



Waste treatment

(continuous)

?

?

?

?

Allen-Bradley

Delta V

Delta V

Delta V

?


RS3 Migration Selecting a new system

14


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

15



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

16



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

17



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



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’



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



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


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



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

23



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



Scoring criteria

Reliability Expected mtbf

System recovery Expected mttr

Security HMI operating system user privilege control

Key / Password / Key + password

25



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



Scoring criteria

Confidence in future support History of product development / evolution

Technical support availability Location Native language Vendor only?

Ease of configuration

27


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


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


Implementation … the story so far

30


Control – from 2013

31

Storage

Precursor formation





(continuous)



Waste treatment

(continuous)

?

?

?

?

Allen-Bradley

Delta V

Delta V

Delta V

?



32

Storage

Precursor formation





(continuous)



Waste treatment

(continuous)

Rockwell PlantPAx

Allen-Bradley

Delta V

Delta V

Delta V

Rockwell PlantPAx

Rockwell PlantPAx

Rockwell PlantPAx

Rockwell PlantPAx



33

Storage

Precursor formation





(continuous)



Waste treatment

(continuous)

Rockwell PlantPAx

Delta V

Delta V

Delta V

Rockwell PlantPAx

Rockwell PlantPAx

Rockwell PlantPAx

Rockwell PlantPAx Rockwell PlantPAx


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

34



35

Storage

Precursor formation





(continuous)



Waste treatment

(continuous)

Rockwell PlantPAx

Rockwell PlantPAx

Rockwell PlantPAx

Rockwell PlantPAx

Rockwell PlantPAx Rockwell PlantPAx

Rockwell PlantPAx

Rockwell PlantPAx

Rockwell PlantPAx


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

36


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.

37



38



39



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

40



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

41



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

42



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

43


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

44


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)

45


Conclusions

46


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

47


Questions

Les Waymont Process Engineering Manager, Warwick Chemicals [Mostyn, Wales, UK] November 2012

rs3 dcs migration at warwick chemicals - rockwell automation · pdf filesystem maintenance...

Documents