Jiri Prochazka (BASF) & Jim Luffman (ABB), April 25, 2012 Session 12 APW C551I BASF Windsor - Harmony system evolution success to System 800xA

Transcription

1 Jiri Prochazka (BASF) & Jim Luffman (ABB), April 25, 2012 Session 12 APW C551I BASF Windsor - Harmony system evolution success to System 800xA April 25, 2012 Slide 1

2 C551I BASF Windsor - Harmony system evolution success to System 800xA Speaker name: Jiri Prochazka Speaker title: Company name: Location: Instrument & Electrical Engineer BASF Windsor, Ontario, Canada Co-presenter Speaker name: Speaker title: Company name: Location: Jim Luffman Project Manager ABB Inc. Burlington, Ontario, Canada April 25, 2012 Slide 2

3 Agenda BASF Windsor Introduction About BASF a brief overview The BASF facility in Windsor, Ontario (Canada) Evolution timeline summary Project integration highlights AC800M control HPG (Harmony PCU Gateway) Profibus Intrinsic Safety Project execution & coordination Questions? Key Learnings (Measureable Results)

4 Introduction About the Speaker Jiri Prochazka BASF April 25, 2012 Slide 8 Instrumentation & Electrical engineer at the BASF Windsor, Canada Paint Plant 18+ years experience in this position Responsible for maintenance and new installation of instrumentation, control systems as well as all mid & low voltage electrical infrastructure for the facility Mandated with the challenges of: Enhancing overall installed base of electrical, instrumentation and process automation Increasing productivity and overall equipment effectiveness Balancing maintenance and operating costs Maximizing equipment uptime Maintain Best-in-Class approach through the application of most up-to-date technology while balancing best utilization of installed infrastructure Training staff

5 About BASF History and products BASF April 25, 2012 Slide 9 BASF The Chemical Company was first incorporated (as Badische Anilin & Soda Fabrik) in 1865 for production of coal tar dyes and other products. Today, BASF is the world s leading chemical company We aim to constantly increase the value of company by profitable growth and to remain the number one in chemistry. We combine economic success with environmental protection and social responsibility. BASF is a publically traded company with ~ 111,000 employees and 2011 annual sales of 73.5 billion Euros BASF is an innovative solutions provider, comprised of chemical, plastics, performance products, functional solutions, agricultural solutions and oil & gas segments BASF is focused on sustainable development for long term growth and profitability The automotive paint plant in Windsor, Ontario (Canada) is part of BASF s Coatings Division, which is part of the functional solutions segment.

6 About BASF Paint plant facility in Windsor, Ontario, Canada Products: OEM coatings, waterborne & solvent borne primers, and basecoats (automotive paints), and refinished products Area: 8.5 acres, land locked Site: over 100 years old Floor space: 110,000 ft2 Total headcount: ~145 Average experience: 20 yrs The site became BASF as part of the Inmont acquisition in early 1980 s BASF April 25, 2012 Slide 10

7 2007 (June) Evolution implementation Operator consoles & engineering work stations Conductor VMS Clients Conductor VMS Redundant Servers (June) 2007 (July) BASF April 25, 2012 Slide 11

8 2010 (September) Adding new controls for refinishing product line In 2009 BASF made the strategic decision to expand the Windsor facility to include refinishing products Existing system has approximately 2000 I/O points for process automation of blending, mixing, batch processes and dispersions Project Scope: New refinishing product line has ~ 600 I/O points Addition of 800xA controllers to existing INFI 90 system including; HPG (Harmony PCU Gateway) 2 x AC800M controller pairs S800 I/O modules (with embedded intrinsic safety) 3 new operator client stations New sequences implemented in AC800M controllers (using Sequential Function Charts) and modified existing BATCH90 configurations BASF April 25, 2012 Slide 12 Addition of INFI 90 library into AC800M controllers

9 2010 (September) Status Adding new controls for refinishing product line System 800xA New refinishing line IS Interface AC800M AC800M BRC400 S800 I/O S800 I/O HPG Profibus to 3 rd party devices (eg. VFD s & PLC s) Profibus to 3 rd party devices (eg. VFD s & PLC s) 2007 (June) (March) 2010 (Sept.) BASF April 25, 2012 Slide 13

10 Challenges and solutions HPG Harmony PCU Gateway Challenge: Operators need to seamlessly control the new refinishing products line while operating the existing blending, mixing, batch processes and dispersions lines Existing plant equipment was moved to the new refinishing products line, yet field wiring remained unchanged, therefore INFI 90 needed to interface with System 800xA Solution: HPG (Harmony PCU Gateway) to connect the existing BRC400 s to the new refinishing products AC800M controllers The Harmony PCU Gateway (HPG 800) is designed to provide a robust, peer-to-peer communications with AC 800M controllers via CI867 Modbus TCP CEX modules Operators have seamless control of the new refinishing line with the addition of some new graphics April 25, 2012 Slide 14

11 Challenges and solutions AC800M Controllers Challenge: New refinishing product line has ~ 600 I/O points. BASF wants to adopt new control technology and integrate it with existing control technology Solutions: April 25, 2012 Slide 15 AC 800M Controller(s) Variable Speed Drives Motor Using AC800M controllers (part of the System 800xA) for the new refinishing products inputs/outputs 2 x AC800M controller pairs (allowed us to communicate to third party devices using Profibus DP), including interfacing to variable frequency drives connected to motors Using Profibus with AC800M allowed BASF to utilize remote I/O distributed to many buildings, minimizing field cabling. This saved many hours of labour and testing Addition of INFI 90 library into AC800M controllers to maintain operator interface standards New sequences implemented in AC800M controllers (using Sequential Function Charts) and modified existing BATCH90 configurations

12 Challenges and solutions S800 Input & Output Cards Challenge: Our process operates in a Class I Zone I environment. We were limited on real estate space with the addition of the new refinishing product line Solutions: S800 I/O modules were added for the new refinishing product line S800 I/O has embedded intrinsic safety in the modules Total of 6 I/O cabinets distributed throughout the process areas Solution minimized footprint required in limited real estate space April 25, 2012 Slide 16

13 Challenges Project execution and coordination Challenges: Time was a challenge. The equipment was received at site in June 2010 and commissioning with loop checks & sequencing needed to be started September 2010 Site equipment and configuration had to be phased in existing process which was still in operation (switched one line at a time) April 25, 2012 Slide 17

14 Solutions Project execution and coordination April 25, 2012 Slide 18 Solutions: The project was planned and scheduled with configurations combined and tested ahead of time The hardware was shipped ahead of time so the wiring could be completed Planned loading of graphics and configuration was used as equipment came on-line, others phased out The final installation was implemented during a weekend shutdown plug and play, once final equipment swing over was complete The upgrade was transparent to the operators, eg. Faceplates, etc. looked the same and operated the same on either the INFI 90 or 800xA system. ABB was able to pool their resources together, plan hardware, loop checks, final configuration and sequence testing

15 Evolution Can you see the difference? INFI 90 Operator graphic System 800xA Operator graphic April 25, 2012 Slide 19

16 2011 (December) Tank farm PLC replacement and power system upgrades In 2011 BASF made the decision to replace the programmable logic controller (PLC) on the tank farm and upgrade the INFI 90 power supplies to MPSIII power systems Existing PLC had approximately 300 I/O points for automation of tank farm Project Scope: Addition of 800xA controllers to existing system; 1 x AC800M controller pair S800 I/O modules 1 x new operator client station New sequences implemented in AC800M controllers (using Sequential Function Charts) and modified existing BATCH90 configurations Replaced INFI 90 power systems with 2 x MPSIII power systems Add 5 new VFD s for mixer control. BASF April 25, 2012 Slide 20

17 2011 (December) Status Adding tank farm PLC replacement and power upgrade System 800xA New refinishing line Tank Farm IS Interface AC800M AC800M AC800M BRC400 S800 I/O S800 I/O S800 I/O HPG Profibus to 3 rd party devices (eg. VFD s & PLC s) Profibus to 3 rd party devices (eg. VFD s & PLC s) 2007 (June) (March) 2010 (Sept.) BASF April 25, 2012 Slide (Dec.)

18 Tank farm PLC replacement challenges Project execution and coordination Challenges: Time was a challenge. The tank farm need to be moved from existing PLC to 800M in a single weekend, including complete loop and functionality checks Minimal training for Tank Farm operators. Upgrade INFI 90 power systems without affecting operations or tank farm upgrade Add 5 variable frequency drives (in phases) with minimal effect on system interruption April 25, 2012 Slide 22

19 Tank farm PLC replacement solutions Project execution and coordination Solutions: Project design included I/O with pre-terminated field cabling, 100% tested before shipment Interconnecting cabling was designed to match the existing PLC cabinet terminal block grouping New cabinet was installed ahead of shutdown. New I/O marshaling cables wired to existing PLC termination panel in less than 1 day (Saturday). New 800xA client computer was installed and tested before replacement Controller, S800 panel installed All control standards from previous project were used for PLC replacement. Complete plant now looks and controls to the same standards > minimized training. April 25, 2012 Slide 23

20 Tank farm PLC replacement solutions Project execution and coordination Solutions continued: INFI 90 power supply upgrade installed weekend before tank farm PLC replacement. This concluded the DCS migration planned since New variable frequency drives added to Profibus segments with minimal new wiring requirements Variable frequency drive logic copied from existing configuration with minimal effort adding logic, updating graphics and checking I/O April 25, 2012 Slide 24

21 Tank farm PLC replacement solutions Tank farm control panel Power supply system upgrade April 25, 2012 Slide 25

22 Evolution Next steps The BASF Windsor site continues to evolve Next steps include existing (obsolete) PLC s evolve to ABB s AC800M controller and S800 input & output cards and thus eliminating control islands. Special reporting for Filler Machine using Information Manager. Expansion of existing pigging system. April 25, 2012 Slide 26

23 Key learning's and conclusions 1. We made the right decision. Protected original investment Innovative approach to evolution as opposed to replacement Minimized staff retraining 2. The new System 800xA systems are stable and reliable 3. All process information is available to operators / management through a single interface, plant controls are transparent to site staff whether they operate an INFI 90 or 800xA system 4. The plant s control system technology is new and up to date Minimizing maintenance costs Easy expandability Low cost hardware Flexible licensing 5. Minimized footprint of new equipment 6. Intrinsic safety embedded 7. Integrated services provided with ABB single contact representative BASF April 25, 2012 Slide 27

24 ABB Group April 25, 2012 Slide 30