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Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Insert Photo Here
Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL – McCormick Place West
Food Ingredients Industry
A complete soybean
processing plant using
PlantPAx (Greenfield)
Jales Junior – SELECTA
Rafael Pezzella Chiea – IASTECH/SP
Fabricio Hayashi – IASTECH/SP
Marcel Almeida – Rockwell Automation
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Agenda
� Process Overview
� Soybean Market
� Selecta General Information
� Rockwell Solution Provider - IASTECH
� Automation Project and Asset Management
� Future Projects
� ScreenShots
� Conclusion
Overview Soybean Market
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
World Soybean Production (Millions of Tons)
Fonte
: AB
IOV
E, 2
010
• US is the first world soybean
producer – 2011: 91 Mtons.
• BRAZIL is the second one
producer – 2011: 75,0 Mtons.
• US+BRAZIL+ARGENTINA
represents 98% of world
soybean business.
Agenda
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
� Process Overview
� Soybean Market
� Selecta General Information
� Rockwell Solution Provider - IASTECH
� Automation Project and Asset Management
� Future Projects
� ScreenShots
� Conclusion
General Information
• Selecta is a 100% Brazilian Company.
• Production site is located in Araguari - Minas
Gerais.
• Production/crushing capacity of 2,000 tons of
soybean a day.
• Main Products: soy concentrated with
different protein tenors (soybean meal), soy
molasses and degummed oil.
• The plant produce a high quality 60% protein
products (Soy protein concentrate).
• Self-energy generation and water reuse.
• Zero effluents and waste emission.
• Main Markets: Brazil, Europe and Asia.
Copyright © 2011Rockwell Automation, Inc. All rights reserved.
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
• PDV/GMP B2+ certification.
• ANEC Member – non-acquisition of
soybeans produced in the Amazon biome.
• Selecta developed the SIPP – Selecta
Identify Preserved Program (audited by
independent certifier) to garantee the
traceabilty from acquisition of raw materials
to product deleivery to the final customer.
• Integrated Laboratory for raw materials,
production and finished product.
• Social projects – Boas Mãos, Plié, Bikila
and Retocar children educational projects.
General Information
Agenda
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
� Process Overview
� Soybean Market
� Selecta General Information
� Rockwell Solution Provider - IASTECH
� Automation Project and Asset Management
� Future Projects
� ScreenShots
� Conclusion
About IASTECH
Copyright © 2010 Rockwell Automation, Inc. All rights reserved.
� Since 1990
� Rockwell Automation Solution
Provider
� Life Science, food and beverage
specialist
� ISO 9001:2008
� EPM e PMI
Rockwell Automation Solution Provider since the beginning of the program !
Rockwell Automation Process Solution Provider !
Rockwell Automation Information Solution !
Agenda
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
� Process Overview
� Soybean Market
� Selecta General Information
� Rockwell Solution Provider - IASTECH
� Automation Project and Asset Management
� Future Projects
� ScreenShots
� Conclusion
Process Overview
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
SELECTA
Soybean Processing Plant
Reception Preparation Extraction SPC1 SPC2
Boiler1
Boiler2
Self-Generation
(turbines)
Soy Protein Concentrate Soy Protein Concentrate
Soybean meal
Soy molasses
Degummed Oil
BIOMASS
Agenda
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
� Process Overview
� Soybean Market
� Selecta General Information
� Rockwell Solution Provider - IASTECH
� Automation Project and Asset Management
� Future Projects
� ScreenShots
� Conclusion
Automation Project
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
A complete soybean processing plant
using PlantPAx (Greenfield)
• 10 x ControlLogix CPUs;
• 1200 x I/O points (Redundant ControlNet);
• 800 x HART Instruments (Redundant ControlNet);
• 900 x Intelligent Motors Controls (DeviceNet);
• 2 x Redudant PASS;
• 10 x Operator Stations;
• 1 x Engineering Station;
• 2 x Local PanelView;
Selecta Automation Architecture
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Reception Preparation Extraction SPC1 SPC2
Boiler1
Boiler2
ETE
ETA
Co-generation
Ring-Ethernet Optical FiberRing-Ethernet Optical Fiber
PASSRedundant
PASSRedundant
AssetCentreServer
10 x OWS
Operator StationsDomainServers
EWS
Engineering Workstation
1200 x I/O Points - 800 x Hart Instruments - 900 x Motors/Pumps
Selecta Automation Architecture
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Typical MCC Automation Architecture
DeviceNet
Redundant C
ontr
olN
et
Ethernet
Industrial
Switch
To Fiber Optical Ring
VLAN Pass
PowerFlex PowerFlexE3+
HART Modules
HART Modules
Flex I/O
ControlLogix L62 Processors
Project Phases
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Selecta - Main Project Phases
1. Hardware Design Specification;
2. Process Description;
3. Functional Specification including process;
4. Control Software Programming;
5. Operation Design;
6. Factory Acceptance Tests with process simulation - FAT;
7. Operator Training - Operation Tests using process simulation;
8. Commissioning and Start-up – Phase 1
9. Commissioning and Start-up – Phase 2
10. Commissioning and Start-up – Phase 3
11. Site Acceptance Tests – SAT;
12. Assisted Operation;
One year
Project
Selecta Asset Management
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
AssetCenter Server10+2000 = 2010
Assets
Disaster RecoveryProcess Device Configuration
Calibration ManagementOWS
AssetCentre AgentsEWS
AssetCentre Client
ControlLogix
10
Rede Automação Ethernet
ControlLogixControlLogix
1200 x I/O Points - 800 x Hart Instruments - 900 x Motors/Pumps
AssetCentre System Architecture
Selecta Asset Management
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Process Device Configuration
Calibration Management
• Use Field Device Type Technology (FDT);
• Access the instruments, parameters and
configuration online or offline;
• Upload or download the configuration device
• Diagnostic;
• Paperless solution for
calibration management
• Manage calibration
requirements
• Schedule, Event History,
Reminders
• Calibration reports for audit
Agenda
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
� Process Overview
� Soybean Market
� Selecta General Information
� Rockwell Solution Provider - IASTECH
� Automation Project and Asset Management
� Future Projects
� ScreenShots
� Conclusion
Selecta Future Projects and Investments
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Reception Preparation Extraction SPC1 SPC2
Boiler1
Boiler2
ETE
ETA
Co-generation
Ring-Ethernet Optical FiberRing-Ethernet Optical Fiber
PASSRedundant
PASSRedundant
AssetCentreServer
10 x OWS
Operator StationsDomainServers
EWS
Engineering Workstation
Corporate Network
FTVantgePoint
FTHistorian
WEB Reports
ProductionQualityAdministrationERP
Server
FTTransaction Manager
MSSQL Server
Mobile Access
Agenda
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
� Process Overview
� Soybean Market
� Selecta General Information
� Rockwell Solution Provider - IASTECH
� Automation Project and Asset Management
� Future Projects
� ScreenShots
� Conclusion
System Screen Shots – Area 1
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
SCREENSHOT
will be presented
System Screen Shots – Area 2
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
SCREENSHOT
will be presented
System Screen Shots – Area 3
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
SCREENSHOT
will be presented
System Screen Shots – Area 4
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
SCREENSHOT
will be presented
Agenda
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
� Process Overview
� Soybean Market
� Selecta General Information
� Rockwell Solution Provider - IASTECH
� Automation Project and Asset Management
� Future Projects
� ScreenShots
� Conclusion
Why PlantPAx System ?
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Why have we chosen PlantPAx System ?
• Scalability – Plant start-up in phases;
• Capability - Process and Discrete Control;
• Technology – High performance processors and I/O modules;
• Reliability – High availability networks;
• Support – Rockwell Techsupport and Solution Providers;
• Asset Management;
• Production Management and Reporting;
• ERP Integration;
Questions ?
Rafael Pezzella Chiea, [email protected]
+55 11 8369 3384
QUESTIONS???
Jales [email protected]
+55 34 2109 7300
Marcel Almeira, [email protected]
+55 11 8472 6222
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Fabricio [email protected]
+55 11 8369 3389