agenda: rockwell automation solutions & technology for the biofuels industry issues facing the...

Agenda: Rockwell Automation Solutions & Technology for the Biofuels Industry

• Issues facing the Biofuels Industry• Partnering for Success • Expertise in Europe• Global Supply & Local Capabilities• Delivering Value• Technology and Expertise

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Solutions & Technology for the Biofuels Industry

Presented By:Grant Watkins

Agenda

• Issues facing the Biofuels Industry• Partnering for Success • Global Supply & Local Capabilities• Delivering Value• Technology and Expertise


Issues facing the Biofuels Industry

• Planning and implementation– Reduce time required for system design and implementation – Lower risks related to plant commissioning

• Process improvement at existing plants– Improve yield – Increase throughput by reducing cycle time

• Reduction of operating costs– Improve maintenance operations– Efficient energy usage– Optimise labour utilisation through training and improved automation– Reduce downtime


Issues

1/4

Issues customers face

Issues the biofuel industry face:• Pressure to increase operational profits to improve the return on investments and

increase shareholder value:– Increased utility and raw material costs– Tight safety and quality standards– Compliances with new environmental regulations – Pressured to look for alternative raw material– Increasing competition

Solutions we provide:• Process technology for high yields and low operating costs, which are on time with

guaranteed performance and within budget:– Asset optimisation related to process, storage, and utilities utilisation– Saving in consumptions of water, energy and reagents– Reducing wastes applying zero effluent process, dehydration and incineration– Professional and experienced project management


Issues

2/4

New plant and start up

• When building a new Biofuels plant, any delay in reaching production and designed capacity, seriously affects the viability of your customers investment

• Achieving full production requires a significant investment in electrical equipment and process automation

• Keeping the plant running profitably requires good equipment maintenance procedures and practices, robust process control, and attention to utility usage and electrical demand

• Rockwell Automation has demonstrated a successful track-record in delivering automation solutions that simplify both the design and operation of a Biofuels plant, resulting in energy-efficient systems with maximum availability, commissioned in the shortest possible time


Issues

3/4

Response

Continuous peak efficiency is essential for any biofuel plant• Reducing engineering and support costs through a single control architecture for process

control & modular packaged plant• Eliminating integration costs through use of “Intelligent Motor Control Centres” • Minimising commissioning through a plant-wide communications architecture• Reducing risk and lowering operational costs by providing “turnkey” modular process skids• Providing connectivity into your customer’s business systems • Maintaining both equipment and personnel safety


Issues

4/4

Partnering for Success

• Our in-depth understanding of the requirements affecting your industry can help you minimize risk, improve efficiency, reduce process variability and achieve greater profitability

• Rockwell Automation has a successful track record focusing optimisation solutions on the issues you confront

• Rockwell Automation is cooperating with your suppliers and partners in order to get the best solution for you. Strategic Alliances (e.g. with Endress+Hauser) provide you with best of class systems and solutions


Partnering for Success

1/1

Collaborating to meet your needsPlanning and implementation

Planning and implementationDelivered value of compatibility and interoperability

• Single system for the plant

– Reduces time for instrument and loop configuration– Reduces development time– Reduces training– Reduces risk

Delivered Value: Reduced engineering hoursReduction of project timeline


Delivered value of tools and software

• Pre-developed templates for instrument and control loops– Instrument configuration

• Reusable engineering for applications, standard P & I D loop control, standard motor control strategy, standard drive control strategy and standard on/off control (valves)– Reduces development time



Planning and implementation

Install/troubleshoot hardware quickly

Ethernet/IP

Maintenance Office

Plant Floor

• Continuous operations - add any device online

• Control, configure and collect over the network

• Troubleshooting and production aid - gather any information from any location without programming

Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 22/27

IntegratedArchitecture

™

Interoperability testing

• Performance measures jointly established by both companies

• Verified through completion of common test procedures

– Assurance Endress+Hauser field instrument meets Integrated Architecture system interoperability performance

Delivered Value: Ensures a reduced risk solution highlighted by ease of integration and optimum performance

Delivered Value: Ensures a reduced risk solution highlighted by ease of integration and optimum performance

• 50 Endress+Hauser devices tested

Planning and implementation

Example: Sodes Lillebonne -Ethanol Production Plant

BENP Lillebonne Ethanol Plant:– Redundant Fiber Optic Ethernet Network– Redundant ControlLogix with redundant ControlNet card

and power supplies– Redundant Servers and Factory Talk View with 10 operating and

engineering stations– About total 7000 I/Os – 1800 Hart I/Os and approx.

2000 Analog I/O – 200 PowerFlex 700 Drives and SNC FlexStarters

with DeviceNet– Fieldcare Software for Hart device configuration– Cabinets for starters and drives– RSSql and Factory Talk Historian


Expertise in Europe

2/3

Biofuel Customers in Europe


Bioetanol de la Mancha– Bioethanol (Alcázar de San Juan – Ciudad Real, Spain),

annual production capacity of 26.000 tonnes

TAGOL - Companhia de Oleaginosas do Tejo, S.A.– Biodiesel (Almada – Lisboa, Portugal)

Tereos– Bioethanol (Lillebone - France), annual production capacity of

820.000 tonnes of corn resulting in 300.000 m3 ethanol

Greenergy International– Biodiesel (Port of Immingham – England),

annual production capacity of 100.000 tonnes

Expertise in Europe

1/3

Expertise in EuropeExample: Biodiesel Plant

Biodiesel Plant (blind story) - ― High Availability: Through redundancy and integrated safety and condition monitoring― Minimised Development, Installation and Start-Up Time: Through integrated multi discipline

control and information solution for discrete, process, batch, motion, drives― Modular and Scalable Process Control Platform: Assures to remain competitive in a

changing environment with the freedom to have the flexibility to integrate changing plant wide operations - making this complex task a simple one

Biodiesel Production Process


Expertise in Europe

3/3

Serving Europe, Middle East & Africa

Europe, Middle East & Africa:

50+ countries

1000+ professionals executing customer projects

Critical domain expertise & industry knowledge

Leading software, hardware & service solutions

Certified project management

Worldwide delivery

Europe, Middle East & Africa:

50+ countries

1000+ professionals executing customer projects

Critical domain expertise & industry knowledge

Leading software, hardware & service solutions

Certified project management

Worldwide delivery


Global Supply

2/3

Global Supply & Local Capabilities

• More than 5000 engineers in more than 80 offices worldwide

• Prompt availability and local support, wherever

• Designed to simplify start-up, reduce installed cost and provide plant and production that you need

• Safeguard equipment, increase energy efficiency, streamline production and lower total cost of ownership


Global Supply

1/3

Delivering Value summary


• Integrated discrete, control & power solutions

– Increase reliability with system wide, actionable information

– Improve operational flexibility with proven advanced technologies

• Utility management– Power & Energy Management solutions

to help maximise energy efficiency

• Reliability-centered maintenance– Industry leading condition monitoring– Proactive rotational equipment analysis

• Improve time to market– Design automation tools & templates– Information software products– Integrated Architecture™ system– Proven track record of project management

capabilities– Deployment of tested reusable modular

designs on process systems

• Global life cycle services– Global customer support locally– Consistent, repeatable solutions to reduce

time to market of new projects

• Partners to expand the value of Rockwell Automation solutions

Delivering Value

4/4

Technology and Expertise

• Integrated Architecture• Manufacturing Execution Systems (MES)• Power and Energy Management (PEMS)• Process Technology (Proscon)• Services and Support (MPS + CSM)


Technology and

Expertise

1/2

Area of expertise


Site ServicesValidation

Production Facility

Process Modules

Control System

MES

Technology and

Expertise

2/2

Integrated Architecture™

• Real-time information is crucial when making decisions that enhanceproductivity and reduce costs

• Integrated Architecture gives you that kind of responsiveness, as well as the ability to improve operations instantly and facilitate real-time instant reporting to higher level business systems

• Full range of control and information disciplines to help you:– Optimise production– Respond quicker to customer or market demands– Reduce costs faster than before



™

1/27

Design and ConfigurationIntegrated environments for creating,modeling & programming your productionprocesses

Production Management Real-time coordination across your plant wide production processes

Data ManagementTools & methods to use for collecting, transforming& integrating production information

Quality & Compliance Ensure operational processes and procedures meet standards or specifications

Asset Management Optimises maintenance and plant operations to improve your resource availability

Performance & Visibility Presents a window into the process so you can make better decisions

Production Disciplines



™

Core technologies

The Logix Control Platform, the FactoryTalk Integrated Production Management and Performance Suite are linked through a set of core technologies allowing seamless interaction and information flow:

• Logix: multi-disciplined, information enabled and scalable controller family– reducing equipment, training and development costs

• NetLinx: common industrial protocol from plant floor device to IT, improving flexibility and productivity while reducing cost

– Control, Configure, and Collect information and data efficiently• View: a common, fully integrated, scalable visualization strategy across your whole

manufacturing enterprise– Delivering the information you need for more effective decision-making

• FactoryTalk: flexible application development framework, common user interface and industry-standard data models

– Premier integration and interoperability



™

Ethanol Production Plant


Ethanol Plant

5/27


™

Conventional Solution - separate systems

Batch(Dedicated Batch

Systems)

Continuous(DCS)

Discrete (PLC)

Safety(Safety Controls)

Different Automation Systems for Different Applications = Lots of Integration Costs & Long-term Maintenance Costs.



™

Process(Logix)

Batch(Logix)

Drive(Logix)

Safety(Logix)

Discrete(Logix)

Enterprise(View)

Station/Unit(View)

Machine(View)

Integrated Architecture™ - A Single Solution

Benefit: The Integrated Architecture Simplifies Ordering, Stocking, Training, Development, Interfacing,

Troubleshooting, & Maintenance efforts …. Saving Time & Money!

Control(NetLinx)

Control(FactoryTalk)



™

Coaxial/Fo ControlNet couplers

ControlNet redundant coaxial

Redundant supply

Profibus

E/S Flex IO

Redundant supply

DeviceNetControlNet redundant Fo

Primary redundant processor

Secondary redundant processor

Master

Server

Sodes Lillebone (Example) E/S Flex IO Version

Details:– Redundant Controllers (2 supply lines + 2 chassis + 2 processors

+ 6 ControlNet cards+ 4 Ethernet cards + 2 Redundancy modules)– E/S Flex IO with redundant supply lines & ControlNet communication cards– ControlNet redundant coaxial & optic fiber network for E/S management– Ethernet network for centralized control and redundant inter-controller exchanges– Specific communication networks DeviceNet, Hart, Fieldbus Fundation, Modbus, Profibus



™

HMI Screens



™

Ethanol Plants


Operator interface screens – one box, one keyboard, one mouse and one operator

13/27


™

• Huge selection of I/O– Fully supported remote ControlNet and Ethernet I/O capabilities for distribution

of I/O throughout the plant including adding I/O online– Intrinsically safe I/O for hazardous locations– Ability to easily integrate into Process Field Devices– Can add 1756 I/O online

• Redundancy available with off the shelf product– Controller, HMI, Intrinsically Safe Cabling, Power Supplies, etc

• Deploy and install plants quickly– Network able devices = Ease of installation and troubleshooting

“Huge reduction in wiring time”

Biofuels Plant Control



™

Intelligent Motor Control

• Combines leading-edge motor control and protection devices with advanced networking and diagnostic capabilities of Integrated Architecture

• Designed to simplify start-up, reduce installed cost and provide plant and production that you need

• Safeguard equipment, increase energy efficiency, streamline production and lower total cost of ownership



™

Cost of a control system

Hardware &software

20%System

configuration

40%

Programdescriptions

40%

•Controllers•Instruments•Network Modules•I/O Modules

•Description of Operation•Drawings•Logic / Rung Comments•Tag Descriptions

•I/O Configuration•Instrument Setup•Network Setup•Task, Programs, Routines•Structures, Tags

80% of the cost of

implementing a

control system is

the program description,

system configuration,

and documentation

Savings

Savings



™

System configuration

1. From P&ID diagram 2. To configuration

3. To faceplates and graphical

displays



™

Software integrationwith field devices

• Automatic integration of devices into Logix programming

• Filed devices pre-programmed displays

Configuration Wizards

Parameter Monitor and setting list

Spreadsheet View of MCC

Electronic User ManualsField Instruments

Electronic CAD Diagrams

Unit Monitor View



™

Process faceplate detail displays

• The main faceplate display links to several detail displays. For example, a PIDE faceplate provides details for:

Instruction StatusInstruction ConfigurationLoop Trend Manual TuningAuto tuning



™

Savings through reusable engineering

• Common Definition– Executing the same project multiple times at lower implementation cost with each

iteration• How we put this into practice:

– Leveraging a library of field proven, modular elements that are transportable across various projects and businesses resulting in lowest installed cost



™

Data collection (process, alarms, batch)with data historian

• Provides reliable process data collection (no more clipboards!)

– Data collection and storage– Analysis of process parameters– Graphical visualisation

• Makes “data mining” a snap• Additional set of charting tools to

drill into your data– Bar Graph, Grid, Pie Chart, Pareto, etc.

• Historian can also analyze data collected by other applications



™

Increase productivity with advanced process control

• 2D graph and 3D graphs with many options including zoom, line, grid density, range, axis, texture, etc

• Simulation mode allows you to watch influence of individual component values

• Value changes appear also in graphs as “path”



™

Model predictive control of a reactor

Controller capabilities

2x2 model predictive control Rank PV’s in order of importance Auto-manual switch for each MV Executed in ControlLogix controller Uses standard function block library Improve yield Increase capacity by 10%



™

Lower Operational Costs

Lower Total Cost of Ownership

Regulatory & Standards Compliance

Better Information

Faster Decisions

Increased Productivity

Lower Operational Costs

Lower Total Cost of Ownership

Regulatory & Standards Compliance

Better Information

Faster Decisions

Increased Productivity

Integrated Architecture™

One Architecture for Plant Wide Control & Information



™

Manufacturing Execution Systems

• Integrated suite of plant wide information software• Easier integration, faster application development• Seamless information-sharing between factory floor and other departments• FactoryTalk and Logix Control Platform are linked through shared communication services

and technologies that allow seamless interaction and technology flow making possible:– Control System Connectivity– Enterprise and Plant System Integration– Human Machine Interface (HMI)– Supervisory Control and Data Acquisition (SCADA)– Manufacturing Execution System (MES)– Asset Management


Manufacturing

Execution Systems

1/2

Manufacturing Execution Systems

• MES can increase the throughput of your plant by:– Eliminating paperwork– Reducing errors – Maintaining high quality standards

• MES can eliminate resources that are performing unnecessary tasks and help reduce material waste– Tighter automation integration & extended capabilities for production and manufacturing

companies– Latest version provides on-demand manufacturing information to help improve productivity and

reduce time-to-market– Extends capabilities in automation information integration – Offers increased flexibility in state-of-the-art data management and process execution– E.g. software helps simplify the integration of information between resource logistics and order

fulfilment


Manufacturing

Execution Systems

2/2

Power and Energy Management

• Log usage, demand and production data• Create historical trend reports and charts• Establish consumption baseline and user

defined time of use periods• Assign rate plans to meters or groups of meters• Create and print daily or monthly cost and billing

reports by meter, business group, department, or site

• Create energy budgets and forecasts.• Compare and contrast alternative utility rates; do

“what-if” for other rate structures


Power and Energy

Management

1/1

Global Applications - PEMS Application Examples


Power & Energy Management (PEMS) Metal Forming Industrial Combustion Advance Process Control (APC) Coal Handling, Ash Handling, Soot Blower De-Mineralizer Water Treatment Material Handling / Packaging Manufacturing Execution System (MES) Safety Solutions Regulatory Compliance Services Batch Solutions Legacy Conversions


Process Domain ExpertiseDistillation & Solvent Recovery Systems

• ProsCon’s highly efficient and energy saving Distillation and Solvent Recovery systems help you recover more from your manufacturing process at lower energy consumption

• Assess the viability of distillation and solvent recovery for your application using– Front end studies– Budget development studies– ROI assured through Waste analysis, distillation and recovery simulation, utilising pilot-scale test

facility and simulation• Benefits include

– Accelerated Construction schedule by parallel path activities– Integrated heat recovery reduces steam consumptions and energy costs– Shrinking the volume of disposable waste and decreasing waste treatment costs– Cut haul-away disposal or incineration charges– Conforming to environmental protection standards– Maintaining quality of solvent and Ethanol concentration


ProcessTechnology

1/3

Process TechnologyRecover More, Waste Less

• Modular Distillation and Solvent Recovery units incorporate all the hardwareand structural elements your installation requires

– vessels– columns– heat exchangers– pipe work– valves,– instrumentation– steelwork

• Integrated process solutions include control systems designed and built in any platform

• Integration with your wider plant control architecture.• Modules shipped quickly and safely to locations throughout the world

from our dockside facility


ProcessTechnology

2/3

Process Technology Modular Solutions


Build Finish Install

ProcessTechnology

3/3

Feasibility study Counseling and conception of the problem solution Device specifications / calculation Product and functional specifications Control and monitoring concepts Function plans Software implementation Special applications Project management and project realization Commissioning Validation and acceptance Documentation Training Support and maintenance Plant management services

MPS - From Concept to Successful Solution


A worldwide support at anytime

Engineering Resource Centers

Major Project Implementation Centers

A worldwide common iPM methodology integrated with our business systems programs and policies.

Global network of domain expertise, industry knowledge, and world-class offerings create an unparalleled solutions in over 80 countries.

Over 1800 engineers with critical domain expertise understand your business and help you to succeed.

Worldwide local support for engineering and maintenance.

Services and SupportSuperior Services & Expertise

• Long-term and reliable support with the immediacy you need• Rockwell Automation’s portfolio of services can meet the challenges

at any stage of the project• Machine diagnostics and optimisation, allowing systems to collect and analyse information

for efficiency measuring• Let us help you optimally manage your assets regardless of the maintenance strategy

employed

PredictivePreventativeCorrective


Services and Support Condition-Based Maintenance

• A strategic approach to maintenance is essential to minimise downtime

• Rockwell Automation offers a full line of services and support that significantly reduces unplanned downtime by:

– Applying a condition-based maintenance program to your rotating machinery and notifying you of problems before they occur

– Applying a preventative maintenance program to your controls equipment– Training your maintenance department to troubleshoot your controls equipment– Giving you real-time access to our global network of world-class Customer Support

Centres and technical resources– Making sure you have the right parts when you need them to get your machine up

and running quickly


Transforming maintenance from an expense to a business asset

• Aligning the Resolutions to Your Issues – Using maintenance as a business asset

means correlating financial and productivity issues with Strategic Maintenance resolutions

– Rather than pick a single mode of maintenance, strategic maintenance combines predictive, preventive and reactive methods in an optimal fashion to reach your goals

By implementing a Strategic Approach to Maintenance, companies can reclassify maintenance from an expense to

a competitive differentiator and profit driver.



™

Integrated Automation and information solutions using best-in-class

solutions for your company

agenda: rockwell automation solutions & technology for the biofuels industry issues facing the...

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