Saint-Gobain Builds for the Future with PlantPAx and Production Intelligence
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Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Tweet About It Using #PSUG Saint-Gobain Builds for the Future with PlantPAx and Production Intelligence. Nick Thompson – Plant Superintendent Larry Grate – Account Delivery Manager Date – 11/14/2014
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The production systems at a key Saint-Gobain facility, where high-tech fiber glass and construction materials are created, was at risk of obsolescence. With limited support and system expertise, maintenance and repairs were hard to sustain on the legacy process system. To remain competitive, the company turned to the PlantPAx process automation system with a production intelligence solution for increased productivity and reduced downtime. The company now has access to a wealth of data for real-time trending and improved electronic data storage from three months to a year.
Transcript of Saint-Gobain Builds for the Future with PlantPAx and Production Intelligence
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
Tweet About It Using #PSUG
Saint-Gobain Builds for the Future with PlantPAx and Production Intelligence.
Nick Thompson – Plant Superintendent
Larry Grate – Account Delivery Manager
Date – 11/14/2014
AGENDA
Who is Saint-Gobain and PREMIER
Business Justification
Migration Strategy to PlantPAxTM
Leverage Production Intelligence
Solution
Results and Look Forward
Questions and Answers
ADFORS OVERVIEW
Saint-Gobain, the World Leader in sustainable habitat and
construction markets, designs, manufactures and distributes
BUILDING AND HIGH-PERFORMANCE MATERIALS, providing
innovative solutions to the challenges of growth, energy efficiency,
and environmental protection.
Saint-Gobain manufactures the following materials:
Flat Glass
Ceramic Materials
Abrasives
Performance Plastics
Saint-Gobain ADFORS
Exterior Wall Insulation (VERTEX)
Wall Coverings (NOVELIO)
Joint Tape (FibaTape)
Bonded glass for thermal insulation and asphalt toppings (NewYorkWire,GlasGrid).
PREMIER OVERVIEW
For more info . . .
Visit PREMIER’s website at www.premier-system.com
Founded in 1991
Privately Owned
100+ Employees
CSIA Certified (6 Years)
Corporate Office Located in Smyrna, TN
Regional Operations in S.E. U.S.
Smyrna, TN
Decatur, AL
Cincinnati, OH
PREMIER OVERVIEW
Rockwell Solution Partner
Rockwell Control Solution Partner
Rockwell Information Solution Partner
Rockwell Process Solution Partner
Competencies
PLC/DCS Programming and Configuration
HMI Development
MES Solutions
Legacy PLC/DCS Retrofits
Coordinated Drives Solutions
For more info . . .
Visit PREMIER’s website at www.premier-system.com
Information
PREMIER OVERVIEW
Industries
Automotive
Chemical
Consumer Products
Food & Beverage
Metals
Pulp & Paper
Power
For more info . . .
Visit PREMIER’s website at www.premier-system.com
BUSINESS JUSTIFICATION
Lost our internal ProcessLogixTM Champion
Have a small PlantPAx system in place for resin blending.
This in conjunction with ProcessLogix being based on 1756 I/O made the best
solution easy to choose.
Had experienced the advantages of built in directed diagnostics.
Liked the ability to find trained resources on Rockwell solutions.
ProcessLogix server stability was becoming a problem.
Unsupported hardware/software (Windows 2000)
BUSINESS JUSTIFICATION
Project justification was on Cost Avoidance.
If a failure occurred the MTTR would be significant, increasing production
costs.
On power outages we were having a difficult time recovering due to issues
with the ProcessLogix servers.
When process improvements were implemented the labor cost for
ProcessLogix integration would be higher than PlantPAx.
MIGRATION STRATEGY
Had existing solution in place for Resin, wanted to build on it.
Had an infrastructure that was expanded multiple times
without a well thought out strategy.
Had legacy code that needed to be cleaned up.
Needed to install the upgrade on a short outage.
Operators were already familiar with the Resin system
faceplates and control.
ORIGINAL INFRASTRUCTURE
Saint-Gobain
Process Network Diagram
Lab Office
Process Control Network X.X.X.0/24
X2
Process
MCN
X3
Business to
ASA
X.X.X.X
Business Network
Process Network Copper
MODE
STACKSPEEDDUPLXSTATMASTRRPSSYST
1 2 3 4 5 6 7 8 9 10 11 12
1X
2X
11X
12X
13 14 15 16 17 18 19 20 21 22 23 24
13X
14X
23X
24X
Catalyst 3750 SERIES
1 2
North
MCC
South
MCC
Control
Room
Operator
Console #1
Operator
Console #2
ProcessLogix
Server
Line Drives
Former
Former
RTO
RTO
Panelview
Resin
PULPER
PULPER
RSView32
Line Drives
Winder
Wrapper
Wrapper PV
Process Network Fiber
ProcessLogix
Processor
Resin HMI
Server
Maintenance
Winder
RSView32
FINAL INFRASTRUCTURE
Saint-Gobain
Process Network Diagram
Lab Office
Process Control Network X.X.X.0/24VMWare ESXi
USRUSAPP2
X.X.X.17
USRUSVAPPDC2
Win 2008 Server R2
sp1
X.X.X.12
X2
Process MCN
X3
Business to
ASA
X.X.X.X
USRUSVAPPDC1
Win 2008 Server R2
sp1
X.X.X.11
VMWare ESXiUSRUSAPP1
X.X.X.19
USRUSVAPPHMI1
Win 2008 Server R2
sp1
X.X.X.13
Business Network
Process Network Copper
Domain
Controller
HMI Server
#1
USRUSVAPPHIST
Win 2008 Server R2
sp1
X.X.X.15
MODE
STACKSPEEDDUPLXSTATMASTRRPSSYST
1 2 3 4 5 6 7 8 9 10 11 12
1X
2X
11X
12X
13 14 15 16 17 18 19 20 21 22 23 24
13X
14X
23X
24X
Catalyst 3750 SERIES
1 2
USRUSVAPPHMI2
Win 2008 Server R2
sp1
X.X.X.14
USRUSVAPPASSET
Win 2008 Server R2
sp1
X.X.X.16
USRUSVAPVP
Win 2008 Server R2
sp1
X.X.X.17
Historian
Vantage
Point Server
USRUSVAPPFTD
Win 2008 Server R2
sp1
X.X.X.16
North
MCC
Domain
Controller
HMI Server
#2
AssetCentre
Factory Talk
Directory and
Activation
Server
South
MCC
Control
Room
Operator
Console #1
Operator
Console #2
Fiber Ring Level 2
Fiber Ring Level 1
Engineering
StationLine Drives Former
Former
RTO
RTO PV
Resin
PULPER
PULPER
Line Drives
Winder
Wrapper
Wrapper PV
Wrapper
Process Network Fiber
LEGACY CODE MIGRATION
Integrator documented all existing loops.
Reviewed code list with production for equipment that was out of
service or provided poor performance.
Converted existing code and tuning values.
Some sequences were eliminated due to better tools in PlantPAx.
Consolidated multiple HMI platforms from other systems into the
new Factory Talk® View SE system.
Pulper RSView32 System.
Line Drive RSView32 System.
Multiple PanewView Plus Applications.
NEEDED TO INSTALL ON A SHORT OUTAGE
Initially targeted a 24 hour production down.
Integrator put together a thorough test plan for critical loops
at startup.
Actual outage was 36 hours due to other maintenance.
Startup went extremely well.
We did have a path back to the ProcessLogix system if we had a
catastrophic problem.
We moved two ControlNet racks to Ethernet due to failing ControlNet
cables installed crossing the machine in the basement.
We did have access to the ProcessLogix code if needed to verify
operation.
OPERATOR FAMILIARITY
Operators were already comfortable with the HMI due to the
existing Resin PlantPAx implementation.
Operator training on the HMI was minimal, screens mimicked
the existing ProcessLogix using familiar faceplates.
OPERATOR FAMILIARITY
OPERATOR FAMILIARITY
LEVERAGING PRODUCTION INTELLIGENCE
Chose to use Factory Talk Historian as a replacement for the
ProcessLogix Historian.
Chose to use Factory Talk VantagePoint to provide production
intelligence to operations management.
Chose to use Factory Talk AssetCentre for Disaster recovery
and backup.
Chose to use ACP Thin Manager for HMI clients and
engineering station.
LEVERAGING FACTORY TALK HISTORIAN
Used to create trends relating critical process values for a
quick overview of production quality.
Used to create ad hock reporting to troubleshoot process
problems as they arise.
Used to create required environmental reporting.
Working on production dashboards for critical KPIs.
THICK STOCK VS LEVEL
AD HOC
ENVIRONMENTAL REPORTING
Repository for plant-wide control of asset programs.
Automated disaster recovery on critical process assets.
FactoryTalk AssetCentre DIRECTORY
FactoryTalk AssetCentre AUDIT LOGS
THIN MANAGER
Tool for managing HMIs across the facility.
Provides for remote shadowing of operator screens for
troubleshooting and diagnostics.
Makes terminal replacement simple.
Simplifies the use of Terminal Services for Factory Talk View
HMI servers.
THIN MANAGER TREE
THIN MANAGER SHADOW
SOLUTION
Live Demo of Graphics
MAIN OVERVIEW
LINE DRIVES CONVERTED PV DISPLAY
DIAGNOSTIC EXAMPLES
RESULTS AND PATH FORWARD
KPI Screens in FactoryTalk VantagePoint
Converting balance of plant to Ethernet
Automated Reporting of Production
Additional Process Improvements
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
Tweet About It Using #PSUG
QUESTIONS
Please email us for additional information.
ANY QUESTIONS?
Please email us for additional information.
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