quimikao: plantpax system helps chemical manufacturer convert japanese plant processes to mexican...

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Quimikao: PlantPAx System

Chemical Manufacturer Converts Japanese Plant

Processes to Mexican Facility

Miguel García Hoo / Salvador Alejandro Rivas Rojas

IT Coordinator / Project Manager

November 17-18, 2014


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Agenda

Conclusions

Implementation Details

Production Process

PCEI Company Profile

Quimikao Mexico Overview


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Quimikao S.A. de C.V. belongs to

Division Chemical of Kao Corporation

Group.

Kao Corporation Group has more than a

century of experience in the cosmetics

and detergents market with more than 30

affiliates worldwide.

Quimikao mainly produces Cationic

Surfactant derivatives of fatty acids.


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Agenda

Conclusions


Productive Process




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PCEI was founded in 2004 at

Guadalajara, Jalisco México.

The company has developed automation

projects in different kinds of industries but

specially in chemical, food and beverage

industries.

PCEI works in Argentina, Brazil, Chile,

Colombia, Belgium, Italy, Japan and

others countries.


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Agenda

Conclusions


Productive Process




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Productive Process

N-2 Reaction system & Hot oil system


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Productive Process

N-2 Distillation system


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Productive Process

N-2 Complementary services/connections

Services

1. Steam system

2. Cooling water system

3. Fatty Acid supply


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Agenda

Conclusions


Productive Process




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Project Specifications

1. PlantPAx platform 2. PlantPAx virtual infrastructure design 3. Asset Management system 4. PAC redundancy 5. Use of intrinsically safe barriers 6. MCC control by I/Os (communication just for status) 7. Energy management metrics by a PowerMonitor 8. Use of Modbus RTU communication to monitor secondary services 9. Use of Modbus TCP/IP communication to control steam system


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Why Qimikao chose PlantPAx platform?

One single platform to control every phase of the nitrile production. An innovative system that handles process and discrete control with

communication. A system that could improve efficiency and decrease the downtime by

using virtual infrastructure. An advanced networking, monitoring and diagnostic system that could

increase preventative-maintenance capabilities, and reduced repair costs.


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Project Timeline from September 18th2013 to April 29th 2014

Opening Meeting Control Engineering Design MCC Engineering Design Wiring Operation Sequences Review HMI Development PAC Program Factory Acceptance Test Installation and Site Acceptance Test


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First steps

Application Checklist


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First steps

Data Checklist


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First steps

FTAssetCentre Checklist


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First steps

FTView SE Checklist


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First steps

Network Architecture


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Rockwell Automation Validation

Architecture review PlantPAx system review Ethernet/IP network

architecture review


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Engineering development

85-265VAC Power Supply

1756-PA75

Redundant PAC Racks 1756-

A4

I/O Racks 1756-A13

Stratix 8000 1783-MS10T

24V,10A Single Phase Input

PS 1606-XLE240E

Buffering for 24V loads 1606-

XLBUFFER. Guaranteed

hold-up time: 0.2s/20A to

3.6s/1A


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Engineering development


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1. 1756 Chassis 13 Slots (1x1756-A13)

2. 85-265VAC Power Supply (2x1756-

PA75R)

3. ControlLogix EtherNet/IP 2-port

module (1x1756-EN2TR)

4. 10…30V DC diagnostic input module

(5x1756-IB16D)

5. 19.2…30V DC 16-point diagnostic

output module (6x1756-OB16D)

1. 1756 Chassis 13 Slots (1x1756-

A13)

2. 85-265VAC Power Supply

(2x1756-PA75R)



4. ControlLogix HART Analog Input

Module (5x1756-IF16H)

5. ControlLogix HART Analog

Output Module (4x1756-OF16H)

6. Modbus RTU module (MVI56E-

MCM)

7. Modbus TCP/IP module (MVI56E-

MNET)


Racks components

1. 1756 Chassis 4 Slots (2x1756-A4)

2. 85-265VAC Power Supply

(4x1756-PA75R)

3. ControlLogix 8MB Controller

(2x1756-L73)



5. ControlLogix RM Module Fiber

Optic Cable (2x1756-RMC1)

6. ControlLogix Redundacy Module

(2x1756-RM2)

Check the product compatibility list before doing any

firmware changes


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Controller Programming – Sequences development

Old way to programing

1. Internal status switch assignment

list

2. Table assignment list

3. Timer, preset, counter

assignment list

4. DO/DI assignment

5. Code Input/output assignment

6. NSM assignment

7. Annunciator assignment


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The use of Sequential Function Chart is very helpful to compare and

understand routines, however it increases data logic memory considerably.


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How do we update a program that was developed 30 years ago?

The use of Rockwell Automation library reduces engineering time.


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How do we update a program that was developed 30 years ago?

Modular design eases construction of complex control strategies.


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Controller Programming – Periodic Task Configuration

Refer PlantPAx reference manual (PROCES-RM001) for configuration guidelines


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Server Virtualization.


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Advantages Using Virtual Server System

1. High Availability

2. Disaster Recovering

3. Space and Energy Saving

4. Extend Life of older applications


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Advantages Using Virtual Server System

5. Application Isolation

6. Optimize Computing Resources

7. Ease of Access and managing

8. Improved System Reliability and Security


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Advantages Using Rockwell Automation Virtual Templates

1. Reduce Engineering Time And Validation Costs

2. Ease Lifecycle Management

3. Enhance Scalability


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Rockwell Automation Virtual Templates

1. Engineering Workstation (EWS)

2. Operator Workstation (OWS)

3. Process Automation System Server (PASS)


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Software Architecture


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Virtual Server System

1


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Setting up Redundancy

1. HMI Server Redundancy


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Setting up Redundancy

1. Alarm Server Redundancy


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Datalog and Reports.


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Rockwell Automation Library

1. Using RA Library Templates is easy and reduces developing and debugging time.

2. They can be easily customized. The changes will reflect in all the instances of the object.


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Final Results


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Conclusions

High availability.

Faster disaster recovering, fast equipment providing.

Space and energy Saving.

Extend life of applications.

Application Isolation.

Using Server Virtualization Advantages .


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Conclusions

Reduces developing, mantainance and debugging time.

Less error prone.

Customization.

Using RA Library Templates of Process Objects Advantages.


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Questions

Miguel García Hoo / Salvador Alejandro Rivas Rojas

IT Development Coordinator / Project Manager

November 17-18, 2014

quimikao: plantpax system helps chemical manufacturer convert japanese plant processes to mexican...

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