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Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Intuitive, Facility-wide PlantPAx System Implemented at Minimum Lifecycle Cost
Chris Heinrichs
EI&C Operations Manager – River Consulting
Booth #635
11/17/2014
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Conclusion
Project Execution Methodology
PlantPAx Features
Project Overview and Challenges
River Consulting
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
RIVER CONSULTING
River Consulting is a leading Mid-Major A/E to global energy, food,
process and industrial clients.
More than 30 years of experience and 250+ multidiscipline staff in four offices: Columbus, OH; Pittsburgh, PA; New Orleans, LA; Tulsa, OK.
Process Control expertise for clients providing reliable process automation for efficiency, productivity and monitoring in industries including chemical, coatings and resins, gas processing, sulfur purification, food, and more.
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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RIVER CONSULTING
River Consulting’s complete design services include: PFD, P&ID, Cause & Effect Development Power Distribution Systems Control System Architecture EOS/MES/Data Integration PLC & HMI Programming Instrumentation Equipment & Panel Supply Conceptual, Preliminary and Final Design Start-up and Commissioning
Rockwell Automation Solution Partner since the program inception in 2003
Rockwell strategic partner for over a decade
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Conclusion
Project Execution Methodology
PlantPAx Features
River Consulting
Project Overview and Challenges
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Project Overview
Intuitive, Facility-wide PlantPAx System Implemented at Minimum
Lifecycle Cost
A Middle Eastern chemical producer purchased a turnkey facility and
required state-of-the-art continuous process control and burner
management platforms. Challenged with an EPC contract and working
with operators, maintenance and engineering staff with little-to-no
experience, River Consulting needed to implement an intuitive solution at
minimum lifecycle cost. Using the PlantPAx Library of Process Objects
and documentation, the plant standardized on a PlantPAx process
automation system with integrated safety, seamlessly integrating burner
management, process and discrete control.
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Project Overview
EPC Contract for a Sulphur Purification Facility (extraction by others)
Modular Construction Fabricated in Oklahoma Shipped in Modules to Iraq
“Updated Copy” of a Facility Deployed in 1990
Original facility operated for one year
River Consulting hired by EPC contractor (sister company) to determine
and implement lowest cost plant automation solution
1) Satisfy all contractual obligations 2) Minimize overall EPC-side costs from concept through turnover
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Sulphur Purification Facility Overview
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Project Description
P&IDs – 38 sheets
I/O – 600
Closed Loops – 40
Power – 6.5 MVA
Burners – 7 (20 MWth)
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Contractual Obligations
“State of the art” Process Control System
Original facility used discrete PLC control, Loop Controllers, Burner Manager Modules, and Plant Computer
Operations manual and operator training
Substantially the same as original facility
Some modifications identified explicitly
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Areas Without Requirements
Human Factors
Platform
Legislative / Regulatory
Availability / Uptime / Reliability
Maintenance
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Control System Lifecycle EPC View - After Contract Award
Requirements Capture
System Engineering
Functional Engineering
Software Development
Software
FAT
System FAT Operator Manual
Operator Training
Site Installation
Onsite Startup
Warranty Period
Support
Hardware Spec / Panel Engineering
Hardware Procurement / Assembly
Hardware FAT
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Platform Independent Cost-Driving Considerations
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Lifecycle Cost Categories with Marginal Cost Benefits from Using PlantPAx
Hardware and Licensing Cost
Software Development Cost
Operator Manual
Operator Training
Onsite Support During Warranty Period
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Platform Independent Cost-Driving Considerations
Each factor, if unsatisfied by selected platform, can cause EPC
project costs to balloon
PlantPAx satisfied each factor, and had at least lower cost in each
Marginal Cost category
PlantPAx was selected as platform of choice to minimize costs to the
EPC contractor
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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PAC Panel
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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BMS
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BMS
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System FAT
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Sulphur Purification Facility Overview
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Reactor Overview
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Reactor Screen (1 of 6)
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Sulphur Forming Plant
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Sulphur Recovery Unit
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Agenda
Conclusion
Project Execution Methodology
Project Overview and Challenges
River Consulting
PlantPAx Features
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Reactor Screen (1 of 6)
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BMS Valves – No Operator Control
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Easy Permissive and Interlock Status
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Engineering Configuration Without Programming
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Device Faceplates
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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PID Loop Faceplates
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Embedded Trending
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Hardware Diagnostics
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Conclusion
PlantPAx Features
Project Overview and Challenges
River Consulting
Project Execution Methodology
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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AGILE
Lightweight Software Development Methodology
Accepted Widely in Business Software Development
Key Agile Principles for Automation
#1 Customer satisfaction by rapid delivery of useful software #2 Welcome changing requirements, even late in development #4 Close, daily cooperation between business people and developers #7 Working software is the principal measure of progress #8 Sustainable development, able to maintain a constant pace
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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SCRUM
Build and maintain a Product Backlog
Allocate some of the Product Backlog to a sprint
Sprint = short duration development cycle (1 week – 1 month)
Development team meets daily
At the end of the sprint, review product with stakeholders
Repeat with new portion of the product backlog
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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AGILE with SCRUM - BURNDOWN
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BURNDOWN – Planning a Sprint
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BURNDOWN – Planning a Sprint
From P&ID From I/O List From Functional Description
From Project Historical Data, Tempered by Current Project Team
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DEVELOPMENT PROGRESS
DAY
0 1 2 3 4 5 6 7
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BURNDOWN – Daily Progress Update
0
10
20
30
40
50
60
70
1 2 3 4 5 6 7
8/20 8/21 8/22 8/23 8/24 8/25 8/26
HO
UR
S R
EM
AIN
ING
Sprint Days Aug 20 - Aug 26
SPRINT 1 BURNDOWN CHART Burndown
Target
Team A
DAY
0 1
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BURNDOWN – Daily Progress Update
0
10
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40
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60
70
1 2 3 4 5 6 7
8/20 8/21 8/22 8/23 8/24 8/25 8/26
HO
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Sprint Days Aug 20 - Aug 26
SPRINT 1 BURNDOWN CHART Burndown
Target
Team A
DAY
0 1 2
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BURNDOWN – Daily Progress Update
0
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1 2 3 4 5 6 7
8/20 8/21 8/22 8/23 8/24 8/25 8/26
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Sprint Days Aug 20 - Aug 26
SPRINT 1 BURNDOWN CHART Burndown
Target
Team A
DAY
0 1 2 3
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BURNDOWN – Daily Progress Update
0
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1 2 3 4 5 6 7
8/20 8/21 8/22 8/23 8/24 8/25 8/26
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Sprint Days Aug 20 - Aug 26
SPRINT 1 BURNDOWN CHART Burndown
Target
Team A
DAY
0 1 2 3 4
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BURNDOWN – Daily Progress Update
0
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1 2 3 4 5 6 7
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Sprint Days Aug 20 - Aug 26
SPRINT 1 BURNDOWN CHART Burndown
Target
Team A
DAY
0 1 2 3 4 5
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BURNDOWN – Daily Progress Update
0
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1 2 3 4 5 6 7
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Sprint Days Aug 20 - Aug 26
SPRINT 1 BURNDOWN CHART Burndown
Target
Team A
DAY
0 1 2 3 4 5 6
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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BURNDOWN – Daily Progress Update
0
10
20
30
40
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1 2 3 4 5 6 7
8/20 8/21 8/22 8/23 8/24 8/25 8/26
HO
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Sprint Days Aug 20 - Aug 26
SPRINT 1 BURNDOWN CHART Burndown
Target
Team A
DAY
0 1 2 3 4 5 6 7
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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WHY USE AGILE WITH SCRUM?
SCHEDULE IMPROVEMENTS
“Get twice the work done in half the time” Multi-team competition improves productivity
PREDICTABLE PERFORMANCE
Development team makes early and frequent commitments Defined short term scope allows team focus
EARLY AND FREQUENT STAKEHOLDER FEEDBACK
Implicit requirements emerge; flexible development team response Stakeholders help ensure their own satisfaction Prevent late project surprises, avoiding rework
PlantPAx OBJECT LIBRARY SUPPORTS THE METHODOLOGY WELL!
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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WHY USE AGILE WITH SCRUM WITH PlantPAx?
Agile with Scrum can work as assembly line
PlantPAx Process object library serve as raw materials to the assembly
line
Process control projects produce engineering documents that support
Sprint Planning
Process control system development costs and schedules ultimately
benefit from early input from many stakeholders, which is a fundamental
tenet of Scrum
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Project Execution Methodology
PlantPAx Features
Project Overview and Challenges
River Consulting
Conclusion
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Conclusions
PlantPAx Faceplate and AOI libraries are approaching maturity in usability, documentation, and help menus, which all reduce cost of project documentation
PlantPAx features in FactoryTalk are so human factors friendly that we were confident deploying it over other platforms for low-sophistication client
Faceplate / AOI library support rapid software development methodologies
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Questions
Chris Heinrichs
EI&C Operations Manager
Booth #635
River Consulting
One Robinson Plaza, Suite 400
Pittsburgh, PA 15205
Direct: 412.894.2257
Cell: 412.522.7906