Transcript Slide 1

Agenda: Rockwell Automation Solutions &
Technology for the Biofuels Industry
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Issues facing the Biofuels Industry
Partnering for Success
Expertise in Europe
Global Supply & Local Capabilities
Delivering Value
Technology and Expertise
Solutions &
Technology for the
Biofuels Industry
Presented By:Grant
Watkins
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Agenda
• Issues facing the Biofuels Industry
• Partnering for Success
• Global Supply & Local Capabilities
• Delivering Value
• Technology and Expertise
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Issues facing the Biofuels Industry
Issues
• 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
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Improve maintenance operations
Efficient energy usage
Optimise labour utilisation through training and improved automation
Reduce downtime
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Issues customers face
Issues
Issues the biofuel industry face:
• Pressure to increase operational profits to improve the return on investments and
increase shareholder value:
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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:
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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
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New plant and start up
Issues
• 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
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Response
Issues
Continuous peak efficiency is essential for any biofuel plant
• Reducing engineering and support costs through a single control architecture for process
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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
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Partnering for Success
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
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Planning and implementation
Collaborating to meet your needs
Delivered value of compatibility
and interoperability
• Single system for the plant
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Reduces time for instrument and loop configuration
Reduces development time
Reduces training
Reduces risk
Delivered Value:
 Reduced engineering hours
Reduction of project timeline
Planning and implementation
Planning and implementation
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
Delivered Value:
 Reduced engineering hours
Reduction of project timeline
Install/troubleshoot hardware quickly
Integrated
Architecture™
• 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
Ethernet/IP
Plant Floor
Maintenance Office
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Interoperability testing
Planning and implementation
• 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
• 50 Endress+Hauser devices tested
Delivered Value: Ensures a reduced risk solution highlighted by
ease of integration and optimum performance
Example: Sodes Lillebonne Ethanol Production Plant
Expertise in
Europe
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
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Biofuel Customers in Europe
Expertise 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
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Expertise in Europe
Example: Biodiesel Plant
Expertise in
Europe
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
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Serving Europe, Middle East & Africa
Global
Supply
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
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Global Supply & Local Capabilities
Global
Supply
• 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
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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
Delivering
Value
• Improve time to market
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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
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Technology and Expertise
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Technology
and Expertise
Integrated Architecture
Manufacturing Execution Systems (MES)
Power and Energy Management (PEMS)
Process Technology (Proscon)
Services and Support (MPS + CSM)
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Area of expertise
Technology
and Expertise
MES
Control System
Process
Modules
Production Facility
Validation
Site Services
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Integrated Architecture™
Integrated
Architecture™
• Real-time information is crucial when making decisions that enhance
productivity 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
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Production Disciplines
Integrated
Architecture™
Design and Configuration
Quality & Compliance
Integrated environments for creating,
modeling & programming your production
processes
Ensure operational processes and procedures
meet standards or specifications
Production Management
Asset Management
Real-time coordination across your plant
wide production processes
Optimises maintenance and plant operations to
improve your resource availability
Data Management
Performance & Visibility
Tools & methods to use for collecting, transforming
& integrating production information
Presents a window into the process so you can
make better decisions
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Core technologies
Integrated
Architecture™
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
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Ethanol Production Plant
Integrated
Architecture™
Ethanol Plant
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Conventional Solution separate systems
Integrated
Architecture™
Continuous
Batch
(DCS)
(Dedicated Batch
Systems)
Discrete
(PLC)
Safety
(Safety Controls)
Different Automation Systems for Different Applications =
Lots of Integration Costs & Long-term Maintenance Costs.
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Integrated Architecture™ A Single Solution
Batch
Process
(Logix)
(Logix)
Control
(NetLinx)
Station/Unit
Drive
(Logix)
Discrete
Enterprise
(View)
Integrated
Architecture™
(Logix)
Machine
(View)
(View)
Safety
(Logix)
Control
(FactoryTalk)
Benefit: The Integrated Architecture Simplifies Ordering,
Stocking, Training, Development, Interfacing,
Troubleshooting, & Maintenance efforts …. Saving Time &
Money!
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Sodes Lillebone (Example)
E/S Flex IO Version
Integrated
Architecture™
Master
Server
Secondary
redundant
processor
Primary
redundant
processor
Redundant
supply
Coaxial/Fo
ControlNet
couplers
Redundant
supply
E/S Flex IO
ControlNet redundant Fo
ControlNet redundant
coaxial
Profibus
DeviceNet
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
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HMI Screens
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Integrated
Architecture™
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Ethanol Plants
Integrated
Architecture™
Operator interface screens – one box, one
keyboard, one mouse and one operator
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Biofuels Plant Control
Integrated
Architecture™
• 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”
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Intelligent Motor Control
Integrated
Architecture™
• 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
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Cost of a control system
Integrated
Architecture™
•Controllers
•Instruments
•Network Modules
•I/O Modules
Hardware &
software
System
configuration
implementing a
Savings
40%
Program
descriptions
40%
•I/O Configuration
•Instrument Setup
•Network Setup
•Task, Programs,
Routines
•Structures, Tags
80% of the cost of
20%
Savings
•Description of Operation
•Drawings
•Logic / Rung Comments
•Tag Descriptions
control system is
the program description,
system configuration,
and documentation
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System configuration
Integrated
Architecture™
2. To configuration
1. From P&ID diagram
3. To faceplates
and graphical
displays
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Software integration
with field devices
Integrated
Architecture™
• Automatic integration of devices into Logix
programming
• Filed devices pre-programmed displays
Field Instruments
Unit Monitor
View
Parameter
Monitor and
setting list
Electronic User Manuals
Electronic CAD Diagrams
Spreadsheet View of MCC
Configuration
Wizards
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Process faceplate detail displays
Integrated
Architecture™
• The main faceplate display links to several detail displays.
For example, a PIDE faceplate provides details for:
Instruction
Status
Loop
Trend
Instruction
Configuration
Manual
Tuning
Auto
tuning
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Savings through reusable engineering
Integrated
Architecture™
• 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
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Data collection (process, alarms, batch) Integrated
with data historian
Architecture™
• 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
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Increase productivity with
advanced process control
Integrated
Architecture™
• 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”
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Model predictive control of a reactor
Integrated
Architecture™
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%
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Integrated Architecture™
One Architecture for Plant Wide Control & Information
Integrated
Architecture™
Lower
Operational
Costs
Lower Total
Cost of
Ownership
Regulatory
& Standards
Compliance
Better
Information
Faster
Decisions
Increased
Productivity
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Manufacturing Execution Systems
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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
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Manufacturing Execution Systems
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
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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
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– E.g. software helps simplify the integration of information between resource logistics and order
fulfilment
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Power and Energy Management
Power and
Energy
Management
• Log usage, demand and production data
• Create historical trend reports and charts
• Establish consumption baseline and user
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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
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Global Applications - PEMS Application
Examples
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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
Copyright
Copyright ©
© 2007
2007 Rockwell
Rockwell Automation,
Automation, Inc.
Inc. All
All rights
rights reserved.
reserved.
Process Domain Expertise
Process
Distillation & Solvent Recovery Systems Technology
• 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
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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
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Process Technology
Recover More, Waste Less
Process
Technology
• Modular Distillation and Solvent Recovery units incorporate all the hardware
and structural elements your installation requires
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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
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Process Technology
Modular Solutions
Build
Finish
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Process
Technology
Install
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MPS - From Concept to Successful Solution
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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
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
A worldwide support at anytime
 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.
Engineering Resource Centers
Major Project Implementation Centers
Services and Support
Superior 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
Predictive
Preventative
Corrective
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
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
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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
Copyright © 2007 Rockwell Automation, Inc. All rights reserved.
Transforming maintenance
from an expense to a business asset
Integrated
Architecture™
• 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.
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Integrated Automation and
information solutions
using best-in-class
solutions for your company