River Consulting: Intuitive, Facility-wide PlantPAx System Implemented at Minimum Lifecycle Cost

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


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Agenda

Conclusion

Project Execution Methodology

PlantPAx Features

Project Overview and Challenges

River Consulting


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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.


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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


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Agenda

Conclusion


PlantPAx Features

River Consulting



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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.


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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


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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


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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


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Platform Independent Cost-Driving Considerations


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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


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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


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PAC Panel


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BMS


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BMS


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System FAT


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Sulphur Purification Facility Overview


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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



River Consulting

PlantPAx Features


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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


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PID Loop Faceplates


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Embedded Trending


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Hardware Diagnostics


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Agenda

Conclusion

PlantPAx Features


River Consulting



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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


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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


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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

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BURNDOWN – Daily Progress Update

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Sprint Days Aug 20 - Aug 26

SPRINT 1 BURNDOWN CHART Burndown

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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!


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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


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Agenda


PlantPAx Features


River Consulting

Conclusion


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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


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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

[email protected]

Technology

River Consulting: Intuitive, Facility-wide PlantPAx System Implemented at Minimum Lifecycle Cost