Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Insert Photo Here
Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL – McCormick Place West
Leveraging PlantPAx
Technology to Survive
and Thrive in a Dynamic
Business Environment
Michael Hilton
Industrial Furnace Company
Today’s Discussion
• Industrial Furnace Company Overview
• Project Inception, Overview and Timeline
• Process Hardware (PlantPAx)
• Bus Network Technology
• Encompass Partnership
• FactoryTalk AssetCentre
• Advanced Process Control
• What did we Learn
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Company Overview
• Broad background in refractory construction and steel erection, IFCO began building
multiple hearth furnaces over 60 years ago.
• Industries we Service : Waste Water and Mining.
• Pre 2004, 70% Municipal & After 2006 30%.
• Mechanical Engineering Services in 1982.
• Electrical & Automation Company in 2000.
• In-House Pilot facility with cyclones and bag house, and fully automated controls.
• Personnel over (105) Total – (22) Project Managers, Engineers, and Support,
(83) in the Field work as Foremen, Mechanics, Electricians and Labors.
Industrial Furnace Company, Inc. (IFCO) family owned company founded in 1948.
Headquarters in Rochester, New York and Division in Atlanta, Georgia
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Project Inception
Late 2008 an investment company contact IFCO
to help design and build a process to produce
240 Tons/Day of Activated Carbon from Coal.
Needed to be on line as soon as possible since
product was already committed. We all have
heard that before in the construction world!
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Brown Field 240 Tons/Day Calcination Plant
Started February 2009
One Customer, (3) Engineering Companies, (2) General Contractors, and (12) Skid Manufactures 15 months from the first shovel in the ground to System Online!
On-Line May 2010
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Project Timeline
Commercial
(3) Months
Process Design
(4-6) Weeks
Engineering Mechanical
12 WeeksEngineering E&I
10 Weeks
Installation Mechanical
50 WeeksInstallation E&I
39 Weeks
Programming E&I
5 Weeks
Startup
(6) WeeksManufacture E&I
8 Weeks
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Logix Hardware and Software
• Versatile from small skid to large process control vendors.
– CompactLogix thru Redundant ControlLogix Platforms
• Common Service and Support Software. (RSLogix 5000)
• Easy to Integrated on Plant’s Main Communication Backbone (Ethernet)
• Separate Factory Acceptance Testing for each Vendor
– Intellectual Property
– Concurrent System Development
First project kickoff meeting with Engineering Teams it was decided
to use Allen Bradley Logix Family for all the skid manufactures.
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Bus Network Technology
ControlNet
• Motor Control Centers VFDs (Flex700 Series)
• Remote IO Racks
• Foundation Field Bus Bridges (FFLDC4)
DeviceNet
• Motor Control Centers 2100 CenterLine (DSA Modules)
• Smart Burner Control Panels
Foundation FieldBus
• Temperature (128), Flowmeters (256) and Valves (210)
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Summary PlantPAx Scope Overview
• HMI
– FT View SE
• Controllers
– 4 ControlLogix L63 V17 (1 / MHF)
– 12 racks
– 1020 I/O
• Instrumentation (600 total instruments)
– 60 total FF networks (15 / MHF)
– 236 E+H Vortex
– 128 E+H Temp
– 236 valves
• 6 Section Centerline MCC (1 / MHF)
– 12 drives
– 52 Motor starters
• Burner Boxes with Point I/O and Flame scanners
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Encompass Partners
• Rockwell Engineering Services
– PAC or Instruments (One stop Shop)
• Startup Team. (Rockwell Local/Engineering and E+H Technicians)
– Quick Physical Layer Checkout (2 Days)
– No Finger Pointing (Team Effort)
• Products Integrated and Worked out of the Box
We utilized two major Encompass Partners, Endress + Hauser
(E+H) and Prosoft Technologies. This was IFCO’s first major
successful Foundation Fieldbus Project do to the Rockwell and E+H
Support Team.
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
FactoryTalk AssestCentre- Process Control
• Asset Center installed with the intent of providing for management of ALL assets,
Controllers, Drives, HMI and INSTRUMENTATION
• Installed with Factory Talk Asset Center –Process Config Option
• Enabled use of DTM technology to commission and configure Instruments (eg Vortex
meters) where there are 12 Key parameters
• Archival of As-Built (Logix Program, Drives Config and Instrumentation)
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Advance Process Control
• Used IMC (Internal Model Control) block instead of PIDE.
• Implemented 124x loops
• IMC provides better control than standard PID algorithms
on processes that have significant deadtime (e.g.
temperature). Results of little or no overshoot, to setpoint
very fast.
• Our experience with IMC:
– Very easy to tune
– Can be used even on fast loops (e.g. flow)
– License is unlimited use per processor so if using, might as well
use throughout
• Our vision:
– Optimize furnace performance with Supervisory MPC
– Utilize software CEM where required
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Lessons Learned
• Surround yourself with the right Team Players
– Internal Management and Engineering Teams
– Use your Partnerships with Suppliers (Rockwell & E+H)
• Use all the tools available
– Advanced Process Blocks
– DTM Technology (Offline and Online)
– Commissioning
• Do not be afraid of Bus Technology
– Certify the Physical Layer (90% of Problems)
– Reduced Commission by half
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Questions
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Michael Hilton
Industrial Furnace Company
