Cougar Automation helps DP World to give its cranes a diagnostics a lift with advanced wireless infrastructureContainer terminal operator enhances its diagnostics and trouble-shooting capabilities thanks to Logix-based Ethernet solution

BackgroundDP World Southampton is the second largest container terminal in the UK. The terminal, which lies on the south coast of the UK, covers a site of 88 hectares. It operates one short-sea berth and four deep-water berths, which can accommodate vessels up to 400m in length.

Like all businesses, DP World operates more effectively when it has access to pertinent, real-time information relating to the operational effectiveness of its assets. It was this desire for information collation and delivery that prompted it to involve Cougar Automation and Rockwell Automation in a project that would significantly help to enhance its crane-to-control room communications infrastructure.

SolutionsA Rockwell Automation solution was installed, which included:

• Allen-Bradley ControlLogix Ethernet Gateway to existing SLC5/04 Controllers over DH+

• Data centralisation via FactoryTalk View SE SCADA

• FactoryTalk Transaction Manager

• FactoryTalk Historian

Results• Access to pertinent real-time

information

• Information available both on crane and in the central control room

• Wireless network to cope with large area

• Better decision making due to real time access

• Easier report generation

• Faster remedial action

Partner

ChallengeThe project was to cover a number of large cranes, positioned over a very large area, which are used to load / unload container vessels.

DP World already had an existing diagnostic-data-capture solution on these cranes, but they were not interlinked. Getting the information from the cranes to the central control facility was often tortuous and sometimes involved photographing HMI displays in order to yield data that was then hand-entered into reporting programmes later down the line.

“What we needed was a way of collecting the information and then delivering it in the most effective way possible to the central control room,” explains Brian Kelly, Engineering Manager, cranes and ancillaries at DP World in Southampton. “We also had to take into account the size of the site and the issues this would present with regards to the data transport infrastructure.”

SolutionEach crane was already equipped with an Allen-Bradley SLC504 PLC coupled to local motors drives and HMIs using DH+. This solution was adequate for DP World’s data capture needs, but it needed a means of subsequently capturing this data and then transferring it to the central control location.

“We were recommended to DP World by Rockwell Automation’s distributor Routeco ,” explains Simon Pape, at Cougar Automation, a Rockwell Automation Recognised System Integrator. “We surveyed the project with Rockwell Automation and Routeco and developed a SCADA-based solution that could gather the data from the six cranes and then transmit it back to the control room. We were also able to duplicate the existing HMI visualisation on the remote SCADA, fostering instant familiarity with the new approach.”

Very early on in the project it was determined that a wireless solution was the only sensible approach to a site this size. While DP World sourced and installed the wireless mesh, Cougar got to work with the Allen-Bradley based solution.

Each crane now has a ControlLogix Gateway, a four slot rack which houses DH+ and Ethernet cards. In operations, the existing PLCs perform all the data capture operations before feeding the information to the Gateway using DH+. This information is then transmitted wirelessly to the control room via the Ethernet card in the gateway. The control room houses a server PC running FactoryTalk View SE SCADA, FactoryTalk Historian and FactoryTalk Transaction Manager.

“We weren’t changing any of the existing control or functionality,” Kelly elaborates, “we just needed centralised data capture in order to monitor the cranes’ operations

in real time. Our cranes are very sophisticated; there is a lot of I/O on each unit. The data being collected was predominantly diagnostic information, pertaining to fault finding, alarms, operational shift data and hours run.”

ResultsDP World now has exactly what it set out to achieve. A contemporary data capture and transmission infrastructure that is able to deliver real-time information in a recognisable format so that the site’s engineers can make qualified, timely decision, helping with maximum uptime and optimum operating conditions.

Commenting on his relationship with Rockwell Automation, Simon Pape explains: “It’s all about

relationships. I know the Rockwell Automation guys very well and I work very closely with my local contact; it is a very open and honest relationship.”

So, what does DP World think of its new system and the team that helped develop it? “We already had Allen-Bradley hardware on site and we had a good relationship with Routeco, so we were happy with its recommendation of Cougar Automation,” Kelly explains. “I am very familiar with Rockwell Automation equipment and the Logix environment and was the main driver to the adoption of Allen-Bradley hardware.

“I can’t fault Cougar,” he continues, “they were very flexible and we had effective and friendly communications throughout the project. They were also flexible to our needs and everything came in within budget. I also know the Rockwell Automation product group very well and have done for a long time. As far as I am concerned it’s more reliable, easier to integrate and maintain. I also know that I will get good support, either from Cougar or Rockwell Automation. All of which are determining factors in selecting a vendor.”

Additional Informationwww.rockwellautomation.com

The results mentioned above are specific to DP World’s use of Rockwell Automation products and services in conjunction with other products. Specific results may vary for other customers.

As far as I am concerned it’s more reliable, easier to integrate and maintain. I also know that I will get good support, either from Cougar or Rockwell Automation. All of which are determining factors in selecting a vendor.

Publication INFRA-AP004A-EN-P – January 2013 Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Printed in the UK.

Listen. Think. Solve., Allen-Bradley, ControlLogix, SLC, DH+, FactoryTalk View SE, FactoryTalk Transaction Manager and FactoryTalk Historian are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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