AP07: Calumet Specialty Products Partners, L.P.: Virtualized PlantPAx Improves Consistency and Throughput

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Calumet Specialty Products Partners, L.P.:Virtualized PlantPAx® Improves Consistency and Throughput

AGENDA

• Introduction

• Project Goals

• Selecting a PlantPAx Solution

• System Overview

• Results

• Lessons Learned

• Next Steps

• Questions

INTRODUCING CALUMET

AND

MALISKO ENGINEERING INC.

WHO IS CALUMET?

A leading independent producer of high-quality, specialty hydrocarbon products.

Headquarted in Indianapolis, IN with locations throughout the United States.

CALUMET LOUISIANA SYNTHETICS –LOUISIANA MO

• Produces polyol ester based synthetic lubricants

• Refinery Facility located in Louisiana, MO

• 36 Million Lbs./Year Capacity

• Refines Fatty Acids and Alcohols into Polyolester based synthetic lubricants

• Batch Esterification Process

PRODUCTS

WHO IS MALISKO ENGINEERING?• Experts in manufacturing automation and validation

• Founded in 1994

• Headquartered in St. Louis, Missouri USA

– Historic Laclede’s Landing on the Mississippi Riverfront

• Regional Office in Denver, Colorado USA

– Serving the Rocky Mountain Region and the West

• Rockwell® Solution Partner for Control, Process,

and Information Systems.

• CSIA Certified Member

• Member of NFPA

Historic Laclede’s

Landing

St. Louis, MO

Denver, CO

Malisko Western Regional Office

RECOGNIZED AS EXPERTS

PROJECT GOALS

PROJECT GOALS

• Automate a Primarily Manual Operation– Convert manual valves to automatic control

– Minimize operator intervention by reducing operator interactions in field by over 200 steps per batch

– Automate Pressure and Temperature Control

• Manage formulations electronically

• Migrate manual batch records to electronic batch records

• Improve Product Consistency

• Migrate Antiquated Tank Farm HMI to New System

CHOOSING A PLANTPAX SOLUTION

“TRADITIONAL” DCS VS. PLANTPAX

Criteria Traditional DCS

Local SupportSingle Local Solutions Provider

Local Eco-System consisting of dozens of local Integrators and Solution Partners

ScalabilityHardware + Additional License required for additional I/O

No additional licensing required

TopologyDedicated Servers.Software and Hardware Upgrades Expensive

Virtualization Fully Supported – Decoupling Hardware from Software

SYSTEM OVERVIEW

DEFINE CONTROL STRATEGY

• Needed to Estimate system parameters such as Server Tags, Memory Usage and Execution Time.

• S-88 Modeling - Define Control Modules, Equipment Modules, Phases and Unit Procedures

PLANTPAX SYSTEM CHARACTERIZATION

Characterization verifies that the system provides the required performance.

SYSTEM ARCHITECTURE

• Single Physical Server with four virtualized images

– FactoryTalk® View Server

– ThinManager Remote Desktop Server

– FactoryTalk Historian

– FactoryTalk VantagePoint® & Transaction Manger

– Two View Thin Clients

• Foundation Fieldbus

– Move segments from existing DCS to PlantPAx

– Combine 3 segments into 1 segment

• “Traditional” I/O used for new field devices

– Easier to troubleshoot for plant support

– No significant cost savings using bus technologies

• VPN Connection into system for Remote Support

PLANTPAX PROCESS OBJECTS

• v3.0 PlantPAx process objects used

• “Out of the Box” PlantPAx AOIs used

• “Enhanced” PlantPAx Global Objects used

FORMULATION

• All Product formulas reside in the program.

• Formulations can be changed, added and removed from HMI with proper security.

CONVERT LOG SHEETS

Convert Manual Data Collection to Automatic Data Collection

VANTAGEPOINT REPORTING

All Log Sheets available via VantagePoint

VANTAGEPOINT REPORTING

Daily Tank Farm Report ran and printed at 7 AM

RESULTS

IMMEDIATE RESULTS

• Batch Consistency

– All Formula Parameters reside in the system

– All operators now run the system the same

• Batch Cycle Time Optimization

– Roll from one step in the batch to the next.

– No longer waiting for the operator to perform the next step before moving forward.

IMMEDIATE RESULTS CONTINUED

• Eliminate the “I Think” and turn it into “I Know”

– All devices historized

– Batch Records can be pulled from VantagePoint since Batch Number one on the System.

– Identify opportunities to increase capacity beyond initial 4-5% capacity by eliminating process bottlenecks.

• Heat Cycle Tracking

– Reliable Data showing heat cycle and adjustments made during the cycle

– Optimize heat cycle over the course of a batch

LONG TERM BENEFITS

– Operator Comfortable with system before major expansion

– Ease of adding additional points to system

• No additional licensing required.

• Using prebuilt PlantPAx objects like the Dosing AOI simplifies brining in externally totalized additions into system.

• Tracking additions gives Calumet ability to bill customers accurately for formulation.

LESSONS LEARNED

LESSONS LEARNED

• Use Domain Controllers– Even on Small systems, managing

security becomes a challenge in a workgroup environment.

• Foundation Fieldbus Network Design– Verify Network Topology Design before

commissioning.

– Poor Design = Poor signal quality & Loss of Device Communications

• Remote Support via VPN is a must!

NEXT STEPS

• $40 million expansion

– Tank Farm Expansion -Automating New Tank farm

– Bring two new fully automated kettles on-line

NEXT STEPS

• Migrate existing Traditional DCS controlling Kettle D to PlantPAx

– Foundation Fieldbus and AS-Interface

• Add Waste Water Treatment into PlantPAx system.

• Convert existing manual tank farm operations unit-by-unit.

QUESTIONS

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