Customer Success Stories

Invensys Solutions at Work

Avantis Eurotherm Foxboro

IMServ

InFusion

SimSci-Esscor

Skelta

Triconex

Wonderware

Norsk Hydro

WONDERWARE MANUFACTURING EXECUTION SOLUTIONS

SUM IT ALL UP FOR YOU!

From product track & trace through enterprise integration - Wonderware MES gives you solutions not problems, options not roadblocks, scalability not one-size-fits-allChalk it up to the power of ArchestrA! Learn how Wonderware has helped hundreds of customers to do the maths and unleash their potential!

Visit www.wonderware.com

Contents

Editorial Introduction by Mark Davidson .......................................................................................5 Chemical Azoty Tarnov ....................................................................................................................7 Calzin, Inc ........................................................................................................................9 Delta BioFuels, Inc. ........................................................................................................12 Imperator .......................................................................................................................15 Borealis Group ...............................................................................................................18 Discrete Manufacturing Meridionale Impianti S.p.a.............................................................................................21 Facilities Management Universit de Strasbourg ...............................................................................................25 Food & Beverage Mount Packaging Systems Ltd. .....................................................................................28 Winkler und Dnnebier Swarenmaschinen GmbH ....................................................32 Imana Food....................................................................................................................36 SAB ................................................................................................................................40 New Belgium Brewing Company ..................................................................................44 United Dairy ...................................................................................................................48 Greene King ..................................................................................................................51 Graphic Arts CRE-A ............................................................................................................................54 Hydrocarbon Processing Gazprom dobycha Astrakhan, LLC ................................................................................57 Idemitsu Kosan ..............................................................................................................60 Life Sciences Sano Pasteur ................................................................................................................63 Xcellerex ........................................................................................................................66 Metals, Minerals & Mining Hydro Aluminium Extrusion Deutschland Gmbh ...........................................................70 Lonmin Plc .....................................................................................................................74 Ash Grove Cement ........................................................................................................77 Assmang Limited ...........................................................................................................81 Hydro .............................................................................................................................84
3

Contents

Plastics Illinois Precision .............................................................................................................87 Power BC Hydro .......................................................................................................................90 CM European Power Slovakia S.r.o. ..............................................................................93 China Huaneng Group...................................................................................................96 ESKOM ..........................................................................................................................99 Ontario Power Generation ..........................................................................................102 RK Powergen ...............................................................................................................104 Southern Mississippi Electric Power Association .........................................................107 Tucson Electric Power Company .................................................................................109 Vectren Corporation ....................................................................................................112 Endesa .........................................................................................................................116 Pulp & Paper Weldwood of Canada ..................................................................................................121 Semiconductor Texas Instruments ........................................................................................................124 Transportation Ferrocarrils de la Generalitat de Catalunya .................................................................127 SALT Societ Autostrada Ligure Toscana p. a. .........................................................132 Wuxi Transportation Tunnel System ............................................................................136 Water and Wastewater Southern Nevada Water System..................................................................................140 Video Success Stories ............................................................................................................144

EDITORIAL

Dear Reader, Welcome to the 2011 collection of Invensys Operations Management Success Stories. I would like to thank our customers, partners and employees who contributed to this most impressive collection of stories that all exemplify: Real Collaboration. Real-Time Results. We believe that only through open collaboration with our customers and partners, can we accelerate progress towards our mutual journey of business optimization. Real collaboration requires innovative solutions that empower teams of people and departments to work together in new and different ways - ways that are more agile and productive, and that facilitate the key areas of Operational Excellence: Assets, Control, Environment & Safety, and most importantly People. Real-Time results is all about achieving measurable business results based on real-time, informed decision-making and orchestrated workflow across our clients organization, systems and equipment. At Invensys, we see our mission as collaborating with you to deliver the right automation and information solutions that enable the success of the entire range of production workers that impact your production operations. In this collection of success stories, you will discover innovative, but proven examples how people are able to do their jobs more successfully in order to achieve impressive business results. The people we can help empower not only include plant and facility operators, but also their supervisors, managers and executives, along with the IT staff that manages the IT systems infrastructure. We can also positively impact quality, safety management, maintenance and engineering staffs. Over 650,000 licenses of Invensys software solutions are in use in over 125,000 locations in over 180 countries in the world. This is an amazing testimony to the widespread applicability of our open, InFusion Enterprise Control System and the underlying ArchestrA System Platform that is helping to integrate, operate and manage manufacturing, infrastructure and process operations. But the numbers only become truly significant when we enable others to innovate for their personal and business success. That is what this book of success stories is all about. We invite you to challenge us, and to collaborate with Invensys and our partners in order to accelerate our mutual efforts towards achieving Real-Time Success.

Sincerely,

Mark Davidson
Vice President, Global Promotional Marketing & Communications Invensys Operations Management

Extio

Mura MPX

Mura MPX Series display wall controller boards offer universal input capture and display including matrix switching, signal conversion, video scaling and de-interlacing in a single PCI Express x16 Gen2 card. Combine multiple Mura MPX boards in a single chassis for high-density, scalable video wall installations. Matrox Extio Series KVM extenders use up to 1 km of bre-optic cable to separate the keyboard, mouse, audio, and up to four displays from the computer. Uncompressed data is 100% available to the SCADA/DCS without relying on network resources for delivery. Interoperability with Mura MPX Series facilitates collaboration between the remote operator desktops and high-performance display walls.

Achieve the features and performance valued in control room environments with the Matrox Mura MPX and Extio Series. Learn more at www.matrox.com/graphics/OpsManage

INDUSTRY: CHEMICAL

Azoty Tarnow S.A.

www.azoty.tarnow.pl

Using the latest technology and IT solutions to build a telemetry and monitoring system shows that Azoty Tarnw is a modern company that is concerned about high quality and low production costs. This is reflected in the competitiveness of our products, the desire to have a safe workplace and a company that is concerned about the environment.
Lucjan Knapczyk, Technology Specialist at Automatyka Sp. z o.o.

New Control and Monitoring System at Azoty Tarnow Increases Plant Production
Goals Increase the production effectiveness, traceability and safety by installing a central control and monitoring system Challenges Very high maintenance costs (energy, methane consumption) Solutions and Products Wonderware Historian Wonderware InTouch Wonderware Historian Client Wonderware Information Server Results Manufacturing costs has been reduced as a result of the new Monitoring System Access to key media parameters analysis (quality, consumption) in real-time resulted in more efficient manufacturing Improved information flow (delivering actual data to technology engineers) has been achieved.

Chemicals
The chemical industry involves the production of a wide variety of products that are toxic, flammable or are explosive. It involves the use of high energy and extreme pressure and temperature ranges in the production floor. Add to this, the concern of most companies in the chemical industries on matters of safety and compliance to standards: There is thus a need to make sure that key parameters are monitored and controlled in the plant. Azoty Tarnw uses Wonderware InTouch for the local monitoring and control of its plants. This allowed Azoty to collect information on energy usage, control and manage the use of methane and steam in the plant as well as operate the water and wastewater plants. The board of Azoty decided to expand to a plant wide monitoring system because of the positive feedback from these existing solutions. This required the creation of a system that will monitor all the plants, store information in a central database and be able to generate reports on quality and plant consumption.

Wonderware Historian, Wonderware InTouch, Wonderware Historian Client, Wonderware Information Server

Pumping stations for drinking and process water 3rd party Nitrogen generator from AirLiquide, Process air compressor station Air for control - drying stations, compressed air station and the liquid CO2 plant, Uninterruptible power supplies All production departments. Aside from the normal process monitoring the Wonderware solution also gets data from the Weather Stations around the plant. This is important in case of gas leak emergencies so plant personnel know which way the wind blows during evacuations.

Construction of telemetric network

The large plant area required that the network architecture be modular and yet integrated. The main communication network is composed of a fiber optic ring with a copper twisted pair redundant connection. There are also drops of RS485 and Ethernet connections to the field devices and local controllers.

Production and Energy Information System

The following are measured in the new Monitoring System: Electricity Air supply Process water for heating and drinking Steam Pressure Water and Wastewater management Ammonia usage Methane usage with the ability to forecast consumption and set purchase limits The monitoring system involves the supply and consumption of raw materials, production and manufacturing of final product, with the ability to monitor efficiency and compute manufacturing costs. The monitoring system also included the main and auxiliary plants: Power and Water Treatment Plants Medium and High Voltage Electrical Substations ,

Data Acquisition
Information is collected from a large number of 3rd party manufacturers each of which has its own communications standard. All of which is collected in a central database. In many cases, the Azoty Tarnw engineers had to create their own device drivers for communication. The DCS and PLC are connected directly to the System Platform via standard communication system.

Industrial database - collection and data archiving

Data collected from the automation and measurement equipment is collected and sent to the Wonderware Historian. This provides a central source for historical data. Data recorded by the Wonderware Historian has a sampling rate of 3.3 ms. The installation of the telemetry and monitoring system at Azoty Tarnw has been implemented entirely by the Automatyka Sp. z o. o..

This document was realized thanks to the support of: Automatyka Sp. z o.o. and Azoty Tarnow S.A.

INDUSTRY: CHEMICALS

Calzin,Inc.
www.calzin.com

The Invensys Foxboro solution measures and maintains a predetermined percent solids ratio based on conductivity, which assures accurate batch composition every time.
Jeff Blanchard, Vice President, Calzin, Inc.

Foxboro conductivity sensing system ensures consistent product quality while reducing labor and material costs
Goals Automate the mixing process to improve product quality and reduce labor and material costs Develop an automated mixing system to enable customers to determine the exact proportions Challenges Determining the exact percent of solids ratio in the solution Reducing the variations in the mixture and the implications on labor, material costs, and product quality Solutions and Products Foxboro Electrodeless and Flow-Through Conductivity Sensors Solutions and Products Foxboro Electrodeless and Flow-Through Conductivity Sensors Results Ensured consistent product quality with the ease of use in release agents and additives Reduced labor and material costs and eliminated human error by automating the mixing Enhanced customer service and supported market leadership position by implementing the Foxboro solution

Chemicals
Hampshire, U.S.A Founded in 1952, Calzin, Inc.,
is an international supplier of coatings for the rubber industry. One of the companys original products is calcium stearate, which is used as an anti-stick agent that keeps rubber from sticking to itself when folded and stacked. As an innovator in its field, Calzin has developed an innovative concentrate mixing system that ensures the proper mixing of calcium stearate based on conductivity sensing to determine percent solids ratios.

Foxboro Electrodeless and Flow-Through Conductivity Sensors

Demanding Applications
Without a properly mixed anti-tack additive, rubber production can indeed be a sticky situation. Too little calcium stearate powder, the main ingredient of the liquid additive, and rubber sheets could adhere to each other; creating costly rework to bring them back into spec. Too much calcium stearate and sheets could slide off of palettes and end up in the scrap pile. Despite the fact that variations in the mixture have tremendous implications for labor, material costs, and product quality, rubber producers have had to rely on human judgment to determine which mix was optimal for their production. Recently, however, Calzin, Inc., has produced a measuring system that enables its customers to determine the exact proportions of calcium stearate concentrate and water for their application. One of Calzins key products is calcium stearate, which when mixed with water, produces a soaplike slurry release agent that inhibits rubber from sticking to itself when folded and stacked. Calzin ships the calcium stearate to customers as a concentrated dispersion, and they in turn dilute it with water for use as needed. Through what has largely been trial and error, customer technicians adjust the flow of water into the premix concentrate until they feel it has the right consistency. According to Jeff Blanchard, Vice President of Calzin, Inc., This is far from an exact science. Theres a fine line between hitting and missing the proper ratio. For instance, if your target is a mixture of three percent solids, a two percent mixture will result in the rubber sticking to itself and may require rework. A four percent ratio can cause rubber sheets to slide off of pallets and possibly result in scrap. Worse yet, the excess can become airborne resulting in sever dust problems that endanger workers. Seeking to help customers make more effective use of his product, Blanchard set out to develop an automated mixing system to remove the guess work and help his customers achieve consistent and repeatable release agent mixes. Figuring that determining the exact percent of solids ratio in the solution would provide a much more accurate and consistent solution, he hypothesized that conductivity sensing could deliver that information. His Internet search for authorities on the subject led him to Foxboro Measurements & Instruments.

Leading Edge Technology Solution

After preliminary discussions about his application, Blanchard met with Foxboro process measurement experts, who demonstrated an electrodeless conductivity system with which he could measure and maintain percent solids ratios with high accuracy. The Foxboro solution measures and maintains a predetermined percent solids ratio based on conductivity, which assures accurate batch composition every time, says Blanchard. The Foxboro system consists of a conductivity analyzer with a tailored custom curve set, and electrodeless conductivity sensor. The sensor measures the conductivity and sends a reading to the analyzer. From there, the software triggers

10

Chemicals
alarms when conductivity setpoints are reached, which control a series of valves and pumps that supply the Calzin concentrate and water in proportion to maintain a predetermined target conductivity setting. The key was converting conductivity measurements into discernable information that technicians could understand. Through trial and error I developed a percent ratio chart as a guide for determining percent solids at different temperatures, says Blanchard. Conductivity is not the easiest thing to work with. It can be very temperamental. But Invensys supplied a complete solution, including technical support that made it possible. If I had a question, Invensys was always there to help. Invensys provided technical support to decipher the analyzers codes and showed Blanchard where and how to link his equipment to the analyzer, and how to work the data for programming the software. I was impressed with their availability and level of technical expertise. Invensys definitely has educated and talented people, says Blanchard.

Foxboro Electrodeless and Flow-Through Conductivity Sensors

Expectations Exceeded
By automating the release agent mixing process, Calzin has improved the use of its additives, while assisting customers in reducing labor and material costs. The most significant benefit for our customers is ease of use of our agents, says Blanchard. They love it because we give them a quality concentrate and the capability to automate mixing specifically for their applications. The automated system also reduces labor and material costs for Calzin customers. In some cases there have been as many as six people checking and adding to the release agent mixtures. Our system totally eliminates the toomany-cooks problem through automation. It eliminates human error while enabling customers to use just the right amount of concentrate, which also reduces waste. The Foxboro-based system enables us to better serve our customers and gives us a competitive edge in the market place, says Blanchard.

Matching the Right Partner to the Project

Finding the best-suited solution along with a The Invensys team hopes to be a part of ongoing BASF projects. Looking to the BASF philosophy, We dont make the products, we make them better, they add, We didnt invent migration, but our solution definitely makes the path better for our customers.

This document was realized thanks to the support of: Calzin, Inc.

11

INDUSTRY: CHEMICALS

Delta BioFuels, Inc.

www.deltabiofuels.com

There are a number of ways to detect phase changes, but conductivity sensing is really ideal for this application. A conductivity measurement system is relatively inexpensive, very clean, and maintenance free. Delta BioFuels brought in Invensys to discuss its Foxboro products and we decided these were the solutions we needed.
Scott Nisula, Chief Technical Officer, Delta BioFuels, Inc.

Foxboro Conductivity Sensing Sparks Automated, Efficient Biodiesel Fuel Processing

Goals BioFuels required technology that would improve the delicate process of separating by products from the final product at various stages Improve technology that would enable frequent and accurate monitoring without interrupting production or jeopardizing worker safety Challenges A solution was required to ensure that the production process of Delta BioFuels biodiesel would not be interrupted during the fuel separation process Sustainable alternative energy sources demands an immediate technology solution that would produce a very pure biodiesel product quickly and efficiently Solutions and Products Foxboro FT10 Noninvasive, Nonmetallic, Electrodeless Flow-Through Conductivity Sensor Results The Foxboro FT10 enables Delta BioFuels to produce between 80-100 million gallons of biodiesel per year, making it one of the largest biodiesel plants in the country Using Foxboro FT10, Delta BioFuels achieved the production goals of its four 20,000-gallon reactors and controls the delicate separation process through accurate conductivity measurements By implementing a reliable and accurate process automation system, Delta BioFuels has been able to eliminate human error and enhance overall product quality

12

Chemicals
Natchez, Mississippi Little did the scientists
in the mid-1800s know that their pioneering work in developing biofuels and diesel engines using vegetable and peanut oils would serve as the foundation for todays efforts to combat the worlds growing energy demands. By spearheading alternatives to fossil fuels, these 19th century researchers paved the way for the options that we enjoy today to help balance the need for additional energy resources with choices that are sustainable and reduce the impact on the fragile global environment. The Energy Policy Act of 2005 passed by the U.S. Congress significantly changed the nations energy strategies by providing tax incentives and loan guarantees for energy production of various types, including the production of biofuels. Biofuel products are made from a variety of feedstocks, primarily soybean oil, vegetable oil and animal fat derivatives. Delta BioFuels, Inc. is a leading private alternative energy company dedicated to producing only the highest-quality biodiesel, meeting or exceeding all industry standards. The company has achieved best-in-class operations with state-of-the-art equipment coupled with a highly experienced management and technical staff. To complement its state-of-the-art production facility, the company selected Foxboro technology to monitor the delicate biodiesel production process. Using the Foxboro noninvasive, nonmetallic, electrodeless flow-through conductivity sensor enables Delta BioFuels to monitor the critical ongoing viability and purity of biodiesel during production process. Located directly on the Mississippi River, the companys 60-acre facility can receive its soybean and vegetable oil feedstocks quickly and directly at the production facility. Delta BioFuels can then easily distribute its final biodiesel products by barge, rail or truck, positioning the company to serve any market on a global scale. The Delta BioFuels facility has the capacity to produce between 80-100 million gallons per year, making it one of the largest biodiesel plants in the country.

Foxboro FT10 Noninvasive, Nonmetallic, Electrodeless Flow-Through Conductivity Sensor

producer of biodiesel fuel, Delta BioFuels overcame this separation anxiety by applying conductivity sensing technology. The Delta Biodiesel plant has four 20,000-gallon reactors and approximately 15 process vessels of various sizes, as well as large field storage tanks used in the delicate separation process. Biodiesel production process is done through a chemical reaction that combines vegetable oil or animal fat as a raw stock, methanol and a catalyst of sodium methylate in proper proportions. The process, called transesterification, involves chemically converting triglycerides to smaller methyl esters that resemble diesel fuel with extra oxygen atoms that make it oxygenated diesel fuel enabling it to burn cleaner. Effective separation is critical to the success of our process and the quality of our product, which we take very seriously, said Scott Nisula, Chief Technical Officer at Delta BioFuels. When emptying the reactors we need to know exactly where the interface is between the biodiesel and byproducts. If we leave byproducts in the fuel, we wont meet product quality standards and have to reprocess the material. If we pour out biodiesel, were throwing money down the drain.

Leading-Edge Technology Solution

Based on more than 20 years of petroleum and refinery experience, Delta BioFuels selected the Foxboro FT10 sensor as the preferred instrument for measuring conductivity. There are a number of ways to detect phase changes, but conductivity sensing is really ideal for this application, said Nisula. A conductivity

Demanding Flow Rates

Biodiesel is a safe alternative fuel replacement for traditional petroleum diesel. However, producing biodiesel fuel is a difficult task that requires precise separation at various stages. As an innovative
13

Chemicals
measurement system is relatively inexpensive, very clean and maintenance free, since there are no moving parts. I brought Invensys in when discussing the process and the company provided the solution we needed. Delta BioFuels is using the Foxboro conductivity probes in three applications. The initial application is in a batch plant mode where the company has a pump on the bottom of the reactor. Directly downstream of that pump is a T configuration that houses the Foxboro conductivity sensor. At this stage, the company needs to separate glycerin, which has a relatively high conductivity, approximately 4,000 to 5,000 microsiemen/cm. The Foxboro probe monitors the conductivity of the fluid passing by and, as the interface occurs, it immediately detects a dramatic drop in conductivity because the methyl ester phase has a conductivity of less than 20 microsiemen/cm. The conductivity sensor then triggers a signal to stop the pump and close the valve. The remainder of what is in the reactor is methyl ester that contains contaminants including excess methanol, glycerin, soaps, catalyst and other impurities. The second application involves removing these components from the biodiesel fuel before it can be released as a final product. The crude biodiesel is mixed with water to scrub out the impurities, and then the water is allowed to settle to the bottom of the reactor. Because wash water has a high conductivity of about 2,500 microsiemen/cm, the Foxboro sensors can immediately detect the interface between methyl ester and wash water. After the washing, the biodiesel goes to the final phase where a vacuum dehydrator warms the wet biodiesel and draws out any residual water. In this third application the Foxboro conductivity sensing probe is used to determine when the appropriate amount of water is removed. At that point what remains is finished biodiesel fuel.

Foxboro FT10 Noninvasive, Nonmetallic, Electrodeless Flow-Through Conductivity Sensor

Expectations Exceeded
Delta BioFuels innovative application of Foxboro conductivity sensing technology has resulted in improved production efficiency, reduced material and maintenance costs, and most importantly, ensured product quality. By automating the phase separation process through Foxboro conductivity sensing technology, Delta BioFuels has eliminated the possibility of human error. Now, the interface between end-product biodiesel and waste byproducts is accurately and consistently detected to ensure product quality. Accurate, automated phase detection also eliminates loss of valuable biodiesel that might otherwise be disposed of with byproducts. Conductivity sensing technology has proven to be the cornerstone of successfully automating our critical phase separation process, said Nisula. This will promote additional and ongoing process improvements such as automated, continuous processing, which will further improve production efficiencies and consistent product quality. The early developers of biodiesel fuel probably would be pleased with the evolution of their pioneering chemical experiments and todays implementation of biofuel technology, albeit more than 150 years later. The ongoing development of biofuels as a viable alternative energy source will surely play an important role as the world transitions from its dependence on petroleum to cleaner, sustainable energy options.

This document was realized thanks to the support of: Delta BioFuels, Inc.

14

INDUSTRY: CHEMICALS

Imperator
www.imperator.fr

We have a huge project to automate our 10 batch production lines for lubricating greases. Wonderwares InBatch gives us the open technical standard, in compliance with standard S88, that we were looking for. As for Wonderware, it provides us solid guarantees that it will be able to adapt to information technology developments over time.
Vincent Duthoit, Imperators Manufacturing Manager

InBatch optimises the production of lubricating greases

Goals Automate the batch production lines for lubricating greases in order to limit the influence of human factors Obtain improved regularity in the quality of the grease produced Increase the production facilities efficiency and avoid losses of production lots Develop a tool that enables Imperator personnel to develop and execute themselves their new formulations, without using the integrator Challenges Adapt to the constraints of the company, which has a weak culture in automated operations and industrial data processing Develop a solution that makes it possible to apply the same formulation on different production lines Solutions and Products ArchestrA System Platform Wonderware InBatch Wonderware InTouch Wonderware Historian Results Fewer variations in the quality of the greases produced Production facilities optimized with 16,000 metric tons produced every year Dialogue facilitated between the formulator and the machine technicians using the same man-machine interface

15

Chemicals
Baisieux (France) Created in the 30s, Imperator
began producing lubricating greases in 1950. Since then it has become one of the leaders in this field in Europe, with more than 16,000 metric tons produced every year. Until very recently, the production was done exclusively under the manual control of operators. The company has just entered an important new phase: We are progressively upgrading and equipping our production lines (at the rate of one line per year) with Wonderware InBatch software. The objective is to reduce the influence of human factors (absences, possible errors) and obtain regular production quality, irrespective of the circumstances, explains Vincent Duthoit, Imperators Manufacturing Manager in Baisieux . In spite of its leadership position in Europe, Imperator is not known to the general public. The reason is quite simple: the greases it manufactures are sold under what is called private brands Under the name of the company that markets them (major oil companies in particular), Imperator has 300 active customers around the world. Automobiles form the first customer segment, followed by customers from the iron and steel industry and then in no particular order the nuclear, aeronautics, public works and related industries.

ArchestrA System Platform, Wonderware InBatch Wonderware InTouch, Wonderware Historian

the sequence of operations. Like kitchen recipes, the operator relies on descriptive documents. Consequently, it is in large part thanks to the quality of its employees that Imperator has been able to establish itself. But the world is changing. Here as elsewhere, there is increased personnel mobility and it is hard to find specialists. Like everywhere else, Imperator has to optimize its production resources and cannot afford to lose a production lot due to the unexpected absence of an operator or an error in the execution of the formulation. These are the reasons why Vincent Duthoit decided to automate his production lines in order to obtain increased regularity in production through an improved repeatability of operations.

S88, a recognized and open standard

When it came to choosing the technical solution, Imperator didnt start from scratch. It had participated in a huge study carried out by its parent company (a major industrial group specializing in hydrocarbons and lubricants) to standardize the batch solutions at its different sites. The parent company was also called on to develop the specifications. The specifications were functional and didnt impose a technical solution. We wanted an open and upgradeable solution based on a standard software program that met the S88 standard and that let us modify or implement our formulations ourselves, without requiring the help of the integrator. We also wanted flexibility in the execution of formulations, without having to reformulate them when we went from one production line to another, sums up Bertrand Guille, manager of new automation work. These eliminated de facto in-house software solutions. Since it involved a long-term commitment, Imperator had also defined a few criteria that the software editor and the integrator had to satisfy. In light of

300 basic components, 260 formulas

According to the definition of the NLGI (National Lubricating Grease Institute), grease is a solid to semi-fluid product resulting from the dispersion of a gelling agent in a lubricating liquid (oil). Other ingredients can be included to provide special properties. Thus it is possible to create specialized greases based on the application. At Imperator, this resulted in the implementation of 260 different formulas, based on 300 base components (in practice, there is an average of 10 ingredients per formula). To further complicate the process, these products are offered in some 20 types of packaging (bulk tank or container, barrels, small casks, pails, boxes and cartridges) and the quantities to deliver vary substantially from one customer to the next. To meet this complex and diversified demand, Imperator has 10 production lines, all assigned to lotbased production. Until recently, the production lines operated in manual mode, with trained operators who have mastered the process. The process is somewhat similar to kitchen recipes, with mixtures of components in a cooker, heating and cooling operations, and addition of various ingredients at well-defined moments, all while being very precise with the dosage, the temperature ramp time and
16

Chemicals

ArchestrA System Platform, Wonderware InBatch Wonderware InTouch, Wonderware Historian

all of these parameters, Wonderwares InBatch was the obvious choice. An important point in the choice of InBatch is its ability to adapt to all process sizes, including small ones (Imperators production lines include approximately 150 inputs/outputs). As for Wonderware, it provided guarantees in terms of life expectancy and services and clearly demonstrated its ability to upgrade its software based on computer standards (especially on the arrival of new operating systems). Another advantage is that several integrators are capable of implementing the Wonderware products. Here, the choice of integrator was obvious. Technord, in addition to being close to Imperator, is one of the best system integrators that specialize in Wonderware products. We are an Endorsed certified partner, the highest level of certification issued by Wonderware. Only some 20 companies can claim such a level around the world. In terms of supervision and batches, we focus all of our energy on Wonderwares product line. We dont disperse ourselves at all. Our customers are the first to benefit from this expertise, with the assurance of having completely perfected applications, contends Rmy Sagot, Sales Manager at Technord.

technical services total autonomy. The description of the phases and their sequencing (operations in series or in parallel) are done easily using a logical diagram (Graphics). The transcription in PLC language is done automatically. We dont have to intervene on the PLC program that Technord developed for us. We concentrate on formulating the formulation and executing it, which when it comes down to it is our basic roles, explains Bertrand Guille. In order to see clearly what happens when the recipe is executed, the operators on the line have an InTouch screen with the graphics of the operations sequence with all of the useful information. The formulators and the operators use the same explicit displays thereby avoiding misunderstanding. Furthermore, this graphics can be understood just as well by operators without computer experience. In terms of the architecture: For each line, there is a PLC (Schneiders Premium TSX57) and an InBatch/ Historian server with redundancy. Three InTouch stations provide the operator interface (one for the formulations and two for the operators on the line). Some ingredient loading operations remain manual, but thanks to InBatch and InTouch, the operators are freed from numerous tasks and they see to it that the sequences are done correctly (otherwise InBatch forbids certain operations). It is easy to find the cause of problems and to do a post-analysis using the data gathered from the Historian.It isnt necessary to store mountains of reports anymore. You just have to do a query and Historian will search for the useful data and immediately create the requested report. When one knows the history of the plants automation under manual control, one can measure Imperators progress brought about by the Wonderware software. These programs have made it possible for the company to do a much better job of supervising its operators work, to be more flexible in assigning them to the different production lines and in the end, to be much more composed.
This document was realized thanks to the support of: Imperator and Wonderware France

Single formulations, irrespective of the production equipment

In practical terms, Imperators formulators write or modify the recipe for the grease they want to produce, using InBatch. The recipes can be transferred to any production line (as they are all equipped with the Wonderware software). According to the S88 standard, recipe execution using the equipment in the elementary phases (opening a valve, activating the heat, agitator, etc.) and their sequence have to be described before they are transcribed in PLC language. Here again, things were made very simple, providing Imperators

17

INDUSTRY: HYDROCARBON PROCESSING

Borealis Group
www.borealisgroup.com

The implementation of the IntelaTracsystem cost less than 100.000 euro in total. That is not more than we would have needed if we had chosen to connect only 10 sensors to our DCS. If the new system will prevent a standstill of only one day of our factory, we will have earned enough to repay the investment.
Wouter Verheyden, reliability team leader at Borealis

Borealis: Leading, innovative provider of plastics solutions based on polyethylene (PE) and polypropylene
Goal: Create an automation system that will reduce risk, lower production costs and address all environment and sustainability goals Challenges: Be able to check static equipment such as piping and pressure vessels Be able to evaluate the functioning of safety systems designed to prevent damage to man and/or the environment Solutions & Products: Wonderware IntelaTrac ArchestrA System Platform Results: An optimal safety systems was completed with less cost that inventing in traditional sensors Preventive maintenance are scheduled effectively

18

Hydrocarbon Processing
Borealis, produces polyethylene and polypropylene products. Using a unique Borstar-technology, it produces tailor-made polyethylene and polypropylene pellets, which is used by its customers in the production of car bumpers, cable coverings, and permeable packing materials. Besides that, Borealis also produces base chemicals like phenol, acetone and melamine.

Wonderware IntelaTrac Archestra System Platform

risks for man and environment are of course also evaluated. To execute RCM we developed a matrix, to we are able to speak the same language in every plant. In that matrix, we systematically map the risk and consequences of possible failure modes.

Management of change
The three pro-active strategies are used together to optimize the preventive maintenance planning. Our Reliability Task Force, regularly evaluates that schedule. To do that, Borealis uses historical data from SAP, in which all the preventive maintenance activities are recorded. For example, analyzing these data it could turn out that carrying out preventive maintenance on a certain redundant pump is more expensive than simply waiting until a failure happens. Changes in the way equipment is maintained are never carried through without an evaluation. We have a management of change process, during which we together with people from production investigate if there are possible new risks. An example is an unwanted side-effect of using a new type of lubricant, according to Verheyden.

Risk Based Maintenance

Risk Based Maintenance aims to reduce risks in the plant as far as possible. The bigger the risk, the more preventive measures we take. That is the central idea, says Verheyden reliabity team leader at Borealis. The focus is on being pro-active, and prevent and/ or reduce the seriousness of failures. Anticipating all possible problems is of course not achievable. But, when a failure occurs, if possible you want to prevent that the same problem happens again in the future. Therefore, when an unexpected standstill of a plant lasts longer than a day, we always form a multidisciplinary team. That team will investigate what the root cause was, and will try to implement effective countermeasures. The improvement projects resemble a Six Sigma implementation, and the project phases are called define, analyze, solve, implement and review. This is called the Borealis Way, because the approach was developed and tailored within and for the company.

Predictive maintenance
Planned care is not the only form of preventive maintenance. Another alternative is called predictive care: that is maintenance carried out at the moment the equipment failure threatens to occur. To trace these situations, the data-historian is an important source of information. In this database - Borealis uses IP21 of Aspentech with data originating from

Pro-active strategy
As part of this pro-active strategy for maintenance and safety, the following approaches are combined: 1. Evaluate the functioning of safety systems designed to prevent damage to man and/or the environment, the Safety Integrity Level method is applied. 2. Risk Based Inspection. To check static equipment such as piping and pressure vessels. This means that critical parts, of which failure would have severe consequences, are inspected frequently 3. The third pro-active method, Reliability Centered Maintenance or RCM, we mainly use for rotating equipment, explains Verheyden. Like in the two other approaches, focus is again on the prevention of problems with the most severe effects. In this case, mitigating financial risks often comes first, but

19

Hydrocarbon Processing
the Distributed Control System (DCS). This makes it possible to determine if for example temperatures or pressures have a tendency to change. However, there is a problem: No less than 40 to 60% of all measurements are not automatically written to the data historian. Take for example a compressor, explains Verheyden. Such a machine comes with trimmings like the measurement of the oil temperature. However, only the pressure is transmitted to the DCS. Therefore you have to find ways to bring the other data in. Theoretically, all sensors could be connected with the DCS. That brings along the advantage of realtime measurements, but it is an expensive solution.

Wonderware IntelaTrac ArchestrA System Platform

inspection round, he or she places the handheld back into a docking station. After that, the data are automatically uploaded to an IntelaTrac server, and from there to our data historian. As a result, everyone can access the information collected in the field with a web browser, even from the office. The collection of maintenance related data by the operators is called Operator Driven Reliability (ODR). We use that name not only for the tools, but also for the process, because it is not only about doing measurements. ODR also includes decision support. Operator Driven Reliability IntelaTrac was programmed for a number of fixed inspection rounds. The handheld mobile computers support barcode scanning. On the one hand this is used to verify if certain tasks are completed, on the other hand scanning a barcode makes it possible that an operator interrupts an inspection round. In that case, he or she will scan an equipment barcode label to resume inspection. That is convenient because sometimes an operator is called away to solve an urgent problem. During an inspection round, the handheld computer indicates what should be measured. And after for example entering an oil temperature, an operator immediately receives feedback if something might be wrong. When that temperature is for example not within the permitted domain, or when there is a large difference with the previous reading, an alarm is given. The operator will get appropriate recommendations to map the problem in more detail, and to solve it immediately if possible. The suggestions can vary from adding oil to checking a valve position, or calling in help. In addition, an operator can make a maintenance order in SAP. The implementation of the IntelaTrac-system costs less than 100.000 euro in total. That is not more than we would have needed if we had chosen to connect only 10 sensors to our DCS. If the new system will prevent a standstill of only one day of our factory, we will have earned enough to repay the investment.
This document was realized thanks to the support of: Wonderware Benelux and Borealis Group

Eyes and ears

Therefore we prefer that our operators collect the missing data, during their inspection rounds, Verheyden continues. An added advantage is that operators detect more than all the sensors put together! They are our eyes and ears in the field. There are process variable that they notices like abnormal sounds, vibrations and leakages. That is important information, because vibrations for example turn out to be the root cause of 25% of the machine failures. In addition, by involving our operators in the maintenance process, we create a feeling of ownership and responsibility Collecting data is however only half of the solution. If it is not done in a consistent way, or if the information does not find its way to the right persons, it all becomes pointless. Until recently, operators used paper checklists which they filled in and handed over to their shift supervisor. However, that person not always took the appropriate action, nor had he or she enough time to enter the data in Excel to perform a trend analysis. In addition, rainy weather conditions sometimes made the papers illegible.

Wonderware IntelaTrac
One year ago, an effective solution was found. Operators now collect data with three Bartec mobile handheld computers. The model they use is suited for application in ATEX zone 1. On the handhelds runs Wonderware IntelaTrac, , explains Verheyden. IntelaTrac supports the workflow during the data collection process. When an operator finishes an
20

INDUSTRY: DISCRETE MANUFACTURING

Meridionale Impianti S.p.A.

www.merimp.com

Through the extensive monitoring of manufacturing stages, we have significantly reduced wastes that have a negative impact on efficiency and production costs.
Giovanni Raffa Business Development Manager, Meridionale Impianti S.p.A.

With the deployment of ArchestrA System Platform and accurate engineering, Meridionale Impianti S.p.A. can offer a 20-year warranty on the productivity of a photovoltaic plant
Goals Ensure excellent quality in the production of photovoltaic panels Real-time action on deviations and negative trends in production Challenges Constant and accurate control of environmental parameters in photovoltaic panel production areas Traceability across the manufacturing process Integration of plant automation systems with enterprise management system (ERP) Diversified access to manufacturing information at different levels of the organization Wonderware Solutions ArchestrA System Platform Results Monitoring of real plant performance to eliminate possible inefficiencies Reduction of manufacturing waste

21

Discrete Manufacturing
Catania, Italy - Meridionale Impianti, a
multinational company with manufacturing sites in Sicily, has been developing its expertise in industrial plants across 30 years, growing into an organization with over 600 employees and 120 million Euro revenues. The company has entered the photovoltaic panel production business with a truly unconventional approach: bet on the quality of production. Strongly expanding markets are typically addressed by companies that exclusively try to exploit a favorable trend. They hardly care about quality and try to maximize their short-term profits. In photovoltaic panel production, the past few years have seen the rise of a number of Italian and international manufacturers often lacking specific experience; and some of them just distribute modules manufactured by others. On the contrary, Meridionale Impianti has decided to invest in high-level expertise and technology to create an offer distinguished by excellent quality.

ArchestrA System Platform

Perfect control
The perfect control of environmental parameters, as well as the optimal management of staff operations, are the result of experience acquired by Meridionale Impianti engineers in hundreds of industrial installations. Despite the most innovative production and automation technology, however, no manufacturing operations can guarantee results that are always ideal. For this reason, Raffa has decided to test and certify each component of each panel, acting promptly in case of deviations or negative trends, in order to achieve a consistent improvement of production. We decided to trace the entire production process - says Vincenzo Orlando, Scada systems manager - in order to identify and handle possible causes that may affect the optimal quality of our modules. However, pursuing this goal with traditional methods was difficult, because manual measurements are both slow and arbitrary. Hence the need to find a software platform to automate these activities in an effective and reliable way, with no impact on the work of plant staff, while providing all people involved in the production and management process with extensive information about current and past activities. To meet these requirements Orlando continues we have discarded the idea of developing a software platform ourselves, as it would have taken too much time to write the code. Furthermore, we would have had to check possible bugs, with the consequent risk of slowing down production or, in some cases, the impossibility to correct possible issues. So, we started to search the market for a solution that could be quickly customized to our specific requirements. The system also had to dialog with the ERP system to receive production orders, check them against available stocks and provide information about current activities.

We make our own panels

In a business where nothing is taken for granted - explains Giovanni Raffa, Business Development Manager we provide customers with a legally binding certification, whereby we declare the production capacity of a solar field built with our technology over the next twenty years. This means we subscribe a ROI warranty for the customer. And to make sure we meet such warranty, we must exclusively deliver panels complying with the highest quality standards. This requirement cannot be always satisfied with standard solutions from trade. So, Meridionale Impianti decided to leverage its expertise in high-tech plants to produce panels and systems internally. To do this, Meridionale Impianti installed new manufacturing facilities in Sicily, in the Etna Valley near Catania. In this territory, within a range of few kilometers, over 60 high-tech companies have been established and you can easily find skilled staff in the production of electronic components, who can work inside low-contamination areas and clean rooms. Meridionale Impianti is among the few companies that execute production in an environment with constantly monitored temperature and air quality. In this way, photovoltaic cells - manufactured to Meridionale Impiantis Intellectual Property specifications by semiconductor specialists - are assembled under ideal conditions, preventing all contamination risks and obtaining panels with consistently high production efficiency rates.
22

MES screenshot: plant layout

Discrete Manufacturing
Searching for excellence
Even international vendors operating in the Italian market had no effective solution to Meridionale Impiantis needs. This is also due to the fact that MES is still relatively uncommon in Italy Orlando continues - and consequently, potential partners turned out to be incompetent, lacking the required technical support and demanding very high prices. On the contrary, Wonderware, partnering with Meridionale Impianti for over a decade in the development of Scada systems based on reliable platforms, presented a professional and collaborative approach. The first impression was then corroborated by facts, in terms of supply and service. Orlando states: We have always received direct support, especially during the most critical project stages. All of this was combined with a range of specific training courses for System Platform. The solution adopted by Meridionale Impianti offers all industrial automation software applications on one single platform: from Scada to Hmi, including supervisory systems and Mes/Emi. These solutions were pre-packaged, and the customer was able to customize, test and deploy them in just two months.

ArchestrA System Platform

MES screenshot: inventory

All the benefits of Mes

Using a Mes system as offered by Wonderware, the Meridionale Impianti management has been able to measure the real performance of their manufacturing lines, taking actions to remove inefficiencies and situations that might affect quality. Furthermore, through the automatic collection of all production information, they could reduce waste dramatically. Besides affecting a lines productivity, waste has significant economic impact. Just think that photovoltaic cells represent approximately 70% of

the cost of a panel - Raffa explains . If you have to discard an entire module because one cell is contaminated or damaged, the economic impact is significant. This situation is even more critical if you consider that, after lamination, you can no longer perform any action on a panels internal components. For this reason, any non-conformity detected during the final quality test results into the elimination of the entire module. Despite strong attention to quality, some noncompliance might still emerge over time. In this case Raffa explains we replace the panel, but still it is essential to trace back to the roots of the problem. Therefore, support offered by the historical track of all data within the System Platform becomes critical. The system allows to trace back across the entire production process, identifying the possible causes of detected problems and the corresponding production batches.

Simplifying complexity
Using Wonderware System Platform to record, process and automatically store all production data, enables the use of information according to the specific requirements of each user, who can access the system from any location. Also for this reason, Orlando explains, we have leveraged the graphical features of the system to create an easy-to-read interface that can generate impact charts to provide an intuitive view of all parameters required for the daily work of plant operators. Individual managers at each level can access the same database for more detailed and specific analysis. It is not easy to develop an HMI suitable for the needs of plant staff, Orlando underlines, as designers must interact with operators and understand exactly
23

MES screenshot: work order

Discrete Manufacturing
how they act and respond to each event. After this activity had been completed, the operating modes to be complied with by each user were defined and standardized, leveraging the platform flexibility. This approach may seem constraining, but it is the best solution to optimize the production cycle management. Being committed to high-quality production, Meridionale Impianti technicians often have to pick some panels in order to execute specific operations or customizations. Our production standards states Raffa are very high and, for this reason, we monitor and check the entire production, both on raw materials and at the end of the manufacturing cycle and during the process. We need to act promptly in all situations of abnormal conditions, but we also have to keep track of all manipulations. With this operating mode based on total monitoring, we have dramatically reduced waste, which not only has a negative impact on productivity, but also represents a significant cost in a production process based on expensive photovoltaic cells. In addition, as we keep track of all components picked from the line, our operators are encouraged to perform periodical operations on semifinished parts, which require a direct action by skilled staff.

ArchestrA System Platform

This document was realized thanks to the support of: Meridionale Impianti S.p.A.

24

INDUSTRY: FACILITIES MANAGEMENT

Universit de Strasbourg
www.unistra.fr

We chose the ArchestrA System Platform to provide a building management system for the equipment in our 140 buildings. The originality of this application lies in the automatic transfer of the information entered in an asset data management program to the ArchestrA System Platform.
Damien Bertrand, Manager of the Energy Department

ArchestrA System Platform provides the building management system for the Universit de Strasbourg
Goals Development of a centralized building automation system interacting with heterogeneous equipment Easily access equipments technical data entered in an asset data management program Exchange data with other application software simply Challenges The standards for the supervisory application needed to be defined Importing of the ArchestrA System Platform directory structure for the installations and equipments identified in the asset data management program needs to be executed without any losses. Solutions and Products ArchestrA System Platform InTouch for Terminal Server Wonderware Historian Historian Client Server Results Simplified creation of the supervisory system based on the asset data management program Better visibility and control of installations based on centralized technical data A functional library and standard graphic created for all of the equipments being controlled Implementation of a technical software platform capable of meeting future needs

25

Facilities Management
Strasbourg, France Its wrought iron gate and
its architectural style evoke the private mansions or executive homes of the 19th centurys great industrialists and land owners: it is in this unlikely setting that the Universit de Strasbourg houses its all new centralised building management system (CMS/BMS), based on the ArchestrA System Platform.The project will progressively take charge of the operating equipment for 600,000 m2. of net habitable floor area in the University premises, divided amongst 140 buildings spread over 60 miles in Strasbourg and other top places in Alsace (Colmar, Guebwiller, Selestat, Haguenau, Schiltigheim Cronenbourg, etc.). Beyond its site location and the extent of the zone covered, the application of CMS stands out because of its close links to the Universitys asset data management program, explains Damien Bertrand, Manager of the Energy Department (electricity, HVAC, compressed air and other technical fluids) : When a new piece of equipment enters the University, we begin by assigning it a name and attributes in Abyla, the asset data management program developed by the French company LABEO (based in Toulouse). The ArchestrA System Platform automatically obtains this information. No re-entry is required. Abyla lists a million entities and draws up an exhaustive inventory of all the premises (walls, doors, windows and floor coverings) and everything they contain (tables, chairs, radiators, computers, etc.), including the technical equipment (PLC controllers, pumps, fans, etc.). Abyla also manages the technical documents like the asbestos files, the calculations of legal floor areas, the maintenance contracts and the commission reports. But it cant process the technical data reported by the PLC controllers (especially the values provided by the sensors) and it is not suited to real time requirements, explains Sbsastien Bahls, Manager of the Asset Information Department.

ArchestrA System Platform, InTouch for Terminal Server Wonderware Historian, Historian Client Server

When it was created, the Energy Departments task looked daunting, given the size of the stock of heterogeneous equipment, and with a multitude of suppliers and subcontractors involved. Add to the fact that each University site operated with total independence, and until then, each had its own standards and practices. The idea of implementing a Centralised Management System (CMS) became obvious to us quickly, but there was something more urgent to do. Initially, this involved finding a way for us to appropriate these facilities, to control their operation. To do this, we began by imposing a standard programming software for all of our automatic operations, in this case CoDeSys by 3S-Smart Software Solutions, explains Damien Bertrand. Of course the controllers for the automatic operations had to be programmable with this software, which led us to choose the Wago and Beckhoff solutions. These controllers were also selected for their ability to handle natively the Ethernet and IP protocols that the Energy Department had chosen to communicate with its future CMS. For the communications, we wanted a simple solution and to avoid the multiplication of gateways. This criterion led us to eliminate a functionally attractive CMS program that was nevertheless too closed, continues Damien Bertrand. More generally, the specialised CMS programs, often proposed by equipment manufacturers, were also excluded due to their lack of openness.

Definition of need and responses to the specifications

Thereafter, the way was clear for a standard supervision program. The specifications submitted to integrators were very explicit. It specified the information systems architecture, the communication protocols, the data structure and how to handle modifications. It also specified that the different pieces of equipment to supervise had to first be entered in Abyla, etc. The Universit de Strasbourg also wanted the integrators to make a technical proposal with a maximum degree of independence vis--vis their software suppliers. Consequently, it required that they propose two solutions based on two different programs. The bidding process stretched over a year, with 10 integrators responding, in most cases with very detailed arguments. The ArchestrA System Platform won the bidding process. We were impressed by

Everything begins with the homogenization of equipment

Abylas beginnings at the Universit de Strasbourg go back to 2004. The Energy Department was created at this time, with the task of maintaining the heating, electricity and special fluids treatment facilities. In practical terms, this involves making sure that the facilities run smoothly, thereby ensuring all occupants are comfortable and that continuous service is provided for certain critical facilities (especially for the laboratory animal houses).
26

Facilities Management

ArchestrA System Platform, InTouch for Terminal Server Wonderware Historian, Historian Client Server

the companys ability to react and the interest it showed in our request. Wonderware contacted the Abyla editor (LABEO) to develop a file conversion solution so data entered in Abyla could be imported in ArchestrA System Platform. The time saving is substantial and there are no risks of errors, underlines Damien Bertrand.

An easy integration between the ArchestrA System Platform and Abyla

This interconnection between Abyla and the ArchestrA System Platform is quite obvious when one looks at how the two applications are presented: one finds in them the same tree structure, which is presented in the same way (zone, building, floor, room). This uniformity is a great advantage. Indeed, the Wonderware operators often have to work with Abyla both to identify new equipment and to obtain additional information on a building, a premise or an existing piece of equipment (e.g.; its precise physical location or the name of the company in charge of its maintenance). Other functionalities of the ArchestrA System Platform were especially appreciated at the time of choosing the CMS program. We are especially attached to the 100% object concept because it corresponds completely with the formalization work that we had carried out before implementing the CMS, explains Damien Bertrand. We also appreciate the ArchestrA System Platform ability to integrate other applications. This

is the case with the following programs: IntraVue (verification of the state of connections, especially the IP addresses with the PLCs), ProgTime (hourly programming server) and Alert (monitoring of critical alarms and sending SMS and telephone messages to operators on call). The ArchestrA System Platform is installed on three servers. The basic supervision application (i.e.; the control of automatic operations) is hosted on two redundant servers, thereby providing substantial availability for the application. A third server hosts the data historization application. Not less than 5 lightweight workstations are connected to these servers. The implementation is done in steps: 3,000 points were installed in the first phase and 3,000 additional points will be added soon. We have seen that up to now the Universit de Strasbourgs Energy Department has endeavored to appropriate the existing technical facilities and control them The ArchestrA System Platform fulfils an essential role at this level. But the department doesnt intend to stop there, concludes Damien Bertrand. We are interested in the energy efficiency of facilities. We have installed several meters and the measurements are archived in Trend. We initially used the automatically edited reports to raise building operators awareness about their consumptions and their change over time. This helps them do a better job of controlling their expenditures and everything leads us to believe that tomorrow they will be proactive. Thanks to the ArchestrA System Platform, the Energy Department is already prepared to confront new requests.

This document was realized thanks to the support of: Universit de Strasbourg and Wonderware France

27

INDUSTRY: FOOD & BEVERAGE

Mount Packaging Systems Ltd.

www.mountpackaging.com

Mount Packaging learned to trust the meter. The company adjusted its equipment to improve performance and we are getting excellent repeatability with the Foxboro CFT50 Coriolis mass flowmeter. We can now prevent lost production, eliminate inaccurate pricing concerns and avoid excess downtime.
Kevin Beaumont Managing Director

Foxboro Coriolis Flowmeter Provides Breakthrough Technology for In-Filling System Measurement and Performance
Goals As a leading supplier of high-quality, state-ofthe-art filling machinery for a variety of chemical and food industries, implementing technology that ensures continuous quality enhancements is a key objective for Mount Packaging Challenges While manufacturers have been largely satisfied with traditional measurement methods, Mount Packaging was concerned because of the limitations in traditional Coriolis technology which often resulted in false readings and measurements Conventional Coriolis meters lack the ability to respond rapidly to flow changes during the course of short batches. When used with viscous fluids like paint, even small levels of gas in liquid (two-phase flow) can skew Coriolis readings Solutions and Products Foxboro CFT50 digital Coriolis mass flowmeter Results The trial system provided precise performance with consecutive runs on filling 1.1 pounds (0.5 kilogram) batches, in short runs of 0.5 seconds, which are repeatable to 0.004 pounds (2 grams) Repeatability was achieved well below 0.1 percent during 64 consecutive batch runs, at 4.2 seconds, to fill 2.64 gallon (10 liter) cans, with a target weight of 30.95 pounds (14.04 kilograms)

28

Food & beverage

Dewsbury, United Kingdom Precise
measurements for packaging of liquid products is vitally important to companies in the food, beverage and chemical manufacturing industries. These businesses use in-line filling machinery to ensure uniform product levels for packaging products in various types of containers. Founded in 1990, Mount Packaging Systems Ltd. custom designs and manufactures a comprehensive line of in-filling systems ranging from semi-automatic, mobile filling machines to fully automatic turnkey systems. The company specializes in providing technical solutions for difficult filling applications for liquids and pastes including paints, chemicals, lubricating oils, adhesives and food products. To ensure the accurate filling of these products in final packaging, in-line filling machinery relies on systems that use precise measurement technology to prevent waste from overfilling and spillage, and to ensure volume and weight uniformity. Mount Packaging implemented Foxboro mass flowmeter technology to manage the wide range of viscosities, temperatures, chemical compatibilities and particulate sizes associated with materials processed by its worldwide customer base.

Foxboro CFT50 digital Coriolis mass flowmeter

Weigh scales, another conventional measurement technology, are limited in a different way. They require trickle or ramping flow at the end of each fill, which is both time-consuming and causes spillage that can lead to erroneous readings. To overcome these limitations, Mount Packaging officials experimented with Coriolis flow measurement technology, which would measure dispensed volume based on flow rate rather than volume. However, conventional Coriolis meters had limitations as well. We tried traditional Coriolis meters, but they did not deliver the repeatability we required, said Kevin Beaumont, managing director at Mount Packaging. While conventional Coriolis meters were very accurate with steady flow in longer batches, they lacked the ability to respond rapidly to flow changes during the course of short batches. When used with viscous fluids like paint, even small levels of gas in liquid (two-phase flow) skewed Coriolis readings.

Foxboro Coriolis Flowmeter Successfully Manages Filling Operations

Mount Packaging implemented the Foxboro CFT50 digital Coriolis mass flowmeter from Invensys Operations Management. This technology is considered a breakthrough in Coriolis flow measurement for automated filling applications because it uses digital technology to keep flow tubes in constant motion so there is no loss of flow measurement during dynamic flow conditions. Using this approach, the Foxboro CFT50 flowmeter re-tunes the drive frequency of the Coriolis flow tubes every half cycle which ensures consistency

Conventional Measurement Methods

Over the years, Mount Packaging has implemented a variety of methods to help its customers achieve consistent, accurate measurement of the materials that its machines dispense. While customers have been largely satisfied with traditional measurement methods, Mount Packaging was aware of certain limitations of each approach and identified measurement technology as an area for improvement. One of the conventional measurement methods used is volumetric piston filling, which uses a device external to the container to measure the volume of material being dispensed. While volumetric piston filling is considered highly accurate, it has a limited turndown ratio of approximately 20:1 and poor repeatability at the bottom end of the range. In addition, trimming the fill size had to be done mechanically.

29

Food & beverage

and reliability. Built-in algorithms also compensate digitally for inaccuracies resulting from two-phase flow. The Foxboro CFT50 digital Coriolis mass flowmeter can handle the highly accurate measurements, while other Coriolis flowmeters fail at such precision. It is able to compensate for common industry problems associated with entrained gases, empty tubes or flash-prone fluids. The Foxboro CFT50 Coriolis mass flowmeter achieves high measurement accuracy, eliminates downtime and avoids workarounds to help keep profit flowing. Customers report the CFT50 provides exceptional performance in the worlds most challenging applications, including tanker and truck loading/ unloading, centrifuge control, ethylene oxide processing, sanitary batching, pharmaceutical batching, and food/dairy/beverage measurement.

Foxboro CFT50 digital Coriolis mass flowmeter

provide useful measurements of both mass flow and density, and the operational aspects of keeping the Coriolis meter running stably in single-phase or twophase flow conditions. One processing system controls the meter drive sequence to provide uninterrupted flow tube operation. The second system processes the measurement data from the Coriolis meter, which ensures precise fluid measurements. Coriolis meters provide direct measurement of mass flow, which is highly desirable in applications requiring precise measurement. This is particularly true for difficult-to-meter materials such as slurries and homogeneous fluids. In addition, the CFT50 reduces overall cost of ownership since the meter continues to operate uninterrupted, eliminating loss of production. Maintenance and operating costs also can be reduced since the flowmeter can be used in applications with a wide variety of fluids without re-calibration. After a few trial runs, Mount Packaging was able to establish new flow profiles for the batch runs, which demonstrated the considerably improved measurement potential that could be achieved with the Foxboro CFT50 flowmeter. Mount Packaging learned to trust the meter, said Beaumont. The company adjusted its equipment to improve performance and we are getting excellent repeatability with the Foxboro CFT50 Coriolis mass flowmeter. We can now prevent lost production, eliminate inaccurate pricing concerns and avoid excess downtime.

Research & Testing Pays Off

Initially, Mount Packaging tested the Foxboro CFT50 flowmeter on a 1 1/2-inch (40 mm) flow tube with a nominal flow capacity of 900 pounds/minute. (6.8 kilograms/second). This application resulted in the Foxboro flowmeter producing pulses that correlate with product weight. For example, three pulses per milliliter of flowing liquid are transmitted to a PLC which counts them and is programmed to actuate the shut-off valve when the target fill weight is achieved. Flowmeters are designed to measure flow of liquids by analyzing changes in Coriolis force of the substance in which the Coriolis force arises from a mass moving within a rotating frame of reference. The rotation produces an angular, outward acceleration. Combining this with linear velocity defines the Coriolis force. A Coriolis meters two main components include an oscillating flow tube equipped with sensors and drivers, and an electronic transmitter that controls the oscillations, analyzes the results and transmits the information. Invensys collaborated with researchers at Oxford University in England to develop digital technology for accurate measurement of flow, even when the flow tube contains entrained air. The group developed the Foxboro CFT50 flowmeter which incorporates new signal processing techniques to
30

Impressive and Consistent Results

Mount Packaging is now getting consistent results well within target ranges. The trial system provided precise performance with consecutive runs on filling 1.1 pounds (0.5 kilogram) batches, in short runs of 0.5 seconds, which are repeatable to 0.004 pounds (2 grams). In addition, the consistency proved itself in full scale production. One customer achieved repeatability well below 0.1 percent during 64 consecutive batch runs, at 4.2 seconds, to fill 2.64 gallon (10 liter) cans, with a target weight of 30.95 pounds (14.04 kilograms).

Food & beverage

The CFT50 finally does Coriolis flow measurement right with its patented, software-based system that prevents the erratic liquid/gas flow tube vibrations that cause measurement failures. It maintains a digitally precise process flow measurement while simultaneously re-tuning the drive of the Coriolis flow tube every half-cycle of the drive frequency. When traditional Coriolis meters encounter even small bubbles, or a start-from-empty condition, they would exhibit bursts of no measurement, or wildly wrong measurement, making accurate process measurement and control impossible, said Beaumont. However, the Foxboro CFT50 flowmeter has provided a significant improvement in flowmeter technology and has huge potential. Mount Packaging is looking forward to providing this

Foxboro CFT50 digital Coriolis mass flowmeter

technology in its in-line filling machines for all of its customers. The Foxboro CFT50 digital Coriolis mass flowmeter enables Mount Packaging to measure from liquid to gas and back to liquid without slippage or stoppage. The company also can achieve accurate measurements with the flow tube starting from empty which is sometimes necessary in certain filling processes. The Foxboro CFT50 flowmeter responds up to 10 times faster than conventional Coriolis flowmeters, which is particularly vital for batch measurement to reduce startup time while increasing production throughput and profitability.

This document was realized thanks to the support of: Mount Packaging Systems Ltd. 31

INDUSTRY: FOOD & BEVERAGE

Winkler und Dnnebier Swarenmaschinen GmbH

www.w-u-d.com

By using ArchestrA System Platform, we could cut development cycle time for large visualization and data systems into half, while substantially improving standardization.
Bernd Plies, Electric and Automation Technology Manager

Setting standards in chocolate production: WDS adopts the innovative and flexible ArchestrA System Platform for plant monitoring
Goals Effective production visualization Design of complex visualization and data systems Use of standard templates Challenges Interfaces to a wide range of systems Open to suppliers of different systems Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware Historian Wonderware Industrial Computer Results 50% reduction of development time Substantial simplification of plant management Easy replacement of clients in case of failure

32

Food & Beverage

The company
Everyone knows the sweet temptations you can find today on the shelves of sweets and candies: seducing chocolate and delicious pralines, sweet fruit gums and fruity candies. But as you are dwelling on sweet dreams, have you ever wondered what kind of complex industry stands behind this sweet temptation? The market demands new creations, and new taste trends emerge at shorter and shorter intervals. Combined with constant pressure for cost optimization, this generates high expectations and requirements from confectionery producers and equipment manufacturers. These are the challenges faced by Winkler und Dnnebier Swarenmaschinen GmbH (WDS), based in Rengsdorf, Germany, a company that, for several generations now, has been developing intelligent solutions for its high-performance manufacturing plants. WDS specializes in the development and construction of forming machines for the confectionery industry. Their product range includes equipment for the production of chocolate (bars or filled pralines), modular plants for the production of fruit gums, jelly, pectin and fondant candies, candy casting machines and extruders for high-viscosity mass processing, such as marzipan.

ArchestrA System Platform, Wonderware InTouch HMI Wonderware Historian, Wonderware Industrial Computer

Summary
To handle these challenges, WDS has adopted a high-performance visualization and management system. For many years, Wonderware InTouch HMI has been used to equip countless single or multiple visualization systems workstations. Today, WDS relies on its ArchestrA System Platform based solution for all product monitoring and visualization operations. The benefits of this upgrade include much shorter development cycle time, as a result of the introduction of an object-oriented development environment. In addition, this system enables WDS to design, commission and efficiently maintain even more complex visualization and data systems. With this solution, several renowned customers in the confectionery industry all around the world have already benefited from WDS easy and intuitive visual machine operation systems based on Wonderware InTouch and ArchestrA System Platform.

Open, object-oriented approach

But why has WDS decided to upgrade from the visualization software Wonderware InTouch to ArchestrA System Platform? As a rule, WDS develops special machines, and no machine is identical to a previous model. For this reason, WDS has adopted a production strategy based on variants and modularity, using standardized templates both

Requirements
Constant development and increasingly tighter interaction between automation systems, IT environment and manufacturing area have resulted into complex and high-performance methods and technologies to help companies approach the market dynamically and deploy effective and flexible production strategies. So, for instance, continuous data flow between physical plant components - such as a motor or a valve - and higher-level management systems, i.e. the equipment control level, has already become a standard. Furthermore, there are increasing demands for the plant level to be able to exchange data with the production control level, i.e. ERP and quality management systems. This is instrumental for the flexible and efficient management of production orders and the optimal exploitation of equipment production capacity.

33

Food & Beverage

ArchestrA System Platform, Wonderware InTouch HMI Wonderware Historian, Wonderware Industrial Computer

in hardware design and in software development. Stepping up from the traditional Wonderware InTouch solution to a modular platform approach, the company has obtained a 50% reduction of development time in the design of visualization, HMI and data management systems. This is where the advantages of ArchestrA System Platform emerges: the modular concept. Object templates are produced, used and stored, as if they were placed in a toolbox. Once developed and tested, these object templates are then constantly updated. An object is taken from a template, graphically incorporated into the visualization at the corresponding station, and declared to the PLC by its name and address. Any sensor, any piece of equipment or any other data element with all its properties is stored as an object. Finally, the new instance of the object is addressed to the corresponding application location within the tree structure, so that it can be used directly, provided the object is available through the data link both in the PLC and physically. This approach is particularly effective when you leverage one of the key features of ArchestrA System Platform: the layout of a model structure. The structure is self explanatory and, through a tree layout, leads come from the complete plant or line to each station and then to the corresponding sensor, actuator or other data object. Furthermore, ArchestrA System Platform provides all necessary interfaces and functionalities for an enterprise-wide data management system, and consequently, it can be easily integrated into higherlevel system environments and process control systems.

WDS uses this solution for all multi-user HMI (Human Machine Interface) systems, built into a Terminal Services Architecture. In this configuration, the Terminal Services clients operate within a connection session to the fully protected server. In this case, the development environment runs from a central location and modifications can be distributed quickly and easily to all stations simultaneously. This solution was also used as foundation for a forming plant (or chocolate shell moulding plant) manufactured for company Brandt ZwiebackSchokoladen. The plant was designed for the flexible production of solid chocolate. With a length of approximately 80 meters, this is one of the biggest praline plants supplied by WDS. It is equipped with 100 servo drives that ensure the smooth shell transport and high-precision positioning and dosing processes. This plant is comprised of three casting stations, each equipped with a panel (Wonderware Touch Panel for Windows CE). Through this panel, the entire plant can be monitored and controlled. However, the central node is located on a server in the switch cabinet. Panel and server communicate via Ethernet, whereby the server retrieves data from the central PLC (Siemens S7-400). The motion control connection to controls and drives (Bosch Rexroth) is also Ethernet-based. The huge quantity of process information, such as data coming from the integrated scales that weigh the shells at each processing stage (empty weight, shell weight, filling weight, final weight), is handled, stored and forwarded by ArchestrA System Platform. The Wonderware solution also includes efficient recipe management. In case of production changeover, it is childs play to reconfigure the system. When a recipe is loaded, the entire plant

34

Food & Beverage

is adjusted accordingly as relates to temperature values, motor rotation speeds, cycle times and limit values. In less than a minute, the plant operator gets the plant fully parameterized for a new selected product.

ArchestrA System Platform, Wonderware InTouch HMI Wonderware Historian, Wonderware Industrial Computer

Always up to date
Through a VPN (Virtual Private Network) connection, WDS can constantly monitor and maintain the plant. Of course, the Web interface can also be used by the customer himself, who can peep into the production plant from external working places to check status notifications and production statistics.

WDS relies on modern technology for product optimization

Brandt-Schokoladen has also implemented an RFID (Radio Frequency Identification) product monitoring system. Each chocolate shell is provided with a tag for correct identification at each reading station. So, for instance, the shell weights are tracked based on the shell codes and analyzed for plausibility and limit values. The shells whose weight is out of tolerance are marked and discarded. Collected data can be used for statistic and process optimization purposes. This process is partially reproduced in the visualization and can be constantly monitored.

Unlimited possibilities
This system based on Wonderware software offers many more capabilities and features. The expandability and flexibility of System Platform represent a milestone for large plants typical of the confectionery industry. WDS relies on this software and additionally develops new approaches in order to add even more color and taste to the production world of sweets and candies.

This document was created in collaboration with: Winkler und Dnnebier Swarenmaschinen GmbH

35

INDUSTRY: FOOD & BEVERAGE

Imana Foods Ltd

www. imana.co.za

Imana Foods would not have achieved HACCP accreditation without this solution in place.
Paul Alcock, MD, Imana Foods

Imana Foods get HACCP accreditation with help from Wonderware

Goals Full traceability of all materials entering and leaving the Savoury Powders blending process Visibility into the blending process Production data to be linked in to the companys ERP system Gain HACCP certification Improve the quality of finished goods Reduce inventory discrepancies Challenges Tracking of all incoming raw materials used in more than 150 recipes Solutions and Products ArchestrA System Platform Wonderware Historian Wonderware MES Wonderware InTouch Results HACCP certification achieved within three months of going live Better insight into the blending operation in the factory Improved raw material stock control Real-time blend closure in the ERP system Factory procedural deviations are highlighted More consistent product quality from following recipes exactly Improved management of the physical blending process Proper temperature control of sensitive blends

36

Food & Beverage

Imana Foods is a member of the Kwaden Investments group and is supported in systems development by a sister company, IT Dynamics, which was tasked with providing a systems solution for product traceability.

ArchestrA System Platform, Wonderware Historian Wonderware MES, Wonderware InTouch

would still be responsible for the queuing and prioritising of work orders. All incoming raw materials needed to be lotmanaged and scanned into their storage locations. They would then be tracked into the blenders. This would need to be done for all materials used in the more than 150 recipes in Imana Foods range of products. Bags of work in progress from the blenders needed to be individually weighed and tagged with bar-coded labels for tracking through to the packing lines. Full traceability would then be achieved by ink jet coding the packed product. One of the most important requirements of the system was that it must guide operators what to do when, so that printed instructions would no longer be necessary. The SCADA system would verify all transactions and would be the source of daily shift reports, says Irvine.

Background
Prior to this project, team leaders had no clear visibility of the blending operations. Blenders worked from instructions printed manually from the ERP system, says Murray Irvine, Project Engineer at IT Dynamics. This meant that the work schedules depended on the reliability of a printer and the recipe integrity on the reliability of the operator. On the ingredient side, while every effort was made to stick to a first-in-firstout transfer of raw material, this was not always guaranteed and stock discrepancies were identified at the end of every month. There was no real traceability.

Project goals
For the Imana Foods leadership team, faced with an expanding marketplace demanding increased food safety focus, there was a need to review its production operations. This led to the launching of a blender project with the following goals: 1 Full traceability of all materials entering and leaving the Savoury Powders blending process 2 Visibility into the blending process 3 Production data (from Wonderware) to be linked in to the companys ERP system for the automation of real-time work order administration 4 Gain HACCP certification 5 Improve the quality of finished goods 6 Reduce inventory discrepancies The scope of the project was to include SCADA, MES and enterprise integration initiatives that would place Imana Foods in control of their existing production and ready to meet future business and operational challenges.

Solution selection
A small InTouch application was already in use, monitoring PLCs in the factory, says Irvine, that was not however the deciding factor for solution selection. For Wonderware, the availability of the MES is core to the solution. The decision was made to go with Wonderware and the purchase of all the other Wonderware solutions necessary to this project (System Platform, Historian Client, Historian and Information Server). Paul Alcock, Imana Foods MD also believed that Wonderwares technology was a very good match for the companys future goals. Wonderware MES enables users to record production events into a standard database and

Solution requirements
To achieve the expressed goals, Imana Foods would rely on a scalable system design where there was to be minimal data duplication between the ERP and production systems. The ERP system

Figure 1: Mobile computer and printer from Intermec

37

Food & Beverage

to know the exact process conditions at a certain step. Users can also report forward and backward genealogy of materials, equipment and production events. The Sequencer Object coordinates tasks that must be executed in a certain sequence or order of operation. It is designed to configure, execute and manipulate a sequence of operations associated with attributes from multiple application objects running within an Industrial Application. The Sequencer object exposes a comprehensive set of attributes that allows users to create SmartSymbols and regular InTouch animations to monitor and control the Sequencer operation. PEM, FMM and Sequencer are now all part of Wonderwares Equipment Operations Module Mobile computers for use by the operators and mobile label printers were both sourced from Intermec due to good service levels, pricing as well as being the only supplier that could support both narrowband and broadband. On the technology front, Imana Foods chose barcodes over an RFID solution. This decision was based on price and the fact that RFID as a technology is not yet mature enough to give an easy, viable solution. For wireless networking with the mobile computers and printers, broadband was chosen because narrowband could not cope with the InTouch-based operator interface even though graphics and complex displays were eliminated.

ArchestrA System Platform, Wonderware Historian Wonderware MES, Wonderware InTouch

Implementation
Because of the scope of the project, many disciplines and skills would be required including a project manager, engineers, business analysts, software developers, network engineers, instrumentation technicians, network administrators and technical support personnel. Figure 2 shows the system topology. The MPI network was expanded to include the blenders, resulting in 22 PLC nodes being connected to the Wonderware system. The blending area was set up for a wireless infrastructure with handheld PCs and wireless label printers. The handheld PCs are running a managed InTouch application through Microsoft Terminal Services which resides on the Application Object Server. The office computers are connected via the Wonderware Information Server portal to allow viewing of custom reports. The system is fully integrated with the companys ERP system which passes the recipe information to the Formula Manager which is queried for each ingredient on a bag-by-bag basis in order to load the blender. The objects store acknowledged data from the operators and provide the traceability for lot-tracked raw materials as well as for finished goods. The Sequencer object is used to sequence the blend process. The ERP system is sent the resultant blending process information in order to close the loop and monitor stock levels and any accounting variance anomalies. In addition, custom reports calculate equipment utilisation from time data captured in the Wonderware production database. The most important item of information supplied by the system is the raw material lot tracking data as fed into the blenders, says Irvine. This is giving Imana Foods a far greater level of control than previously. On the handheld units (figure 3), the blender operators are shown the recipe details as well as an ingredient by ingredient breakdown

Figure 2: System topology

38

Food & Beverage

ArchestrA System Platform, Wonderware Historian Wonderware MES, Wonderware InTouch

Benefits
HACCP certification was achieved within three months of going live Better insight into the blending operation in the factory from a material usage variance point of view Improved raw material stock control Real-time blend closure in the ERP system Factory procedural deviations are highlighted More consistent product quality from following recipes exactly Improved management of the physical blending process Proper temperature control of sensitive blends

Figure 3: Examples of handheld unit displays

of what they have to scan or acknowledge as having been fed into the blender. The blender is on load cells which register its weight increase as it is loaded. There are built-in timers that capture the total blend time as well as any additional mixing times that may be required. When being unloaded, platform scales underneath the blenders register the weight of the offloaded bag and this data is captured by the objects.

Conclusion
Imana Foods has achieved all its initial project goals and has ambitious plans for expanding and extending the capabilities of the system. This was made possible through the use of a flexible platform in the hands of a very capable project team which amply demonstrated that technology is no longer a barrier to achieving business and operational objectives.

This document was realised thanks to the support of Paul Alcock, MD of Imana Foods and Murray Irvine, Project Engineer at sister company IT Dynamics who did the implementation 39

INDUSTRY: FOOD & BEVERAGE

The South African Breweries Limited

www.sablimited.co.za

After the testing and development phase, we were able to roll out the project to the rest of the sites and commission within 2 months! This is a reflection on the power of the underlying ArchestrA technology. Then theres the matter of cost. The time saved with the project roll-out had a direct impact on the cost and we were able to finish within budget.
Hein du Toit, Business Analyst, SAB Ltd.

The South African Breweries Limited manage the big picture with help from Wonderware Intelligence
Goals Provide a centralised system for the early detection and warning of mission-critical problems Implement a centralised data repository for analysis purposes Identify key KPIs for PLCs, Wonderware Historian, System Platform and MES hardware and software systems for all seven beer manufacturing regions Present the information in dashboard format so that it could be easily read, interpreted and viewed from a divisional level at head office. Challenges Collating data from a wide and disparate number of sources from seven breweries nation-wide. Current historian performance to remain unaffected Solutions and Products Wonderware Intelligence ArchestrA System Platform Wonderware Historian Results Risk reduction. Early detection of issues that impact system performance. Cross platform comparison and analysis facilitates decision making. Cross-regional analysis highlights trends and areas to focus on for development or support.

40

Food & Beverage

The South African Breweries Limited (SAB) is a vast, geographically-distributed network of breweries involved with complex production processes that have to satisfy the demands of millions of discerning customers in real-time. While this may sound challenging enough for the management of a single brewery, coordinating the efforts of seven manufacturing regions so as to provide an in-depth, unified and comprehensive view of KPIs was best done with help from an application known as Enterprise Manufacturing Intelligence or EMI.

Wonderware Intelligence, ArchestrA System Platform Wonderware Historian

Solution selection
We selected Wonderware Intelligence because not only would it provide the functionality we were looking for but it would also fit into SABs strategic architecture and alignment with our standardising on the Wonderware Application Server (System Platform), says Hein du Toit, Business Analyst at SAB Limited. Buying into suite-based products gives long term value and it also gave us seamless access to time-based Wonderware Historian production data. It also allowed us to plug into MS SQL databases for MES and other applications. One of the main functions of any EMI application such as Wonderware Intelligence is to collate data from a wide and often disparate number of sources and to provide data warehousing, data aggregation as well as roll-up and drill-down functionality. But this information is less than helpful if it cant be displayed in a format that is easy to define and understand. Wonderware Intelligence provides user-friendly, drag-and-drop dashboarding functionality, says du Toit. Once you have explored the Dashboarding tool, Tableau Server, it really does make creating dashboards easy. It is an extremely powerful tool. Since its an SAB rule that all system integrator work done on the System Platform be performed by ArchestrA-Certified SIs, SAB chose system integrator Advansys for the implementation. The company has a good knowledge of the Food and Beverage industry in general and the brewing industry in particular. Advansys specific advantage is knowledge of not only the beer making process but also the manufacturing system architecture that we use such as our eQMS, which is our quality/MES system, says du Toit. In addition, if any custom development had to be done, the expert use of the ArchestrA Application

Introduction
Before this project, there were limited facilities to proactively monitor critical systems in SABs beer manufacturing systems department and this led to the requirement for the implementation of a centralised monitoring system that would detect and warn about mission-critical manufacturing systems within SAB that were in difficulty with respect to meeting their KPIs. Although distributed in nature, manufacturing enterprises such as SAB still need to operate as unified entities with respect to meeting their business objectives and it is in this regard that the company looked for a solution that would provide a collated picture of its production facilities and that made the best use of its existing information assets while providing the least change to operators and users.

Project objectives
Project Dash (short for the dashboard view it was to provide into the individual and collated production facilities of SAB) was started and it had to plug some important information holes by: Providing a centralised system for the early detection and warning of mission-critical problems Implementing a centralised data repository for analysis purposes Identifying key KPIs for PLCs, Wonderware Historian, System Platform and MES hardware and software systems for all seven beer manufacturing regions Presenting the information in dashboard format so that it could be easily read, interpreted and viewed from a divisional level at head office.

Figure 1: Required regional system architecture

41

Food & Beverage

Wonderware Intelligence, ArchestrA System Platform Wonderware Historian

configuration, says Advansys Director Graeme Welton. The main reasons for this were that SAB didnt want another system to maintain and ArchestrA is already the standard system control platform at all the breweries. Systems engineers are familiar with its IDE and the System Platform provides builtin change propagation and object derivation, a deployment installation model as well as an integral security model. In other words, everything was in place to allow Advansys to focus on the Intelligence application and not spend engineering time on fundamentals. This phase of project Dash focused on collecting and collating diagnostic data with respect to system performance, traffic volumes, CPU usage, scan times, memory usage, message status (MSMQ), I/O Server

Figure 2: Required national system architecture

Object Toolkit was important. This gives the ability for any custom development to conform with SABs architecture and standards while making it easy for the engineers at regional level to understand and maintain the system. Lastly, Wonderware Intelligence is a Business Intelligence tool and Advansys knowledge of data warehousing was important to understand and implement the project on a tight timeline, concludes du Toit.

Implementation
Starting at the regional level, we wanted to make use of the existing infrastructure at the regions and did not want to introduce anything that would affect the performance of the historians, application object servers or even the PLCs, says du Toit. The project team drew up the required regional system architecture shown in figure 1 which collates KPIs from the PLCs as well as the Historians and MES servers for storage in the regional data warehouse from which it can be extracted and viewed in dashboard form according to the needs of users. This regional architecture was replicated seven times for each of the regions and connected to the central data warehouse at head office as shown in figure 2 where the dashboard views not only represent an aggregated picture but also allow drilling down to the views of each region independently. SAB stipulated that we make use of the existing ArchestrA System Platform install-base, providing centralised change management, change propagation and its user-friendly Integrated Development Environment (IDE) for all data retrieval
42

Figure 3: Final regional architecture

item counts (total, active, etc.), disc space availability, unprocessed SQL messages and many more. This would include everything from the PLC, Server Platform, the process and the ArchestrA engine to the I/O Server, the file system, Microsoft Message Queue and any SQL database (MES). Because of the nature of this data, most of which comes from operating system diagnostics, as well as SABs requirement to use ArchestrA, we decided to use the ArchestrA Object Toolkit which gave us full use of the ArchestrA Object Framework and access to low-level C#.Net coding, says Welton. This approach also allowed us to use standard, out-ofthe-box alarm and history primitives and compile editors for easy configuration. This all meant that no scripting was required for engineers to configure the data retrieval objects.

Food & Beverage

Wonderware Intelligence, ArchestrA System Platform Wonderware Historian

Benefits
I feel I should comment on three important aspects of the project, says du Toit. First of all, time; after the testing and development phase, we were able to roll out the project to the rest of the sites and commission within 2 months! This is a reflection on the power of the underlying ArchestrA technology. Then theres the matter of cost. The time saved with the project roll-out had a direct impact on the cost and we were able to finish within budget. The third point is the exceptional quality of the work delivered by Advansys. One immediate benefit was risk reduction. With an immediate view of the status of each system, engineers were able to detect issues that impact performance of the various systems under scrutiny. Cross platform comparison and analysis makes decision making easy when deciding on deployment of areas. Cross-regional analysis shows trends and areas to focus on for development or where support should be given.

Figure 4: Final national architecture showing the addition of another instance of Wonderware Intelligence at head office and an identical structure to that found at the regional level.

Welton believes that the dashboard development tool is much more than it appears at first and that Wonderware have produced a solution whereby almost anyone with some basic training can collect and collate information from virtually any combination of sources to suit their needs. This is rather different to traditional Business Intelligence tools that require large IT teams to support and develop.

Conclusion
At the moment, we are only using a tiny fraction of the power of Wonderware Intelligence, says du Toit. The next step is Manufacturing Intelligence at every level of production and we have no doubt that the products ability to connect easily to different data sources and reporting flexibility will be of real value in the real-time production arena. With Wonderware Intelligence, the islands of information of a decade ago have vanished and companies can become the unified entities they were always meant to be.

Figure 5: Drill-down status determination of the status of the Application Object, eQMS, Galaxy Repository and Historian servers at all breweries

This document was realized thanks to the support of: The South African Breweries Limited

43

INDUSTRY: FOOD & BEVERAGE

New Belgium Brewing Company

www.newbelgium.com

One of New Belgium Brewings core values is to honor nature at every turn. The health of our community and of our business depends upon the health of the natural environment.
Jennifer V. Orgolini Director of Sustainability and Strategic Development

New Belgium Brews Up Sustainable Manufacturing

Goals Minimize impact on the environment by transitioning from fossil fuel-based sources to total renewable energy options New Belgium Brewing has set an ambitious objective to reduce its wastewater impact by increasing its waste diversion rate (sans spent grain and sludge) from 73% in 2007 to 95% by 2015 By 2015, the company plans to decrease the water use per barrel of beer produced by 10% and curtail greenhouse gas emissions by 25% Challenges With the reduction in energy usage and materials consumption, New Belgium Brewing was concerned about maintaining high manufacturing standards In order to meet stringent environmental and sustainability goals, the company had to ensure that it would continue to produce the high quality products expected by its loyal customers Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware Historian Wonderware ActiveFactory Results The Invensys solution helped in the efficient and sustainable production of more than 600,000 barrels (18 million gallons) of beer annually The methane rich biogas byproduct from the wastewater plant is now captured and converted into electricity, producing 15% of New Belgiums operating power requirements The solar photovoltaic panels installed on the roof of the bottling plant are able to produce up to 200 KW New Belgium Brewing is the first US. brewery to acquire 100% of its purchased operating electricity from wind power

44

Food & Beverage

Fort Collins, Colorado New Belgium Brewing
Company, based in Fort Collins, Colorado, produces millions of gallons of beer annually to appreciative customers across the nation. It started with a bucolic bicycle trip through Belgium and an amber ale called Fat Tire, and now is a major microbrewery with devoted legions of beer aficionados. Along with its emphasis on brewing world-class beer, New Belgium Brewing also understands the importance of a sustainable relationship with the environment and has invested in environmental stewardship from its first days of operation. New Belgium Brewing strives to maintain an environmentally, socially and economically conscious business. As winner of the Environment and Safety Excellence Award from Invensys Operations Management, the company has proven to be a stellar example of sustainable manufacturing. One of New Belgium Brewings core values is to honor nature at every turn, said Jennifer V. Orgolini, Director of Sustainability and Strategic Development at New Belgium Brewing. The health of our community and our business depends upon the health of the natural environment. New Belgium Brewing is the third largest craft brewery in the U.S., producing more than 600,000 barrels (18 million gallons) of beer annually. Regardless of its size, New Belgium Brewing still managed to be the first U.S. brewery to obtain all of its purchased electricity through wind power. Additionally, New Belgium Brewing has increased its recycled paperboard usage from 44 to 88 percent. It is a recognized leader in sustainable manufacturing practices, and continues to balance business objectives with efforts to reduce waste and minimize its impact on the environment. New Belgium Brewings notable environmental accomplishments have been achieved with the help of solutions from Invensys Operations Management. The brewerys manufacturing intelligence system uses Wonderware software to provide extensive track and trace capabilities in order to adhere to New Belgiums conservation and performance goals. The level of monitoring is at the very highest levels of plant vigilance. For example, the Invensys technology enables the brewery to track any bottle or tank of beer back to all of its ingredients and processes within 30 minutes.

ArchestrA System Platform, Wonderware InTouch HMI Wonderware Historian, Wonderware ActiveFactory

ArchestrA System Platform serves as the foundation for managing the complex network of product production and energy management systems. Wonderware InTouch provides an intuitive graphical interface to help managers run overall plant operations, InBatch manages batching operations and Wonderware Historian is the brewerys archive of real-time and historical production data. The Production Events Module enables the recording of production events that help New Belgium Brewing understand product and production history. It captures and distributes information related to the genealogy of materials, equipment usage, events and which personnel were utilized during production activities.

Sustainable Technology Goes Down Smooth

Every project that we design, we think of the environment first, said Igor Valuyev, Chief Electrical and Automations Engineer. Brewery operations can be very material and energy consuming, so we try to design our equipment around not just our processes and our beer production, but, also, our energy consumption. Thats where Wonderware was able to offer the additional benefit of managing operations and helping us achieve high levels of sustainability. New Belgium Brewing strives to act as a role model at every opportunity. It strives to serve as an industry influencer, encouraging a shift toward sustainable technologies with other businesses throughout the community. Within the company, managers refer to the energy policy as alternatively empowered. Alternatively empowered means making business decisions based on minimizing environmental impact, encouraging the growth of its employee owners and being a socially responsible contributor to the community.

45

Food & Beverage

Alternatively empowered encompasses everything we do here at the brewery, said Orgolini. That makes us different and gives us the energy for our success. Invensys has had a long-time commitment to sustainability so it has been a great asset in our business mission to minimize our footprint on the environment. With the help of Wonderware West, an Invensys partner and system integrator, New Belgium Brewing has used Invensys solutions to make its environmental and sustainability projects succeed. New Belgium Brewing has directly implemented three technologies to reduce waste and maintain a sustainable business. At its on-site process water treatment plant, the brewery uses microbes to clean all of its production wastewater. The water treatment results in a methane-rich biogas. The excess methane is then captured and converted into electricity. This engine produces up to 15 percent of New Belgium Brewings electricity needs, turning a waste stream into a power source. Wonderware InTouch HMI plays a key role in visualizing, optimizing and controlling the entire wastewater treatment process so that New Belgium Brewing can manage its biogas production and leverage the energy power return on its water treatment process. Wonderware ActiveFactory software is deployed throughout New Belgium Brewings operations so that managers can analyze and optimize all energy usage. ActiveFactory monitors every detail, from room temperatures to facility usage to cleaning requirements. Even the accountants use ActiveFactory to monitor batch data and product alcohol content to meet government reporting and taxation requirements. New Belgium Brewing has also employed photovoltaic technology to produce electricity from the sun. Panels have been placed on the roof of New Belgiums packaging hall. These solar photovoltaic panels are able to produce up to 200 KW. With the Invensys technology, the company is able to monitor total production of kilowatt hours generated on a real-time basis as well as track historical power production records to optimize operations based on seasonal solar energy patterns. The historical records also are key to helping the company determine exact solar panel upgrade requirements for business growth resulting in higher electrical demand.

ArchestrA System Platform, Wonderware InTouch HMI Wonderware Historian, Wonderware ActiveFactory

Finally, New Belgium Brewing was among the first to harness the power of the wind. In 1999, the company started purchasing power from a neighboring wind farm in Wyoming, significantly increasing its sourcing of renewable energy. All three of these efforts to maintain a sustainable business have effectively worked to reduce waste and protect natural resources. The Wonderware software plays an integral role in New Belgium Brewings energy conservation efforts, from monitoring power production to tuning operations to maximize its renewable energy sources. Steam, water and electricity consumption is tracked continuously through the brewery and every effort is made to minimize energy demands. For example, the Invensys solutions control the entire lighting system for the brewery operation, with sensors that can dim or turn off lights in areas where no workers are present.

A Smart Approach to Energy Management

With high energy costs, the energy component of production cost is critical to any business. New Belgium Brewing has recently incorporated the Smart Grid to manage its technologies and equipment. This allows for load shedding, or intentionally engineered electrical power outages, when the strain on the municipal power grid is too high, while also maintaining a two-way communication with the local power company. In the future, most facilities will be nodes on an intelligent energy supply chain network and managing the cost of energy will produce a competitive advantage over plants unable to leverage the opportunities offered by demand response, self generation, dispatchable distributed generation and real-time market pricing for energy.

46

Food & Beverage

The Smart Grid delivers tangible benefits to both the brewery and the community. Wonderware software, which is optimized for energy management, was finely tuned by Wonderware West to help New Belgium Brewing maximize its Smart Grid initiatives. The Smart Grid provides the internal metering that lets us know how much energy we are using throughout the process, said Orgolini. The Wonderware software helps us communicate with our local utility to inform them immediately what we are using and communicate with us when we need to shed load. Using the Smart Grid gives New Belgium the strength to grow its business and improve the welfare of its employees while helping to protect the environment in a cost efficient manner. With the help of Invensys, New Belgium Brewing protects the environment while maintaining a safe and sustainable business. The journey toward sustainable operations is never ending. New Belgium Brewing is continuing to improve its carbon footprint and hopes to reduce greenhouse emissions by 25 percent by the year 2015.

ArchestrA System Platform, Wonderware InTouch HMI Wonderware Historian, Wonderware ActiveFactory

Every Wonderware system is what our operators pretty much use. Thats where our data is being extracted from, so it kind of unites all of the systems together. We unify our plant information through Wonderware, said Valuyev. Weve been utilizing InTouch for 10 years plus for extended period of time. Were pretty happy with this system. What started with a pastoral bike trip through the fertile valleys, sandy plains and thickly forested hills and plateaus of the Ardennes has become a major employee-owned microbrewery with a dedication to protecting the worlds natural resources. Focusing on sustainability and the environment gives New Belgium Brewing the strength to grow its business, improve the welfare of its workers and help protect Mother Earth, with a little help from Invensys.

This document was realized thanks to the support of: New Belgium Brewing Company

47

INDUSTRY: FOOD & BEVERAGE

United Dairy
www.uniteddairy.com

The Invensys custody transfer solution proved to be just what we needed. We now have reliable, indisputable measurement of the milk we are receiving, which has resulted in substantial savings. And the system has paid for itself within 60 days.
Tom McCombs Director of Milk Procurement

Leading National Dairy Implements Low-Cost, Highly Accurate Custody Transfer Solution from Invensys
Goals A measurement solution that would comply with stringent federal standards in operations ranging from procuring raw resources to delivering the final product Implement a solution that would lower initial capital costs, be inexpensive to maintain and provide highly accurate measurement data Challenges The current industry solution of using scales for custody transfer has significant drawbacks including high initial capital costs, expensive maintenance and inaccurate reporting of data Effectively measure 15 to 20 truckloads of unprocessed milk daily that is between 24,000 and 54,000 pounds Accurate accountability of raw materials is critical to the business because of the variances in volumes from one truckload to the next Solutions and Products Foxboro CFT50 Digital Coriolis Mass Flowmeter Results Enhanced accuracy of truck unloading applications with a demonstrated accuracy of 0.2 percent Cost accountability during custody transfers has been greatly improved Maintenance costs have been reduced since the Foxboro CFT50 Digital Coriolis Mass Flowmeter has no moving parts in the stream, requiring little or no maintenance

48

Food & beverage

Martins Ferry, Ohio From the dairy farm to
the kitchen table, the distribution of milk and milk products have evolved tremendously. More than a hundred years ago, many Americans received their milk from Bessie, the cow out in a familys pasture. Today more than 100,000 commercial dairies operate in the United States and these dairies produce 80 percent of the nations milk. To keep up with the countrys demand for milk and milk by-products, dairies and dairy processing facilities must employ the latest technology to maintain efficient production and distribution processes. United Dairy was established nearly 50 years ago with a single plant and has grown to be one of the largest family owned dairies in America. With plants located in Martins Ferry, Ohio, Charleston, West Virginia and Uniontown, Pennsylvania, the company provides a full line of dairy products throughout the Northeast. Over the years, United Dairy has remained focused on consistently improving operations to provide customers with quality products. Dairy processors must comply with a host of stringent standards in operations ranging from procuring raw resources to delivering final product. However, historically, milk processing plants have had no standard for custody transfer systems. United Dairy has employed a custody transfer solution by applying advanced flow measurement technology to reduce costs and improve material accountability. The system, based on Invensys technology, provided an almost immediate return on the companys investment. Milk is the basis of our business, and like any other business, United Dairy needs accurate accountability of raw materials, said Tom McCombs, Director of Milk Procurement at United Dairy. This is particularly critical in our business because of the variances in volumes from one truckload to the next.

Foxboro CFT50 Digital Coriolis Mass Flowmeter

Conventional Custody Transfer Methods Unusable Invensys is Key Solution

United Dairy receives 15 to 20 trucks of unprocessed milk daily that is between 24,000 and 54,000 pounds. The company turns this raw product into a full line of dairy products ranging from skim milk to cottage cheese to ice cream. Custody transfer of raw products from milk suppliers is vital to United Dairy profitability. While a number of conventional custody transfer measurement methods have been tried through the years, all have significant drawbacks. Some of the larger dairy processors have used scales, however these measurement devices have a high initial capital cost, are expensive to maintain and have proven inaccurate. Coriolis meters have emerged as the instrument of choice for custody transfer in other industries, and are now being accepted for milk custody transfer applications. Coriolis mass flowmeters have no moving parts in the stream, and thus provide a lowmaintenance solution. But conventional Coriolis meters are not suitable for measuring two-phase fluid flow, a common condition when transferring milk. We continually look for ways to improve operations while maintaining our high quality standards, said McCombs. Given that the cost of raw materials has a direct impact on our profitability, we needed a custody transfer measurement system that establishes a recognized standard for accuracy and reliability, and is easy and inexpensive to use.

49

Food & beverage

Invensys Digital Coriolis Mass Flowmeter Key to Controlling Costs
United Dairy chose to implement the Invensys custody transfer solution which requires little or no maintenance and is certified internationally for accurate fiscal metering of milk. The Invensys Digital Coriolis Mass Flowmeter was first installed at United Dairys Charleston, West Virginia facility and the accuracy requirements were 0.2 percent. In addition to surpassing the reliability and accuracy requirement, with a demonstrated accuracy of 0.2 percent at the well site, the Invensys custody transfer solution includes seal out hardware enabling a local inspector to verify and protect the flowmeter from tampering after the certification procedure is complete. Having proven itself in United Dairys Charleston facility, the Invensys custody transfer system was subsequently installed at the companys headquarters facility in Martins Ferry, Ohio. This implementation achieved equal success. The heart of the Invensys custody transfer solution is the Foxboro CFT50 Coriolis transmitter, which employs patented digital technology that compensates for variations in the amount of gas or liquid in a flow. Developed collaboratively by Invensys and Oxford University in the United Kingdom, the CFT50 transmitter provides accurate measurement from the beginning to the end of a custody transfer batch and has no moving parts to wear out or internal mechanisms to replace, and can operate up to a year without calibration. In addition, the Invensys Digital Coriolis Mass Flowmeter custody transfer solution includes a transfer indicator with a printer interface. The Foxboro CFT50 Coriolis transmitter sends pulses to the indicator to start the batch count. The custody transfer indicator then communicates with the printer to produce a ticket that accurately documents the total mass of milk transferred during the operation.

Foxboro CFT50 Digital Coriolis Mass Flowmeter

The Invensys custody transfer solution proved to be just what the dairy needed to improve operations and control costs, said McCombs. United Dairy now has reliable, indisputable measurement of the milk its receiving, which has resulted in substantial savings the system has paid for itself within 60 days. At United Dairy, the Invensys system has proven to be ideal for fast and accurate custody transfer of milk from tank trucks. A high volume of air from the bottom of the trucks accompanies the liquid, so miscalculations of actual product occur frequently. Because the Invensys solution provides a high-level of accuracy in calculating the amount of the actual product being transferred, United Dairy has gained additional revenue by avoiding overpayments due to the trapped air issue. United Dairy also is saving considerable maintenance costs previously spent on calibrating scales because the Invensys Coriolis Mass Flowmeter requires little or no maintenance. With the dairy industry evolving from the local farm to large cooperatives in just 100 years, the American publics demand for milk products has dramatically increased, with 99 percent of all U.S. households purchasing milk today. The average American consumes almost 25 gallons, or 400 glasses a year, and there are no signs that U.S. consumption of milk is declining. Thanks to the Invensys solution, United Dairy can maintain its pledge to provide customers with quality products by continually improving operations with innovative technology solutions.

This document was realized thanks to the support of: United Dairy 50

INDUSTRY: FOOD & BEVERAGE

Greene King
www.greeneking.co.uk

Wonderware delivers consistency, product uniformity and repeatability, assisting us in getting it right first time.
Roy Matchwick, Greene King Automation Engineering Manager, Greene King PLC

Maintaining Brewing Excellence at Greene King

Goals To make sure that within the Brewery, everything is consistent, stays under control and everything is executed at the right time. Challenges To be able to extend a standard SCADA solution to all parts of the brewery To enable automatic data gathering and improve plant production Solutions and Products Wonderware InTouch HMI Wonderware InTouch Compact Edition Wonderware Historian Results Single plant wide standard - all displays are now recognisably similar across the current systems, this allows operational staff to be deployed more flexibly across the business as they quickly feel familiar with the process interfaceHistorian is proving to provide reliable information in high fidelity, missing nothing that needs to be seen and working continuously as the plant runs, week in and week out.

51

Food and Beverage

For over two hundred years, the master brewers of Greene King have been brewing fine ales in the heart of Suffolk, in historic Bury St Edmunds, where they have been making beer since the time of the doomsday book. They use the countrys finest locally grown barley from the bread basket of England, malted just two miles from the brewery. Water is still drawn from the chalk aquifer beneath the brewery the same that Benjamin Greene and Frederick King used when they first started making beer 200 years ago. However Greene King has also to stay abreast of the times as they have many of todays business challenges that are faced by other manufacturers. They recently completely refurbished their brewing and ancillary control systems using Wonderware InTouch and Historian. It is crucial in modern brewery control that everything stays under control and everything is executed at the right time. To achieve this one requires reliable controllers and supervisory systems. Also the data within controllers can provide a rich source of manufacturing information. At Greene King it was decided that a phased upgrade of controllers and supervisory systems was required. This was primarily because of an accruing business risk in their increasingly legacy systems combined with the need to make other improvements which would require more functionality. Modern manufacturing information and control is now usually undertaken on a modular, object-driven basis, thus the selection of an appropriate solution was critical as one has to live with the decisions that are taken at the outset.

Wonderware InTouch HMI, Wonderware InTouch Compact Edition, Wonderware Historian

Standardisation
It is standardisation which has underpinned the successful use of Wonderware technology at Greene King. All systems there use a mix of InTouch and PLC objects (the latter being as standard function blocks at the Omron PLC level). This involves standard faceplates for valve control, inverters, PID loops and pump control. Doing this delivers engineering savings and design standards which ease maintenance and use when troubleshooting. However, the broader business benefit is that all displays are now recognisably similar across the current 12 and later to be 17 InTouch systems, this allows operational staff to be deployed more flexibly across the business as they quickly feel familiar with the process interface. Furthermore, the standardisation of objects allows Greene Kings engineering department to specify work undertaken by external integrators to be better detailed and to meet with their requirements exactly. Roy Matchwick, Greene King Automation Engineering Manager, Standard Wonderware objects and PLC function blocks allows the SI to have a detailed set of tools to undertake work; projects are undertaken faster and meet with the detail of the Greene King specification.

Reliability
System reliability is vital for effective production and for achieving on time delivery in full. The new system obtains its tag information from a dual redundant tag server; this uses the latest Wonderware InTouch functionality to provide ease of setting this up and, more importantly, bump-less swap over should a problem occur. The whole benefit of which is fundamental to the metrics of OEE and Schedule Adherence, measured by the principle KPI of on

A Plant-Wide Solution
Greene Kings engineering department selected Wonderware technology as its new standard. There were many reasons for this, such as its large installed base and significant functional benefits; however, it was its object oriented approach that made the difference by delivering sustainable engineering and operational advantages that benefit Greene Kings business. InTouch is now in use throughout the brewing, fermentation and bottling operations and will in the next phase be deployed in the kegging and casking operations. As is often the case not all the requirements in the kegging and casking operations require complex functionality and here InTouch Compact Edition will be used which runs on low cost CE panels, alongside the full InTouch stations. This allows the site standard to be deployed cost effectively across the whole operation, regardless of complexity.
52

Greene King Brewhouse

Food and Beverage

time delivery in full, these activities are undertaken at Greene King on a basis of Continuous Improvement. This is a multistranded approach which involves the use of Wonderware Historian data from the plant being used to produce highly detailed trend displays to determine what happened, how can we improve information through scripted reports. Historian is proving to provide reliable information in high fidelity, missing nothing that needs to be seen and working continuously as the plant runs, week in and week out.

Wonderware InTouch HMI, Wonderware InTouch Compact Edition, Wonderware Historian

Integration
Greene King utilises advanced scheduling software in its planning process, it is Brewhouse Copper Mimic now working on the integration of this directly with production using the data Environment within Wonderware Historian. Initially this will be done with scripting to demonstrate a proof Greene King abstracts water from a chalk aquifer of concept as was the case prior to installing beneath the brewery; abstraction is metered to Historian. This approach ensures that all involved comply with the Environmental agency license. parties can see planned extra functionality before Brewery effluent is typically alkaline, this is the allocation of budget and developing detailed neutralised initially with slightly acidic by-product requirements specifications. Initial requirements and, when needed, this is supplemented by the are for planning to be able to automatically take controlled addition of acid, carefully monitored by into account production realities and events and InTouch and a record maintained in Historian, to thereby make changes accordingly. Roy Matchwick, ensure that Greene Kings environmental credentials The integration of our systems will produce are always high. measurable and sustainable business benefits, Wonderware technology allows us to proceed with this confidently.

Summary

As Roy puts it, Wonderware delivers consistency, product uniformity and repeatability, assisting us in getting it right first time. However, it should not be assumed that the brewing process is now simply an automated process. At Greene King the Brewer can readily see what is happening by using various automation interfaces to all parts of the process, this allows the Brewer to ensure that all is well and that production is on target. It also ensures that the Brewer has time to constantly ensure that Greene King ales have the product uniformity and consistency that their customers expect, with a little help from Wonderware!

This document was realized thanks to the support of: Greene King

53

INDUSTRY: GRAPHIC ARTS

CRE-A Impresiones de Catalunya

www.grupogodo.com

Thanks to the full integration of production equipment, CRE-A now has useful, reliable and timely information available of its production process, which has facilitated the implementation of a work methodology based on the philosophy of lean manufacturing, one of the main challenges of the company.
Jos Ramrez, head of industrial computers at SICMA 21

CRE-A Imppresiones de Catalunya improves production on using Invensys Wonderware Technology

Goals To provide one of Europes most modern printing plants with a control architecture that is able to maximise plant efficiency. To integrate information from each of the production areas between each other and also link information from the presses with the companys ERP system. Challenges To ensure communication between the wide variety of existing plant machinery regardless of the communication protocols to be used. To achieve production excellence in a pioneering facility of its kind, which was already achieving extremely high levels of efficiency Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware Historian Software Results Total integration of information at both the production process level and with the companys business system. CRE-A is today implementing better production planning and more efficient production management.

54

Graphic Arts

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian Software

Barcelona, Spain. CRE-A Impresiones de

Catalunya is a Grupo Godo company and one of the major publishing holdings in Spain. It is responsible for printing, collating and distributing the newspapers published by the group: La Vanguardia, a reference general news daily in Catalonia and one of the most prestigious in Spain, Avui and El Mundo Deportivo, as well as other specific additional publications such as La Vanguardia Dossier or El Magazine. Inaugurated in 2007 with an investment of 120 million euros, the CRE-A printing plant in Barcelona is today a pioneering facility with an average monthly print run of 22 million copies. Divided into four production sections warehouse, printing, packaging and distribution the plant performs the entire cycle of its publishing production in a fully automated manner, converting it into one of Europes most modern printing plant of its kind.

the use of the machinerys capacity was sufficient, it could still be optimised further. The need was identified to correlate the information generated between the different sections warehouse, printing, packaging, distribution while ensuring the soundness of the data collected individually in each of these areas, explains Jos Ramrez, head of industrial computers at SICMA 21, the systems integrator responsible for the project. The plant had first-rate machinery, but there was as many islands of information as operational units. This lack of consolidated data meant that the facility had still not reached its full potential and level of production. In general terms, three major challenges were established at the beginning of the project: to integrate the different machinery of the production system into a single management system, to control

Advanced Control System for Pioneer Facility

The renewal of the Grupo Godo presses was from the outset seen as an opportunity to maintain leadership in the holdings offer of news and information. Therefore, the investment involved printing press machinery equipped with the latest technology to help publish the groups newspapers at quality and speed levels never before achieved by automating each of the tasks performed in the plant. With production already underway and motivated by a pursuit of excellence and continuous improvement, the companys management accepted the challenge of optimising the performance of its facilities. Therefore, through an internal audit in which overall equipment effectiveness (OEE) indicators were used to measure current production efficiency, it was found that while

plant information in real time (it was hitherto obtained with a slight delay that made in situ decision-making difficult) and to integrate data with the companys ERP system to provide reliable information for proper cost management. Our main objective, explains Oscar Mateu, technical director of CRE-A, was to obtain realtime information of our activity in order to establish appropriate operational indicators to help us with decision-making during the production process of the presses and other related activities. Wonderware softwares ability to communicate with the various existing latest generation machinery and the ease of deployment led to management opting for its technology to ensure a qualitative leap in terms of the efficiency sought by the printing plant.

Maximum Connection, Maximum Information

The complexity of each of the tasks performed in the printing plant obliged the team involved in the project to study the best option to begin
55

Graphic Arts
implementation. The decision was made to start with the packaging area, in which the printed material is packed for delivery, because it is where the least amount of information is handled, explains Jose Ramirez, adding that this first deployment represented a litmus test for the project because it would show if data collection could actually be improved and a new level of excellence achieved for operations at the plant. One of the main challenges faced was related to the diversity of communication protocols incorporated in the different machines that worked the different sections of the plant. As explained by the system integrator, Wonderware software adapted perfectly to the various existing units regardless of origin or the technological language used. Thanks to this ability to adapt, full connection was guaranteed between each of the units involved in the production process, thus helping to begin implementation with full guarantees. The dynamics through which the project was structured were similar for all sections of the plant. The first stage began with the mapping of data, involving an extensive analysis of the information collected thus far to confirm the soundness of the information. After this process, and once the main needs in the pilot packaging section of the project had been defined, the system was configured with the parameters that would provide a full picture of what was actually happening in the plant in real time. After a year and a half of work, during which the other production areas of the press replicated this development model, the last stage of each of these micro-projects involved the full connection of the data on two levels: first, between each of the sections in order to provide maximum continuity and efficiency to the processes of printing, packaging and distribution, and second, between the plant and the companys ERP system to ensure maximum consistency between production events and management decisions. This was how the technological architecture of the CRE-A plant was configured in a modular manner. Each area has a data server connected via Ethernet to the database of objects. Once the information is collected, the three types of existing clients responsible for installation area manager, technical director and operator can access it according to their privileges through InTouch to see real-time production behaviour. In addition, plant information is stored through Historian, allowing for in-depth analysis to help move closer every day to the model of production efficiency sought by the company.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian Software

Operational Excellence with Wonderware

Extensive analytical work by SICMA 21 prior to the deployment of Wonderware technology has helped to ensure to a large extent that the new control system will provide the expected results. CRE-A is today able to implement better production planning and, therefore, more efficient management of production costs, points out Jos Ramrez. The plant information that Wonderware helps us to collect and analyse has led to important business decisions, such as an optimal human resources policy, more efficient predictive maintenance of facilities and streamlining the document management process. The greatest overall benefit of the new technology architecture is determined by the integration of information at both the production process level and with the business system of the company. Wonderware allows us to make an objective assessment of production activity based on real information. As a result, it is now easier for the company to create process improvement teams aimed at fulfilling established indicators, explains Oscar Mateu. At a technological level for Jos Ramrez, the advantages of working with Wonderware derive mainly from its open architecture: It is now possible to have communication within a complex facility, where there are various types of machines with different technological features, managing to create a single language that tells us what is happening at each moment and why, sums up Ramrez. In terms of development, the possibilities of Wonderware to replicate objectives helped the deployment of control technology in each of the sections after the initial test made in packaging. The modular capabilities of the software have also opened new avenues for improvements in several areas that go beyond production. Following a very satisfactory evaluation of the improvement process by CRE-A, the prospects for the future are to implement Wonderware solutions on off-site issues. In order to meet an energy-efficient approach of its activity, CRE-A will in the near future embark on a modernisation process of the control system of the building housing the facility, and it also plans to launch a monitoring and system optimisation project for wastewater treatment to decrease the volume of waste generated at the plant by 80%.

This document was realized thanks to the support of: CRE-A and Wonderware Spain

56

INDUSTRY: HYDROCARBON PROCESSING

Gazprom dobycha Astrakhan, LLC

www.gazprom.com

In addition to improving the control and safety system, the solution achieved outstanding performance results in separated gas and condensate production.

Invensys helps Astrakhan Gas Processing Plant achieve Operational Excellence

Goals Improve safety and minimize environmental impact through modernization of control system. Increase productivity. Challenges The environment is hostile with the hydrogen sulfide content of the formation fluid up to 25% The manufacturing process is complex with pressures of more than 600 atmospheres and temperatures of up to 110 degrees Celsius. Solutions and Products Foxboro Distributed Control System - I/A Series Triconex Critical and Safety Systems Results Overall all improvement in the safety and control system of the plant In 2010 increase in separated gas and condensate production

57

Hydrocarbon Processing
Gazprom dobycha Astrakhan, LLC , Russia is
a subsidiary of Gazprom, one of the largest energy companies in the world. The Astrakhan gas and condensate field was launched on December 31, 1986 with the comissioning of the Astrakhan gas complex, a major sulfur producer in the former USSR. The main activities of the company involve the following: The exploration of hydrocarbon deposits Production of sour hydrocarbons, gas and condensate processing resulting in production of dry and liquefied gases, gasoline, diesel fuel, fuel oil as well as liquid, solid and prilled sulfur R&D, exploration and design work. Currently, Gazprom dobycha Astrakhan is the world leader in the production of sulfur, with an 81% share of all the sulfur produced in Russia and about 10% of the worlds total production. The entire plant is a complex that embraces 19 subdivisions within a unified process chain involving the Astrakhan gas processing plant. This involves oil, gas and gas condensate processing.

Foxboro Distributed Control System - I/A Series Triconex Critical and Safety Systems

The Foxboro I/A Series DCS and Triconex Tricon Safety System use of the state-of-art technologies and architectural solutions that meet the operational requirements of Gazprom dobycha Astrakhan. The goals of the automation and control system include: 1. Improve safety and meet its environmental goals by upgrading the control system and try to avoid erroneous operator actions during unit start-ups and shut downs. 2. Improve the working conditions of plant operations personnel by creating a central control room with easy display of plant information 3. Have the ability to edit the supervisory and control functions and improve display screens. 4. Increase in companys profit by increasing technical capability and making efficient use of use of raw materials, auxiliary facilities and energy. 5. Increase productivity by increasing the production of separated gas, condensate and sulfur. 6. Enabling remote monitoring while being able to control and manage the entire plant from a central control room. 7. Be able to solve production problems by analyzing historical information

Improved environmental safety and production efficiency

Astrakhan gas condensate field is unique in Russia. It has an extremely high content of hydrogen sulfide in the formation fluid (25%), it is very deep (4000 - 4100 m), it has high reservoir temperature (110 degrees Celsius) and pressure (more than 600 atmospheres). Due to the high complexity of technological processes during gas processing, the primary goal of the company is to improve environmental safety. The project required a phased reconstruction, modernization and expansion of the gas processing plant so that it meets the current and future European requirements. Because of these goals, the executive management decided to modernize the control system by replacing the legacy system into a modern, high-speed, microprocessor-based system.

The Characteristics of the process

The control of the Astrakhan GPP plant is characterized by a variety of a complex and continuous batching process that involves control of gas, condensate and mined products. It also involves the storage, preparation, processing, shipping and transportation of critical products that are highly explosive and are potential fire and gas hazards. A number of processes take place at high pressures (over 600 atmospheres) and at high temperatures

Choosing the right solution and partner

The automation and process control system modernization was entrusted to the Russia office of Invensys Operations Management because of its experience in completing similar projects.

58

Hydrocarbon Processing

Foxboro Distributed Control System - I/A Series Triconex Critical and Safety Systems

The Invensys solutions at Gazprom dobycha Astrakhan

Invensys installed a control system that includes a Foxboro I/A Distributed Control Systems (DCS) and a Triconex Tricon Safety for seven processing units. Invensys, Russia plant modernization at the Astrakhan gas processing plant that included the following: 1. Detailed engineering of the process control system including, documentation and development 2. Supply of all equipment 3. Installation at end user site 4. Installation, testing and commissioning according to a clear project schedule that took into consideration, planned maintenance shutdowns 5. Integration of new subsystems (nodes 6, 7) with the existing process control system without shutdown 6. Training of engineering and operations personnel. The works was carried out within schedule, despite the complexity of the processes. There was effective communication and full cooperation with the entire team and this contributed to the projects success.

(110 degrees Celsius). All processes of gas processing, storage, shipment, transportation are closely interrelated and require clear central control. The environment inside the plant is also hazardous because the hydrogen sulfide concentration in the formation fluid is 25%. This results in a lot of corrosion and if unchecked, also makes the raw materials toxic. Furthermore, the possible mixture of hydrogen sulfide with hydrocarbons is a real danger to the equipment. This required Gazprom dobycha Astrakhan to specifically ask for a control solution that will be able to meet the following requirements: The Control System should be able to operate in the limits of the hazardous environment prescribed above, without component failure The Control System should be spread out and distributed so that the operations personnel is not present in the dangerous product areas. The Control System should be redundant and provide a high operational tolerance (that is, the faults and failures of individual components will not lead to the failure of the whole system). The Control System should be built as an integrated, multi-level hierarchical solution that is easy to maintain and upgrade.

Achieved results and Business Metrics

In addition to improving the control and safety system, the solution achieved outstanding performance results in separated gas and condensate production. Invensys is proud to have been part of this endeavor and is prouder to be part of the team that helped its customer record operating results that are above expectations.

This document was realized thanks to the support of: Gazprom dobycha Astrakhan, LLC

59

INDUSTRY: LIFE SCIENCES

Sanofi Pasteur
www.sanofipasteur.com

The Invensys solution has met all of Sanofi Pasteurs expectations by providing easy migration with the existing system, high availability and a secure architecture to store and manage all the facilitys technical data.
Christian Colin Life Sciences & Systems Business Manager Invensys Operations Management

Sanofi Pasteur

Invensys Helps Sanofi Pasteur Achieve 30 Percent Increase in Overall Equipment Effectiveness
Goals Sanofi Pasteur needed to implement a solution that would enable the company to continually gather information and monitor its manufacturing processes The company required a system that could be easily integrated into a pharmaceutical validation system Challenges Sanofi Pasteur was limited in the flexibility and expandability of its previous proprietary system The instability of the former system triggered numerous false alarms, resulting in operators being sent incorrect hardware and network failure information Only manual written records could be produced and these were prone to operator mistakes resulting in data entry errors Solutions and Products Foxboro Programmable Automation Controller (PAC) System Results Sanofi Pasteur has achieved an estimated 30 percent increase in overall equipment effectiveness (OEE) The stability of the Invensys architecture and its object-oriented technology enabled Sanofi Pasteur to achieve a 15 percent reduction in time and engineering costs Maintenance operations have significantly improved with the ability to immediately address issues on the line when operators are notified by the Foxboro PAC System alarms and alert information

63

Life Sciences
Val de Reuil, France Protecting the health of
people around the world is Sanofi Pasteurs primary focus and concern. As the worlds leading producer of vaccines to safeguard the worlds population from infectious diseases, Sanofi Pasteur is the largest company entirely dedicated to vaccines. Recently, the company produced 1.6 billion doses of vaccines to immunize more than 500 million people across the globe. Conforming to strict quality and regulatory requirements is a constant challenge for Sanofi Pasteur. That means the companys manufacturing operations have to maintain the highest level of control and accuracy to meet the health needs of the public with a reliable supply of vaccines. To ensure that its production of vaccines complies with strict international regulations for quality and efficacy, the company implemented the Foxboro Programmable Automation Controller (PAC) System from Invensys Operations Management to operate its facility in Val de Reuil, France.

Foxboro Programmable Automation Controller (PAC) System

meet various regulatory requirements. Because of the proprietary nature of the former system, Sanofi Pasteur was limited in the flexibility and expandability of its manufacturing operations, said Christian Colin, Life Sciences and Business Systems Manager at Invensys. After reviewing the manufacturing requirements that were not being met by the original system, the company began researching various technologies that could not only address Sanofi Pasteurs requirements for today, but provide the scalability to meet expansion needs in the future. Because of continued production downtime, new international regulations for product quality control and increasing market demands for its vaccines worldwide, Sanofi Pasteur was forced to find a more reliable and productive solution.

Sanofi Pasteur Implements Foxboro PAC System to Provide High Performance, Increased Reliability and Cost-Effective Redundancy Options
After completing an intensive evaluation process, Sanofi Pasteur selected the Foxboro PAC System from Invensys Operations Management. The Invensys solution offers high availability architecture at all operations levels, Colin said. The reliability and redundancy features provided by the Foxboro PAC System and data servers ensure that Sanofi Pasteur operators and management receive a continuous flow of information. The Foxboro PAC System provides Sanofi Pasteur with an estimated 30 percent increase in reliability of its manufacturing operations. The company experiences less downtime and has more confidence in the integrity of the reports provided by the Invensys system. The Foxboro PAC System is a high-performance hybrid automation controller system. It is an

The Importance of Quality in Vaccine Manufacturing

As the worlds largest company entirely dedicated to producing vaccines that immunize the public from more than 20 infectious diseases, Sanofi Pasteur recently expanded its manufacturing operations to fulfil the ever-growing demand for its products. The new production facility was designed as a highly advanced and rapid production operation which, in the event of a global influenza pandemic, could rapidly produce large quantities of vaccines to accommodate the high volume of anticipated demand. The prior system was unable to manage this manufacturing requirement because the technology was obsolete and built on a specific proprietary hardware platform that could only be maintained by the company that developed the system. This required Sanofi Pasteur to enter into costly service contracts with the developer in order to keep the manufacturing facility running. In addition, the proprietary system had several instability issues. Alarms were triggered erroneously, causing the production line to halt and resulting in significant downtime and lost revenues. The system experienced numerous hardware and network failures which also contributed to unacceptable downtime events. Moreover, the previous system was unable to provide electronic data reporting; instead Sanofi Pasteur had to rely on paper reports to complete production audit trails to
64

Sanofi Pasteur

Life Sciences
extremely reliable technology featuring high I/O densities with cost-effective redundancy options. Its control unit and I/O system form the basis of a complete distributed control and recording environment capable of continuous analog, logic and sequential control. Combined with secure data recording for accurate manufacturing measurement parameters, the Foxboro PAC System collection of features is designed to maximize Sanofi Pasteurs return on investment. The Foxboro PAC System offers data record integrity which is critically important in regulated industries such as pharmaceutical manufacturing. A production batch of vaccines can result in significant revenue for the company. However if accurate records on the production cycle are not maintained properly, a batch can be scrapped and the production cycle must be done all over again wasting time and money. The Foxboro PAC System is designed to store vital information collected during the production process and is managed locally within the device and then forwarded to the appropriate business system via the network. In the event of a network failure, the Foxboro PAC System will store the information and then send it to the appropriate locations once network connectivity and operations are restored. The data storage feature of the Foxboro PAC System is vitally important to Sanofi Pasteur operations, Colin said. If the company was to lose the process data due to a hiccup in the connectivity of their network, they would be looking at a tremendous loss in revenue because production batch could potentially be thrown away and they would have to start all over again. The savings in production cost and production time is an invaluable feature of the Foxboro PAC System.

Foxboro Programmable Automation Controller (PAC) System

Invensys Helps Make Vaccines Available to Everyone

Working closely with Sanofi Pasteur, Invensys is assisting the company to ensure that everyone has access to vaccines to prevent disease no matter where they live. An important element in the pharmaceutical business is the ability to anticipate specific vaccines and quantities that will be needed by the worlds population. With the use of the Foxboro PAC System, Sanofi Pasteur is able to better manage production at its facility in France to effectively meet these ever-changing requirements and world demand. Not only can the company better monitor and adjust quantity production, Sanofi Pasteur can now address quality control issues with use of the Foxboro PAC System. To constantly improve their customer satisfaction and meet regulatory demands, while keeping the business highly competitive, the Sanofi Pasteur quality teams work closely with operations managers at its manufacturing facilities, Colin said. Together they define quality policies and guidelines to ensure that processes correspond to good manufacturing practices. Use of the comprehensive Foxboro PAC System enables Sanofi Pasteur to effectively meet these business objectives. With more than 50 percent of its staff dedicated to the companys industrial operations, Sanofi Pasteur is focused on ensuring that its manufacturing processes employ the most advanced technology that enables the company to continue to be the leading supplier of vaccines in the world. Invensys is making a significant impact on Sanofi Pasteurs ability to protect the world from deadly diseases that can impact the worlds population.

Reduction in Operating Costs Ensures High ROI

The ArchestrA technology built into the Foxboro PAC System provides Sanofi Pasteur the ability to create custom objects that can be quickly replicated at other plant sites. This feature has resulted in more than a 15 percent decrease in engineering costs. Sanofi Pasteurs selection of the comprehensive Invensys solution has met all expectations by providing an easy migration path with the existing system, native high availability and a secure architecture to store and manage all the technical data across the manufacturing operation, Colin said. The power of the Foxboro PAC System has been a key element in the success of the companys strategy to revamp its vaccines manufacturing operations.

This document was realized thanks to the support of: Sanofi Pasteur

65

Sanofi Pasteur

INDUSTRY: LIFE SCIENCES

Xcellerex
www.xcellerex.com
With the integration of Wonderwares software, Xcellerex has been able to deploy FlexFactory manufacturing capacity, very quickly, resulting in an overall reduction in development time of nearly 60%. This directly impacts customers with reduced costs and shorter time to market. In fact, weve been able to reduce deployment time from 3-5 years to an amazing 12-18 months. This results in huge implementation savings and the ability to begin producing high value product 2 to 4 years sooner than traditional technology.
John A. Chickosky Chief Commercial Officer and President, Biosystems

Invensys Enables Xcellerex to Achieve Significant Reductions in Overall Operating Costs and Accelerates Time to Market
Goals Address the growing demands in the biomedical market space for more effective biopharmaceutical manufacturing processes Develop a solution that would define a model for improving how biopharmaceuticals, vaccines and other therapeutics are developed, manufactured and commercialized Challenges Integrating complex technology with ultrahigh levels of functionality was considered the greatest challenge in creating a biomanufacturing platform that employs a single-use technology, controlled environment modules, process automation and electronic batch records Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware InBatch Wonderware Historian Results Xcellerexs FlexFactory enables companies to achieve significant cost savings in several areas, including a capital investment reduction that can exceed 60 percent The solution decreases the facility space required by 40 percent, lessens water usage and waste by 85 percent, and lowers the overall cost of finished products by 32 percent FlexFactory reduces deployment time from three to five years to 12 to 18 months, which enables the production of high value products two to four years sooner than traditional technology The solution achieves an overall reduction in development time of nearly 60 percent, with an estimated 80 percent saving in rework time, which reduces costs and shortens time to market

66

Life Sciences
Marlborough, Massachusetts Xcellerex
is revolutionizing the way biopharmaceuticals and vaccines are developed, manufactured and commercialized with the development of FlexFactory, a manufacturing platform designed to enhance production of these critical biopharmaceutical products. During the development stages of this pharmaceutical production solution, Xcellerex quickly identified the need to integrate single-use technology, controlled environment modules, process automation and electronic batch records into its FlexFactory platform. Working with Invensys Operations Management solutions in past product development, Xcellerex identified Invesys Wonderware software as ideal for integrating with this new, innovative manufacturing technology platform. Xcellerex selected ArchestrA System Platform as the backbone of the complete biopharmaceutical automation software application. Other Invensys solutions included Wonderware InTouch as the HMI, Wonderware InBatch to provide effective batching operations and Wonderware Historian to serve as the systems powerful application to maintain historical production data. The integration of Wonderware software components has enabled Xcellerex to offer customers significant improvements in production processes, including 70 percent faster deployment, 75 percent reduced capital investment and an unmatched level of flexibility. Years of single-use biomanufacturing experience enabled Xcellerex to design and integrate a solution offering an efficient, highly functional biomanufacturing technology platform. FlexFactory from Xcellerex enables customers to reduce capital investment by more than 60 percent, said John A. Chickosky, Chief Commercial Officer and President of Biosystems at Xcellerex. FlexFactory is able to decrease the actual space needed to build a manufacturing facility by 40 percent, lessen water usage and waste by 85 percent and lowers the cost of goods sold by 32 percent.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware InBatch, Wonderware Historian

Examining a Changing Market

The biomanufacturing market is currently undergoing enormous growth and change. Previous manufacturing models can no longer address the expectations and standards of this evolving industry. Instead, companies such as Xcellerex chose to re-evaluate the biomanufacturing process and develop strategies designed to greatly improve overall efficiencies. In the old business model, much of the cost came from the need to maintain clean, sterile conditions in process vessels as well as to preserve air quality in large-scale manufacturing suites. This required a manufacturing facility to invest $100 to $300 million and spend three to five years in the validation process before a single product could be developed for commercial sale. With the single-use technology from Invensys, deployment time has been reduced to a remarkable eight to twelve months. This results in significant implementation savings and the ability to begin producing high-value products two to four years sooner than what was achievable using conventional technology. Xcellerex advances in developing innovative manufacturing solutions has revolutionized the way companies are starting to manufacture the drugs that we use, said Darren Kline, Director of Marketing and Business Development at Wonderware North. FlexFactory has tremendously accelerated the time of building a plant, reducing on average from several years to only several months.

67

Life Sciences
Excelling Toward a More Efficient Future
Xcellerex utilizes patented process equipment in conjunction with Wonderware software from Invensys to achieve a highly productive and profitable manufacturing process to bring pharmaceutical products to market. The Invensys solution allows for reusable object-based technology, which enables a reduction in time to test, validate and debug the system throughout a customers facility. By developing innovative designs and approaches, as well as bundling them with Invensys software, Xcellerex has developed an operations approach totally different from most manufacturing solutions while remaining on the leading edge of manufacturing technology development, said Dr. Peter Martin, Vice President of Business Value Generation at Invensys Operations Management. Wonderware software gives Xcellerex a more efficient technology framework, while ensuring the highest quality in biomanufacturing. In 2010, Xcellerex was awarded the Grand Pinnacle Award during the Invensys Operations Management Open contest, in a field of 40 competing entries. Xcellerex has proven to be a leader in operational excellence while remaining both efficient and innovative. Xcellerex is a strong proponent of operations excellence but from a very different angle than what we normally see, said Martin. The company has an innovative group of engineers that come together to review what needs to be addressed to improve the biomanufacturing industry and they are not afraid to change the rules. They looked at what is feasible and moved forward to completely reverse the way manufacturing is done in the biotech industry for the better.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware InBatch, Wonderware Historian

biomedical industry automation and information personnel. By featuring an industrialized application server, a powerful historian server and an easy-to-use information server, ArchestrA System Platform offers unparalleled connectivity for demanding, precision-driven real-time biomanufacturing environments. The biggest benefit for Xcellerex is the Invensys solutions comprehensive object architecture functionality, said David Mills, Senior Director of MES and Automation at Xcellerex. This feature adds tremendous value to Xcellerex and its customers by providing a unified architecture across all different types of process designs. Users of FlexFactory are able to create application standards via ArchestrA System Platform with the development of templates for re-use in any application with similar functionality. ArchestrA System Platform enables the creation of standardized templates resulting in reduced training time and lower costs while driving consistency and quality across the enterprise. It also features Wonderware Historian, a highperformance real-time database for historical information. This software component enables process and performance decisions to be evaluated and made by management in real time. Xcellerexs application of Invensys solutions also features Wonderware InTouch, which provides advanced graphic visualization. Wonderware InTouch is designed to maximize productivity, optimize user effectiveness, increase quality and lower development, maintenance and operational costs by featuring custom graphical views of realtime industrial processes.

The Solution for Winning Wonderware Software from Invensys

To achieve significant implementation savings and accelerated production, FlexFactory is strategically integrated with Wonderware software, resulting in a system designed to provide a business benefit in the shortest period possible. With ArchestrA System Platform, FlexFactory provides a single, scalable software solution for all the SCADA, supervisory HMI and MES needs of
68

Life Sciences
The Invensys solution also includes Wonderware InBatch, which enables users to deploy batch functions that adhere to the ISA S88 flexible batching standard. InBatch software offers comprehensive batch execution and equipment history, material genealogy, stringent security, Web-based reporting and the ability to facilitate the design and implementation of systems that are compliant with FDA 21 CFR Part 11 regulations. The Invensys system is an excellent, comprehensive solution for Xcellerex and its FlexFactory technology, said Mills. To make any system changes, operators simply modify the object template once, and related objects are fixed across all instances saving us an additional 80 percent in rework time.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware InBatch, Wonderware Historian

Operational Excellence at its Finest

With the innovative strategies implemented by Xcellerex in its FlexFactory platform, the company has developed a solution that revolutionizes the way pharmaceutical companies manufacture products vital to the health and well-being of the worlds population. This type of forward thinking is the cornerstone of operations excellence. Invensys solutions used in FlexFactory from Xcellerex have enabled biomanufacturing companies to achieve a significant overall reduction in development time of nearly 60 percent. This achievement directly impacts the customers bottom line with substantially lower manufacturing costs and shorter time to market.

This document was realized thanks to the support of: Xcellerex 69

INDUSTRY: METALS, MINERALS AND MINING

Hydro Aluminium Extrusion Deutschland GmbH

www.hydro.com

We were looking for an easy-to-use configurable system; ArchestrA System Platform turned out to be the ideal solution thanks to simple object creation, configurationand inheritance properties.
Oliver Houb, Software Department Manager, EMP Planungsgesellschaft fr Prozeautomation mbH

More efficient energy management and optimized building automation at Hydro

Goals Reduction of energy costs through the accurate management of peak loads to prevent expensive consumption peaks effectively Counter measures by optionally switching off users and/or switching on power generators Unified visualization of existing building automation/control systems Challenges High availability System openness Standardized interfaces Integration of existing systems Centralized data collection and analysis Easy management Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware Historian Wonderware Historian Clients Wonderware Device Integration Server Results Centralized monitoring of consumption Reduction of peak loads by complying with fixed load limits Possibility of counter measures before peak load limits are achieved Quicker ROI by avoiding incalculable costs and/or reducing calculable costs Short project deployment time Limited training requirements as a result of easy management

70

Metals, Minerals and Mining

Germany is among the worlds biggest users and producers of aluminum. Hydro, a major supplier of aluminum and aluminum products, provides most of the metal for this industry. With a century-long tradition, Hydro relies on its capacity to create added value and future-ready solutions for its customers, partners and the entire community. Hydro Aluminium Extrusion Deutschland GmbH employs 19,000 people in 40 countries. The Grevenbroich factory (between Cologne and Dsseldorf, in Germany) is the biggest site of the Hydro Group with 1,950 employees, has a long record in aluminum production. This factory has been part of Hydro since 2002, as the main site for rolling operations. It is one of the worlds leading factories for the production of high-value aluminum belt, film products and for value-added aluminum processing. Just like many manufacturers, Hydro Aluminium has high energy consumption levels. The related costs represent a significant share of production costs. Electricity prices for big consumers are basically made up of an operating price and a capacity price. The operating price corresponds to the cost per kilowatt-hour (KWh) of power consumption. These costs can only be cut by reducing consumption. The performance price on the other hand, is based on the capacity offered by the utility company: the peak load. If the prescribed peak load is exceeded (15-minutes average value), the capacity price in the following invoicing period (normally one year) increases proportionally to the achieved annual peak load. Therefore, the efficient management of peak loads is a necessary measure for cost reduction.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian, Wonderware Historian Clients, Wonderware Device Integration Server

In the building automation sphere, existing building control systems from different vendors offer no standard and unified visualization.

Goals and challenges

The project goal was to implement an integrated solution for peak load management and building automation. For both activities, the key task was to provide a unified user interface. Such complex requirements could not be handled with the existing systems (ABB, Kieback & Peter) due to their proprietary nature. Peak load management contributes to the reduction of energy costs based on the maximum annual 15-minute load peak. The key task of peak load management is predicting the current 15-minute interval based on current consumption levels and the targeted switching-off of single users based on preconfigured rules. This enables Hydro to reduce the annual peak load and/or to avoid exceeding the prescribed peak load. The company looked for an open, modular, future-

proof solution capable of gathering and displaying data and information from all buildings/plants, as well as interacting with the building process control system. Another requirement was the integration of process-near components. The application of an easy interface concept should make future expansions simpler and consequently more costeffective. Another request by Hydro was to enable employees - with just limited training - to modify and expand the system as required and without specific programming knowledge. EMP recognized that the functions and capabilities of ArchestrA System Platform would be perfectly fitting for this application.

71

Metals, Minerals and Mining

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian, Wonderware Historian Clients, Wonderware Device Integration Server

plant expansions can normally be carried out quickly and easily by employees who do not have specific programming knowledge.

Benefits and results

Within just a few months, the peak load management system was put in place and it is now an integral part of site operations. Easy configuration based on the ArchestrA System Platform have enabled the quick deployment of the project and will support future expansions in the system. Furthermore, employees at Hydro Aluminium Extrusion Deutschland GmbH can execute the modifications themselves after a short training session. In Grevenbroich, Hydro can now collect an extensive set of energy consumption data, visualize and evaluate them, and when necessary, use them to prevent additional costs. Since the introduction of the system, calculable costs like electricity have been reduced, while incalculable costs like extra charges for exceeding peak load have been effectively avoided.

Implementation
The implementation process for this peak load monitoring and management system had to be tested in the aluminum film department at the Grevenbroich site. An intensive consulting phase involving Hydro and the longstanding Wonderware partner and system integrator EMP quickly resulted into the development of a workable solution. Peak load management is carried out in two ways. Based on measured values, a consumption prediction is made every 15 minutes. If the predicted level exceeds the nominal value, users are switched off or generators are switched on. Energy-hungry users, like rolling mills for instance, start only when forecasts indicate that the nominal value in the current 15-minute interval is not going to be exceeded; the peak load management system generates the corresponding control signals. Then, depending on the downstream process, these signals may trigger switching operations, or alternatively, the operator may be required to take action. ArchestrA System Platform turned out to be the ideal solution thanks to simple object creation and configuration. For EMP, a totally object-oriented approach was the basic condition for a futureoriented solution. First, a comprehensive template library was developed, including building automation devices and energy users and peak load management rules. Then, through instances and configuration, a model of the plant was created, that complies with all submitted requirements. As properties and methods are already programmed in the templates, future
72

Metals, Minerals and Mining

Conclusion
While developing this energy management solution, the Wonderware system integrator EMP also considered the usefulness of a Web-based representation of collected data and their analysis. Users from the plant now have the ability, through Wonderware Information Server, to review reports for peak load analysis, via the Internet or corporate Intranet.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian, Wonderware Historian Clients, Wonderware Device Integration Server

Ecosystem - The Wonderware Partner: EMP Planungsgesellschaft fr Prozeautomation mbH

EMP is an engineering company specializing in process automation in the pharmaceutical, chemical and metal working industries, industrial equipment, energy and power stations. EMP GmbH was established in 1984 in Leverkusen and currently employs 130 people (IT, engineers and technicians) in four sites in Berlin, Bottrop, Leverkusen and Frankfurt. Since 1996, EMP has been a partner of Wonderware GmbH, acquiring significant experience in the successful implementation of projects using Wonderware Software. EMP is also proficient in the deployment of solutions from the other Invensys Operations Management brands, including Foxboro, Triconex and Avantis.

This document was realized thanks to the support of: Hydro Aluminium Extrusion Deutschland GmbH

73

INDUSTRY: METALS, MINERALS AND MINING

Lonmin Plc
www.lonmin.com

What impressed us most is that, with ArchestrA, engineering and configuration time is sliced in half.
Johan Louw, Automation Specialist, Lonmin

Major real-time SCADA upgrade at Lonmin and who knew it was happening?
Goals Upgrade of System Platform 3.0 to release 3.1 involving all 7 concentrators and a large SCADA infrastructure. Improve system performance Challenges The upgrade would have to be done live during full production but with no plant downtime or loss of production. Operators to have visibility into the plant at all times Solutions and Products ArchestrA System Platform Wonderware InTouch Wonderware Historian Wonderware Historian Client Results Major system upgrade with no downtime and no loss of visibility into the plant Improved system performance Development of a risk-free method for implementing future upgrades Improved user confidence in the capabilities of the system and its upgradeability

74

Metals, Minerals and Mining

Lonmins Marikana complex is one of the largest and most significant platinum mining and processing operations in the world. Upgrading its extensive process control operations which, in this case affected all seven of its concentrators, was no casual exercise which demanded guaranteed results and zero downtime.

ArchestrA System Platform, Wonderware InTouch Wonderware Historian, Wonderware Historian Client

schedule making it impossible to arrange for a full concentrator shutdown. The upgrade would have to be done live during full production but with no plant downtime or loss of production.

Concentrator architecture
Lonmin has defined an operating environment for its concentrators which, for security purposes, has a DMZ which isolates the control VLAN (PLC connection) from the production VLAN (viewing, development, etc.) (figure 2). The Historian is also standardised for each concentrator. A viewing station and its backup are included as well as an ArchestrA IDE station. This makes each Concentrator a self-contained production unit with a standardised architecture but individual control.

Background
Lonmins Marikana operation spans an area of 33 X 13 kms near Rustenburg in the North-West province of South Africa and is in the business of mining and processing platinum group metals on a 24/7/365 basis. The complex consists of 14 shafts, 7 concentrators, a smelter and a base metals refinery. The Marikana operation uses 5 ArchestrA Galaxy Repository (GR) servers, 43 ArchestrA Object Servers (AOS), 42 view stations and 14 Wonderware Historian servers. Of this, the Concentrator Galaxy (figure 1) consists of 16 AOS, 16 view stations and 9 Integrated Development Environment (IDE) stations monitoring nearly a quarter million tags across 68 PLCs. The rest of the system is used for the shafts, services, smelter and metal accounting. This was a project involving the upgrade of System Platform 3.0 to release 3.1 involving all the concentrators, says Lonmins Automation Specialist Johan Louw, While upgrades are normally routine affairs, this one bears mention because each of the concentrators involved operates individually and has its own shutdown

Challenges
Implement upgrade with no plant downtime Production stoppages would not be tolerated yet any upgrade normally requires installing new software and restarting the system. So a way had to be found to work around this problem. Operators to have visibility into the plant at all times Once again, this precluded any system downtime. Improve system performance The magnitude of the concentrator complex demands highly optimised approaches if system performance is to be improved. Get buy-in from users Its not unusual for system changes to be viewed with some degree of scepticism and the success of the project would largely depend on empowering users to take ownership of the new solutions.

How it was done

Fortunately the sites were designed to each run 2 AOS servers (1 backup see figure 2) and this architecture supported what we wanted to do, explains Louw. With the help of Wonderware Southern Africa, we introduced an additional upgraded Galaxy Repository (GR) Server to form a parallel galaxy. We then upgraded the backup AOS servers. This could still be done with no downtime. The next step was to upgrade the view station and the IDE,
75

Fig.1: The Concentrator shop floor at Lonmins Marikana complex (map by Google Earth)

Metals, Minerals and Mining

ArchestrA System Platform, Wonderware InTouch Wonderware Historian, Wonderware Historian Client

According to Louw, the most impressive aspects of the system architecture include: Scalability. We were able to do load sharing on areas where a lot of processing power was required. The ability to enable redundancy on critical areas. Distributed architecture which simplifies the process of backups and restore. This reduces downtime in the event of hardware failure.

Benefits
Figure 2: Concentrator architecture

so that two view stations were running the same applications on two parallel galaxies. Once each IDE was upgraded, users could start doing development on the new galaxy. Any new development on the old galaxy would at this stage be lost. The next step was to change over the Historian and finally the old AOS. After all the sites were done, the old GR was decommissioned and prepared for the next upgrade. The result was a major system upgrade with no downtime and no loss of visibility into the plant. Since the rollout wasnt done on a full-time basis and was interlaced within normal day-to-day activities, it took about 3 months. This also gave us time to implement best practices and to validate our existing GRs, says Louw. What impressed us most is that, with ArchestrA, engineering and configuration time is sliced in half. Another notable feature is the ability to manage the software from a central point, as well as enforcing standards across the business.

Major system upgrade with no downtime and no loss of visibility into the plant Improved system performance Development of a risk-free method for implementing future upgrades Improved user confidence in the capabilities of the system and its upgradeability

Conclusion
A seamless upgrade of this magnitude goes to show what can be done with modern technologies and ingenuity - and thats how it should be. Systems are there to help monitor, control and improve production - not to stop it dead in its tracks for a routine software upgrade. Marikanas six Historians log 350 million readings a day (4050/sec.) in the Concentrator galaxy alone and to have this continue in real-time during a plant-wide system upgrade with nobody noticing and without missing a beat is impressive for two reasons: its a great example of merging inventiveness with technology and its now become routine rather than a career-defining moment.

This document was realised thanks to the support of Johan Louw, Automation Specialist at Lonmin

76

INDUSTRY: METALS, MINERALS & MINING

Ash Grove Cement

www.ashgrove.com

By closely monitoring and managing what we use, reorder activities, and parts and materials pricing, we have reduced inventory by at least $2 million in the last few years. This is a significant contribution to keeping our prices competitive in the marketplace.
Mike Ralls Plant Systems Administrator

Avantis Solution provides solid Enterprise Planning, Scheduling and Compliance Management for Ash Grove Cement
Goals Automate maintenance data collection at each facility for a well-defined enterprise asset management process to support equipment performance reliability Challenges Improve the availability and utilization balance of production assets and develop a standardized solution for each of its nine separate production facilities, while maintaining production Solutions and Products Avantis.EAM Avantis.PRO Avantis VIP Advanced Scheduling Results A $2 million first year inventory reduction Improved ability to manage inventory, as many as 8,000 items at each plant, maintaining between $2 million to $12 million in inventory Compliance with the Federal Environmental Protection Agency (EPA) regulation called the Portland Cement Maximum Achievable Control Technology (PC MACT) Minimizes the potential loss of $3,000 per hour for every hour the kiln is offline

77

Metals, Minerals & Mining

Overland Park, Kansas Founded in 1882, the
Ash Grove Cement Company is the fifth largest cement manufacturer in the United States, with an annual production capacity of more than 8 million tons per year. Company headquarters are in Overland Park, Kansas, with production facilities located throughout the U.S. The Portland and masonry cements produced at these plants are used in the construction of highways, bridges, commercial and industrial complexes, residential homes, and numerous other applications.

Avantis.EAM, Avantis.PRO, Avantis VIP Advanced Scheduling

and reach temperatures as high as 3000 degrees Fahrenheit. If the kiln goes down, we can lose as much as $3,000 an hour, which makes the kiln one of our top maintenance priorities. Typically, the kiln drives our maintenance outages, which gives us a limited window of opportunity to do major overhauls. We need to tightly manage what has to be done, who is going to do it, and what is needed to get the job done most efficiently for ongoing reliable operation, said Farr. To make most efficient use of that maintenance window, Ash Grove automated all data collection on kiln-related maintenance activity at one plant and extended it to remaining facilities in the following year. Ralls explained, Our long-term goal was to automate maintenance data collection at each of our facilities for a well-defined enterprise asset management process to support equipment performance reliability while interfacing with our financial software, JD Edwards One World. We needed a system that we could implement to improve operations, with the scalability to contribute to sustainable development. With the global rollout underway, Ash Grove set out to improve equipment reliability and cost savings further by tapping EAM functionality for enterprise planning and scheduling, document management, regulatory compliance, and inventory management. Our original need was maintenance functionality and some cost tracking information, mostly a data capture and get it into the system so we dont lose it type of solution. But when we saw that Avantis could also help us sort and interpret this data, we were pretty excited, said Bernard Sherin, Maintenance Manager at the Durkee plant.

Maximizing profit in a highly costcompetitive market

Cement producers can pretty much sell as much cement as they can make, but maximizing profit in a highly cost-competitive market requires continuous innovation. Mike Ralls, Plant Systems Administrator, said, Were sold out all year long and thats just the way we want it, but we dont have the luxury of non-production time. We must continually find better ways to balance both availability and utilization of our production assets. This challenge was compounded by having to develop a standardized solution that worked for each of its nine separate production facilities. As the fifth largest U.S. cement manufacturer, the Ash Grove enterprise includes management, finance, and administration functions at headquarters in Overland Park, Kansas, and autonomous mining, transportation, production, and distribution facilities in nine U.S. states. The scope of the equipment at these facilities ranges from capital expense drilling and excavating systems to motors and power transmission belts. All are in constant use and need regular maintenance. According to Ryan Farr, Corporate Reliability Manager, Its a challenge to schedule maintenance work when you run 24 hours a day, but usually we get a 2-4 week period once a year based on kiln outage. While all phases of production are important, the high temperature kiln, which converts calcium, silica, alumina, and iron components into the base cement clinker is the heart of the operation. The Ash Grove kilns are large ovens that rotate at about 3.5 RPM

Analyze failure causes and histories and take action accordingly

The expanded Avantis functionality enables Ash Grove management to share maintenance data from diverse, geographically separated operations, covering several square miles of quarries and the cement production plant. It is a computerized maintenance management system (CMMS) that uses an entity concept to enable tracking of cost and

78

Metals, Minerals & Mining

maintenance activity. Parent-child relationships can be set up easily to build detailed hierarchies for cost rollups and operating statistics. Sharon McGuire, Planner/Scheduler at the Durkee facility, said, Following safety, our top priority is minimizing downtime of revenue-producing equipment, so planned outages of this equipment drive our planning. Proper planning gives us more control over the situation, but requires facilitywide coordination, and that is one area where the Avantis software has proven to be particularly helpful. This detailed history of equipment information enables supervisors to analyze failure histories, track failure causes, and take action accordingly. Maintenance parts inventories can be better managed, especially when dealing with large numbers of unique and low-unit-value items that can often be subject to unpredictable demand. Workflow can be better planned and purchasing and procurement functions can be tied directly into planned outage maintenance programs. The software also supports contingency planning for unanticipated equipment failures. Technicians can review work backlogs easily, adjust work schedules, and determine appropriate maintenance procedures by studying the equipment history. Pre-entered coding helps technicians determine which equipment must be shut down during the maintenance and which can continue running. To help all maintenance teams stay on top of required maintenance, Ash Grove has an open access policy to relevant information by all Avantis users throughout the enterprise from maintenance to management. This is particularly useful for managing work requests. For instance, if a guard on a piece of rotating equipment needs to be replaced, the equipment operator can enter a work request from his station. Planners and schedulers in another office will review the work request, schedule the repair, and define the most efficient procedures. The system then generates the work order automatically, and places it in a backlog, for regular review and reprioritization, as needed. The system automatically issues work orders to technicians, who replace the guard and enter details into the system. The system then notifies the operator that the job is complete and to submit a review and comment.

Avantis.EAM, Avantis.PRO, Avantis VIP Advanced Scheduling

To enhance the scheduling and planning efficiency further, Ash Grove has added Avantis VIP Advanced Scheduling software, which manages availability of all project resources. The VIP software helps schedule maintenance and measures schedule compliance. It enables better employee work utilization and facilitates changes in plans and schedules. Ash Grove uses Avantis VIP in conjunction with handheld personal data assistants (PDAs). Planners download work orders to PDAs, which are given to technicians at the beginning of each day. The work orders can include information on labor, materials, tools, drawings, and any special instructions for the job. Technicians record status electronically during the day and update the central database by docking the PDAs in the evening. The advanced planning and scheduling software also improves processing of emergency work orders. If technicians encounter situations that can be corrected immediately, without further coordination, they go ahead and do it. For more involved procedures that cannot be handled right then, the technician generates an emergency work order through the PDA, which goes to the planner as a high priority. These are closely monitored, and the planner coordinates with other related departments to determine the most efficient remedy. In addition to improved maintenance efficiency, Ash Grove has benefited from eliminating the cost, inaccuracy, and time-consuming aspects of paper processing, including better documentation of all maintenance activities, easier compliance with environmental regulations, and improved inventory management.

Electronic Documentation
The Avantis.PRO software builds a detailed history of equipment information based on day-to-day maintenance activities. Equipment statistics include hours of operation, cause and frequency of downtime, and labor and material changes, all of which can be easily reviewed and analyzed. We can look at historical data and trend it to evaluate whether we need to spend more or less effort in a particular area. Its given us an easy way to determine whether a particular piece of equipment has had an inordinate amount of work done on it. With proper cost justification, we can judge whether we should replace any equipment thats costing too much to maintain, said Farr.

79

Metals, Minerals & Mining

Documenting Environmental Compliance
The Federal Environmental Protection Agency (EPA) regulation called the Portland Cement Maximum Achievable Control Technology (PC MACT) requires all cement plants to follow an approved plan for continuous compliance with environmental regulations and provides for regular monitoring of adherence to that plan. Farr commented that, One critical requirement in the PC MACT program is to have preventive maintenance schedules set up and documented, including standard operating procedures that demonstrate that weve followed these procedures. We rely on Avantis to maintain our history of all operations to meet these new requirements. This is particularly critical for visible emissions monitoring. Visible emissions can generate complaints, resulting in a visit from Department of Environmental Quality (DEQ) inspectors. By law we are required to document these incidents and the inspectors want to see it. They want to know what time the incident occurred, what we did about it, and what time the emissions were abated. Avantis provides this documentation to validate our actions. Without this, we could face serious fines, said Farr.

Avantis.EAM, Avantis.PRO, Avantis VIP Advanced Scheduling

Inventory Management
To help Ash Grove manage procurement, the Avantis software stores and simplifies retrieval of vendor information such as pricing, lead times, and manufacturers cross-references, and uses this data to drive automatic replenishment and tracking of inventory items. Included with every work order is a list of parts required to complete tasks. Inventory warehouse managers pull parts and have them ready for the technicians. At the same time, Avantis tracks items coming out of and going into inventory, so purchasing can prepare to replenish these parts most efficiently by researching price, availability, and delivery of these items.

Gains in inventory management

Expanding the scope and functionality of the enterprise asset management system has contributed to gains in inventory management, kiln uptime, and overall maintenance costs savings. Inventory management gains are in reduced inventory size. By increasing kiln usage, Ash Grove minimizes the potential loss of $3,000 per hour for every hour the kiln is offline. Because most maintenance must be done during planned outages, it is critical that all required parts be available for that outage. With the Avantis planning and scheduling functionality, the system now predicts what parts will be needed at the time of the outage, and automates ordering so that it is there when needed.

This document was realized thank to the support of: Ash Grove Cement 80

INDUSTRY: METALS AND MINING

ASSMANG Limited
www.assmang.co.za

We are thankful for the Invensys ArchestrA technology because its developers obviously understood our very real needs and built an environment that allows us to grow painlessly, quickly and to the benefit of our clients.
Johann Pienaar, Iritron director

ASSMANGs Khumani mine turns to Iritron and Wonderware for its expansion project
Goals Expand the original SCADA installation by 50% using the same tools and technology Challenges The expansion project is large and critical in nature but it needed a rapid completion schedule Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware Historian Software Results Re-use of templates developed during the initial project phase greatly reduced development time (10% of the initial time for a 50% expansion) Proof that system components will rapidly cope with increasing mine demands

81

Metals and Mining

ASSMANGs Khumani iron ore mine is situated in the Northern Cape Province of South Africa and close to Sishen. The Khumani deposits are among the best iron ore resources in the country in terms of quality and quantity. Based on current reserves, a new mine producing 8.4 million tons annually would have a life in excess of 40 years and at double that capacity, a life in excess of about 25 years. System Integrator Iritron was contracted by DRA Mineral Projects (Pty) Ltd during the initial (2008 greenfields) ASSMANG Khumani project to take responsibility for the implementation of the overall SCADA (Supervisory, Control and Data Acquisition) system using the ArchestrA System Platform.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian Software

In terms of hardware, the existing System Platform was expanded by adding an additional pair of redundant Application Object Servers and six additional InTouch View Nodes in the new plant sections King Primary Crushing, 2nd Load-Out Station and the Jig Plant Extension. No other hardware additions were required the existing servers and networks had more than sufficient spare capacity in terms of processing power and licensing.

ASSMANGs Khumani iron ore mine is an ambitious undertaking by any definition. Completed in just two years from a foundation of Kalahari sand, Khumani is well on the way to becoming a principal player in the global and competitive world of primary metal production.

Expansion project
For the mines expansion Project, ASSMANG again appointed DRA Mineral Projects as the Managing Contractor for the project and Iritron was again contracted by DRA to implement the extensions to the already-installed System Platform. Iritron is a certified ArchestrA System Platform integrator and has a long track record with ASSMANG and extensive knowledge of their standards and requirements. To date, Iritron has successfully implemented five large ArchestrA projects ranging from the Northern Cape to the United States and the company is currently busy with another four projects. Iritron is also actively involved in the Beta and systems testing of current and future releases of System Platform. One of the main advantages of System Platform is its scalability, flexibility and ease of expansion once standards and templates have been developed for a specific implementation, says Iritron director Johann Pienaar. In this case, the standards and templates that were developed during the initial phase of the project could be re-used for all the new plant sections. In terms of software development, the effort put in during the definition and development of the standards and templates during the initial project finally paid off. All that was required was to create new instances of the existing templates (motors, valves, conveyors, crushers, screens, etc.) for each piece of equipment that had to be added, says Pienaar. No testing and integration was required, seeing as these templates had already been thoroughly tested. The same applied to the PLC programmes.

82

Metals and Mining

Once the object instances had been created (exports from the FDES instrumentation design software and CSV imports were used to automate this process in both System Platform and in RSLogix5000), the new mimics were created by dragging and dropping the associated object graphics on to the mimic pages and adding the static detail. The graphics and animation form part of the object templates, so no additional configuration or testing was required. The size of the Khumani Expansion Project is about 50% of the original project, but the SCADA development took less than 10% of the original development thanks to the standards enforcement of the underlying ArchestrA technology. The savings in time will be even more pronounced during commissioning. We are thankful for Invensys ArchestrA technology because its developers obviously understood our very real needs and built an environment that allows us to grow painlessly, quickly and to the benefit of our clients, concludes Pienaar.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian Software

Using standards developed during the initial phase of the project greatly reduced engineering time Thoroughly tested existing templates could be redeployed with confidence The System Platform provided all the necessary scalability, flexibility and ease of expansion the project required

Conclusion
Proof positive that the bottom line is impacted positively when industrial production solutions understand the long-term view rather than cater for the immediate fix. Based on soaring world demand, its predictable that Khumani will continue to expand and continue to hone its production processes to maximise profits. Through design, the solutions now in place understand that this is the norm of todays industrial marketplace and will continue to deliver results that keep pace with the inventiveness and ingenuity of their owners. After all is said and done, its results that count not promises.

Benefits

This document was realized thank to the support of: ASSMANG LIMITED 83

INDUSTRY: METALS, MINERALS & MINING

Hydro
www.hydro.com

By using the lowtemperature Oxyfuel method, we can melt 50 percent more cold aluminum in the same amount of time as we did previously. In addition the propane consumption and carbon dioxide emissions have been cut in half which also is very positive.
Wenche Eldegard Cast House Manager
Norsk Hydro

Invensys Helps Hydro to Significantly Increase its Aluminum Cold Melting Capacity as well as Reduce Waste and Emissions
Goals The company required a solution that would enable it to achieve increased melting capacity and reduce waste The technology needed to not only increase production efficiency but also reduce production costs and increase energy savings Challenges The aluminum manufacturer needed to accurately control combustion operations and enable the smooth transition of various metallurgical processes Optimizing energy output during the aluminum melting cycle was vital to achieving overall production efficiency To maintain profitability, the technology needed to provide both cost savings in production as well as assist in minimizing the companys environmental impact Solutions and Products Foxboro Programmable Automation Controller (PAC) System Results By utilizing the key features of the the Foxboro PAC System, Linde Gas has enabled Hydro to increase its aluminum cold metal melting capacity by more than 50 percent The company was able to reduce dross to less than 2% and fuel consumption by 50% A significant reduction in carbon dioxide and nitrogen oxide emissions also was achieved to maintain the companys commitment to reducing its impact on the environment The Linde Gas Low Temperature Oxyfuel technology, using The Foxboro PAC System, now enables the continuous production of 125,000 tons of foundry alloys annually

84

Metals, minerals & mining

Ardal, Norway In 1957 the tin can made a significant leap in design and functionality by incorporating the most abundant metal in the Earths crust -- aluminum. Though the new aluminum container still had to be opened with a knife, it became cheaper to produce and reduced the possibility of lead poisoning associated with solder used to seal tin containers. The low density, corrosion-resistant metal also offered greater malleability, enabling it to be manufactured in a wider array of shapes and sizes.
During the last decade, aluminum manufacturing has made various evolutionary leaps in processes and materials thanks to the development of new production technologies. Hydro is one of the worlds leading producers of aluminum and is a supplier to a wide range of industries spanning automotive and transportation to building supplies, packaging and consumer goods. To provide top-quality and cost-effective aluminum products, Hydro employs intelligent burner control solutions for low-temperature Oxyfuel control. The use of Oxyfuel combustion substantially increases the thermal efficiency of the production facilitys furnace operations because the radiant heat transfer of furnace gases produced are significantly more efficient than those created from air-fuel processes. Using the Foxboro Process Automation Controller (PAC) System, in conjunction with Linde Gas Oxyfuel burners has resulted in significant economic savings and supports Hydros commitment to reducing greenhouse emissions and dross, which is a mass of solid impurities found floating on molten metal such as aluminum.

Foxboro Programmable Automation Controller (PAC) System

The challenge at Hydro was to optimize the amount of energy required in the manufacturing process when producing its more than 125,000 tons of foundry alloys each year. Combined with the lowtemperature Oxyfuel technology, the Foxboro PAC System delivers higher melt rates with reduced oxidation, lower fuel consumption and ultra-low nitrogen oxide emissions. The re-melt capacity has now been increased, with capacity up 50% while dross is less than 2%. Although Oxyfuel is accepted as state-of-the-art for rotary furnaces, the aluminum industry has been more cautious to adopt the technology in reverberatory furnaces. With the risk of creating hot spots due to overheating the aluminum surface, a more effective process had to be found. Hydro now effectively manages these risks by employing lowtemperature Oxyfuel technology combined with the Foxboro PAC System intelligent burner control solution. The Foxboro PAC System is a high-performance hybrid automation controller which offers high performance, reliability and high I/O densities with cost-effective redundancy options. Its control unit and I/O system form the basis of a complete distributed control and recording environment capable of continuous analog, logic and sequential control. Combined with secure data recording for accurate manufacturing measurement parameters, the Foxboro PAC Systems collection of features is designed to maximize Hydros return on investment.

More Than Just Aluminum Foil

Working in conjunction with Linde Gas, a leading gases and engineering company, Invensys Operations Management installed the Foxboro PAC System for process control, data acquisition, remote equipment monitoring, machine vision and motion control. The whole System reduces Hydros engineering costs and provides high availability of data, maximizing the companys process uptime.

85

Metals, minerals & mining

Oxyfuel and Foxboro PAC Technology
By using the low temperature Oxyfuel technology, Hydro can replace 20,000 tons of liquid aluminum by re-melting cold metal. Previously, the process included the mixing of 8 tons of cold metal and 22 tons of liquid metal which had a high production cost factor. Now the mix is 13 tons cold and 17 tons liquid metal, reducing overall operations costs. The Oxyfuel process and Foxboro PAC System technology has enabled the company to increase its overall average re-melting capacity by more than 50% for the four furnaces at the cast house. The key element Hydro needed was increased capacity on melting cold metal, the solution gives them that alongside large energy savings. It was vital to provide accurate combustion control and a smooth transition between all aspects of the cycle while optimizing the melting cycle and applying the maximum energy when the thermal efficiency is highest, said Lars Goran Elfgren, Project Manager at Invensys Operations Management. Thanks to improved thermal efficiency and increased heating/melting rates, overall productivity is increased while at the same time saving on fuel costs and reducing carbon dioxide and nitrogen oxide emissions. The two production lines for primary foundry alloys were converted to the low temperature Oxyfuel and Foxboro PAC System process resulting in a 50% increase in re-melting capacity. Combining the low-temperature Oxyfuel burner for aluminum melting with the Foxboro PAC System, Hydro has taken a significant step toward enabling more efficient re-melting of aluminum in reverberatory furnaces. Integrating the Foxboro PAC System with the plants PLCs enable Hydro to maximize Return on Investment (ROI) by offering automatic dualredundancy options to guarantee process efficiencies and protect against controller or communications failures. This powerful, cost-effective process automation controller also uniquely provides secure data recording with dual-redundancy at point of measurement.

Foxboro Programmable Automation Controller (PAC) System

at a process unit and can be easily configured using Invensys technology, said Constantine Lau, Director of Product Marketing for Control and Safety Products at Invensys Operations Management. While the Foxboro PAC System can be easily integrated into a control or plant network, it will continue to control the process even if a network link is lost. Combined with optional controller redundancy, this provides a high degree of fault-tolerance at a very low cost.

Foxboro Combines PLC Architecture and DCS Functionality

In addition, the Foxboro PAC System enables redundancy of processors, power supplies, recording and networks. The controller/recorder redundancy is automatically commissioned by simply plugging the additional processor module into the redundant base and initiating the E-Sync technology with a single button press on the front of the unit. During the E-Sync process, all files from the primary processor are copied to allow a secondary processor to mirror and monitor the primary processor. No special cabling or engineering is required to configure a secondary processor. With the E-Sync technology, the Foxboro PAC System provides a high-performance solution that offers extremely cost-effective redundancy options. The control unit and I/O system form the basis of a complete distributed control and recording environment capable of continuous analog, logic and sequential control all combined with secure data recording at point of measurement to maximize ROI. As aluminum has demonstrated its ability to be used in a multiplicity of products with myriad business and consumer applications, Hydro has been a leader in advancing improvements to the metallurgical processing of this extremely abundant metal. With the help of Invensys, Hydro has implemented redundant capabilities that maximize process uptime in its aluminum melting process, resulting in lower engineering costs and a reduced impact on the environment.

The Foxboro PAC System allows low-cost, multiloop process control capability to be deployed right

This document was realized thanks to the support of: Hydro

86

INDUSTRY: PLASTICS

Illinois Precision
www.illprec.com

The Eurotherm MACO Compact control system manages a wide range of variables which are needed for the successful implementation of medical molding processes such as repeatability, mold storage, setup storage and maintaining a complete history of the overall molding process.
Steve Schroeder Business Development Manager Invensys Operations Management

Invensys Eurotherm MACO Compact Control System Enables Illinois Precision to Expand Business into Medical Industry
Goals Illinois Precision wanted to increase its market share by expanding into other industries, especially medical products Standardizing the control application of its medical press machines was a primary objective for the company Illinois Precision wanted to offer its OEM customers improved operations and streamlined manufacturing processes Challenges The company needed to identify technology that could provide more precise process control The competitive marketplace demanded an expansion of company leadership in the medical molding market space Transitioning from an open-loop process to a closed-loop process required a technology that could provide a more precise and repeatable process for medical injection-molding applications Solutions and Products Eurotherm MACO Compact Control System Results The Eurotherm MACO Compact control system integrates more precise control of injection-molding processes for the medical industry Illinois Precision has made the Eurotherm MACO Compact standard for all brands of its presses The companys presses can better meet environmental requirements because the Eurotherm MACO Compact provides a more precise material processing application reducing scrap and improving overall operating efficiency

87

Plastics
Bicknell, Indiana Injection-molding processes
are key to the manufacturing of consumer and industrial plastic items used every day, from bottle caps and pipe fittings to eating utensils and surgical tubing. The process involves melting plastic pellets and transferring the molten material to molds to create products for a wide array of applications. The technology incorporated into the injectionmolding machinery has a significant impact on how quickly manufacturers can produce large volumes of product to meet customer needs as well as reduce overall production costs. All of which has a direct impact on the availability and price the customer pays for finished products. Illinois Precision Corporation (IPC) has been in the business of developing injection-molding equipment since 1970. Machinery designed and developed by the company has been used in the production of products for a variety of industries such as electronics, automotive, appliances and sports. Recently, the company identified the medical industry as an area for expansion and realized that a closed-loop system is required for this market segment, which demands extremely precise manufacturing standards. To successfully compete in this market space, IPC selected the Eurotherm MACO Compact control system from Invensys Operations Management as standard technology to be incorporated in both its regular line of Echo presses and its new Echo MD line designed specifically for the medical industry.

Eurotherm MACO Compact Control System

systems and blood collection sets, as well as infusion, flushing and drainage kits. The process of injection molding for medical product manufacturing requires specialized tooling in the form of an injection mold and an injection-molding press. The process melts plastic in a heated cylinder which is then injected into the mold to form specific parts or components. This process may involve many variables which can affect the finished product. Therefore, the machinery must maintain precise calibrations in order to produce products that meet the stringent medical industry manufacturing requirements for quality and consistency. Many injection-molding methods use the simple open-loop process which is a low-cost, nonerror controlling approach commonly used when reporting of production data is not critical, said Steve Schroeder, Business Development Manager of Plastics at Invensys. However, in the production of plastic medical products, precise measurement and manufacturing statistics must be adhered to exactly, so a closed-loop system must be used in production. The production process of these mass produced injection-mold products must not vary. Each batch produced must be exactly the same. In a closed-loop process, a sensor monitors the system output and relays that data to a controller which then adjusts the process for the optimal control of the system. This is done throughout the manufacturing process to maintain the exact system production criteria and ensure that the exact output specifications are met. The MACO Compact offers a full range of features including closed-loop process control, clamp control, linear-positioning control of machine or auxiliary functions, pressure/flow control, auto-tuned temperature control, sequential machine control, and built-in timing and counting. Its operator interface is designed to support maximum flexibility enabling IPC to run the system using its preferred interface design. The MACO Compact control system offers several keyboard options, from touchscreen to full numeric keypad functionality, with a display that supports in-depth process data trending, custom machine graphics, text displays, alarm messages and control standards charts. These features and benefits make the MACO Compact control system a reliable, cost-effective solution for any injection-molding operation.

Critical Medical Manufacturing Processes Expand IPC Market Reach

With a strong business commitment to improving and expanding its line of injection-molding equipment for the medical industry, Illinois Precision recognized the need for its presses to continuously perform at peak levels. IPC selected the Eurotherm MACO Compact to provide more precise machine control functions. The Eurotherm MACO Compact supports the precise manufacturing requirements demanded by the medical field. Some of the medical products manufactured via the injection-molding process include oxygen masks and airway management systems, tracheal and feeding tubes, catheters, IV

88

Plastics
With all types of molding, but especially in medical injection-molding manufacturing, precise and repeatable processes are very important, said Schroeder. The Eurotherm MACO Compact control system has enabled IPC to expand its offerings of machinery to the medical market since the Invensys technology provides required repeatability, and such needed features as mold and setup storage, and complete molding historical data.

Eurotherm MACO Compact Control System

Eurotherm MACO Compact Control System Offers More Precise Shot Control
Illinois Precisions new Echo MD Press with the Eurotherm MACO Compact control system features a new servo-electric rotary table that can pivot 90 degrees in one second. The servo-electric rotary table enables operators to have more control of the injection process. Because process reliability is critical in medical injection molding, these new tables provide smoother movements and braking to ensure faster and more accurate production of injection-molded plastics items. With the Eurotherm MACO Compact, IPC is able to achieve a more precise shot control during the injection process, ensuring reproducible product specifications. Illinois Precision has gone from the basic push and squirt process characteristic of an open-loop system to a closed-loop system for more accurate measurement and control of the injection process, said Schroeder. For medical molding processes, IPC machinery has to deliver an extremely precise and repeatable process which is inherent in closedloop process control and statistical process control applications. The Eurotherm MACO Compact was also selected for its enhanced processing features and ease of operation. In addition, because the Invensys technology is a comprehensive packaged solution it can be used to retrofit other IPC machine designs. The Invensys solution enables IPCs injection-molding machines to manage a wide range of manufacturing variables, provides storage mold design and setup specifications and maintains a complete historical database of molding operations. With the implementation of the Eurotherm MACO Compact control system, Illinois Precision is positioned to successfully increase its market share in the medical injection-molding industry segment. By standardizing the control application of its medical press machines on Invensys technology, IPC has achieved a milestone in the design and functionality of its injection-molding machinery. IPC can now offer its OEM customers improved manufacturing operations and standardized processes, with greater precision, efficiency and repeatability.

This document was realized thanks to the support of: Illinois Precision.

89

INDUSTRY: POWER

BC Hydro
www.bchydro.com

Our BMS migration from Bailey Symphony to the Foxboro I/A Series Distributed Control System went very smoothly. Checkout of the new BMS was substantially complete within three days.
Huitt Manering Principal Engineer and Task Manager

BC Hydro gets upgrade from aging Bailey control system to Foxboro I/A Series Distributed Control System
Goals Replace obsolete Bailey control system to increase efficiency and reliability of power generation Improve and optimize unit heat rates Centralize plant controls in one room Provide a real-time focus for plant operation, and improve process control Challenges Continue delivering reliable power with the least possible environmental impact to its growing base of commercial and residential customers Solutions and Products Foxboro Distributed Control System - I/A Series Foxboro Measurement & Instruments Results Provides clean energy to more than 1.6 million customers Decreased maintenance time/effort, Burner Management System checkout was reduced from three weeks to three days Reduced upgrade costs by half and shortened downtime from weeks to days

90

Power
British Columbia, Canada BC Hydro provides
high-value, reliable power to fuel economic growth and development throughout Canadas British Columbia province. The utility provides energy solutions to more than 1.6 million customers in a socially responsible way, balancing its users energy needs with environmental concerns. BC Hydro has constructed a world-class integrated hydroelectric system of close to 11,500 megawatts of generating capacity over 87% of which is hydroelectric. Due to this efficient, reliable system, British Columbians enjoy some of the lowest electricity rates in the world.

Foxboro Distributed Control System - I/A Series Foxboro Measurement & Instruments

Upgrade and easy migration to a Foxboro I/A Series Distributed Control System
After comparing proposals from Bailey, Fisher, and Invensys Operations Management, BC Hydro determined that a Foxboro plug-in migration solution would provide the greatest reliability and performance at the lowest cost with the least interruption of service. Rather than bulldoze the existing infrastructure a costly and highly disruptive alternative BC Hydro was able to implement the Foxboro I/A Series Distributed Control System on its legacy racks, without rewiring. The Foxboro migration solution simply replaced the Bailey I/O modules with I/A Series electronics packaged in the exact same form factor. Most of the actual migration then involved simply substituting the repackaged I/A Series I/O modules for those from Bailey. This unique approach reduced upgrade costs by almost half and shortened downtime from weeks to days. Invensys also provided the BMS design and the boiler/generator coordinated controls, as well as balance-of-plant (BOP) controls, and seamless integration with data from new safety systems and other on-site third-party systems. In addition, Invensys handled the upgrading of Foxboro intelligent field transmitters and intelligent valve positioners.

BC Hydros Challenge
To continue delivering reliable power with the least possible environmental impact to its growing base of commercial and residential customers, BC Hydro implemented an ambitious environmental improvement and plant modernization initiative. A vital element: migration to a modern digital control system at the utilitys Burrard Generating Station in Port Moody, on Vancouver Harbor. Supplementing the utilitys 32 hydroelectric facilities, Burrard is one of two thermal plants that supply critical base load support to the electrical grid in years of low water run-off or during maintenance outages. The stations six gas-fired CE boilers generate 155 MW each of electric power. However, its obsolete Bailey control system was becoming increasingly difficult to maintain. It also jeopardized operation of the selective cathodic reduction (SCR) technology installed in 2000 to reduce nitrogen oxide emissions by 90%. Besides repairing these deficiencies, other upgrade objectives included improving and optimizing unit heat rates, sustaining required availability, centralizing plant controls in one room, providing a real-time focus for plant operation, and improving process control. Requirements also included a burner management system (BMS) and upgraded boilers.

91

Power
Delivering higher levels of control and efficiency
The migration enabled Burrards system engineers to retain existing field wiring terminations, system enclosures and power supplies. Their new system delivers a major leap in functionality and ease of use in startup, runup, rundown and runback sequences. Huitt Manering, Principal Engineer and Task Manager, said, Invensys developed a new discrete I/O module to meet our requirements, and the result was a well-designed card that was delivered on time for our first installation. Our BMS migration from Bailey Symphony to the Foxboro I/A Series Distributed Control System went very smoothly. Checkout of the new BMS was substantially complete within three days as compared to approximately three weeks for the initial Bailey BMS commissioning.

Foxboro Distributed Control System - I/A Series Foxboro Measurement & Instruments

Burrard operations personnel report the new I/A Series System is delivering levels of control and efficiency higher than they have ever experienced before.

This document was realized thanks to the support of: BC Hydro 92

INDUSTRY: POWER

CM European Power Slovakia s.r.o.

www.cmep.sk

An industrial power plant upgraded to face new market challenges, efficiency and environmental standards
Goals Power plant modernization with construction of two new boilers and construction of a new circulation centre for cooling water and related activities. Increase of the installed capacity of the heating plant from the 114 MW to 169 MW Reduction of sulphur dioxide emissions of approximately 70% Challenges Power supply demand growth by 40% High availability request to secure continuous processes in refining and petrochemical production New environmental project: Flue gas desulphurization unit Solutions and Products Foxboro Distributed Control System, I/A series Version 8.4.3 Results Heating capacity increased by 30% Hi-availability Power generation increase 40% Sulphur dioxide emissions reduced by 70% Flue gas emissions kept below the limits Real-time production data available non-stop for evaluation

93

Power
CM European Power Slovakia s.r.o. is a power generation and heating plant owned by the Czech energy corporation CEZ, CM European Power Internation BV and Slovnaft a.s. The power plant is built on the premises of the MOL Group Refinery Slovnaft in Bratislava, Slovakia, providing steam and electricity to the refinery and supplying its production surpluses to the outside grid. SLOVNAFT a.s., based in Bratislava is a refinery with annual processing capacity of 5,5 6 million ton. The Slovnaft companys core business is production, warehousing, wholesale, retail sales and distribution of fuels and other products of hydrocarbon processing.

Foxboro Distributed Control System, I/A series Version 8.4.3

and construction of a new circulation centre for cooling water and related activities. The installed capacity of the heating plant should thus increase from the current 114 MW to 169 MW and the generated power should fully cover Slovnafts energy consumption. The plan also included a sulphur recovery unit to secure reduction of sulphur dioxide emissions by approximately 70 %.

Let the modernization begin

The project begun with an overall assessment of requirements placed on the control system to be installed. First considerations dealt with combining Foxboros modern electronic controllers with Expert Adaptive Control Tuning (EXACT). As this solution was not flexible enough, Invensys suggested the customer to go for the new I/A Distributed Control System (DCS). Projected budget allowed control system modernization on the first two revamped boilers K7 and K8. With ongoing time, project management decided to install the I/A DCS system on all reconstructed boilers and other equipment, step by step. The old pneumatic panel in the Control Room was decommissioned and the entire plant control, with its numerous local Control Rooms, was moved to one single Central Control Room. In the next phases of the power plant modernization project, all boilers were revamped. In 1997, a new boiler of 350 t/h performance was built instead of 2 old boilers, each producing 120 t/h of steam. Other boilers (K1, K2, K7 and K8) followed, they were equipped with new burners and flue gas dust emission was resolved by installing electrostatic precipitators. The DCS was continuously extended

Redefining demand for industrial power generation

From the start of its operation in 1957 the Slovnaft refinery had to go undergo several makeovers having an immediate influence on its power supply. Slovnaft Power Plant was built in several phases to feed the refinery with heat and electricity. At that moment the Power Plant was equipped with 5 boilers, with total capacity 740 ton per hour(t/h) and 4 generators with a total power supply of 114 MW. Along with standard oils and natural gas also non-standard heavy oils were burnt in the plant. The measurement and control system in 1986 was pneumatic and had many constraints, outdated analog electronic system included. With Slovakia joining the EU and Slovnaft becoming an integral part of the MOL Group in 2004, the management was facing a new challenge of a much larger and more sophisticated market combined with growing ambitions of a new corporate owner. The demand for reliable power supply grew significantly. To cover this demand Czech energy firm CEZ was invited to join a strategic partnership on the power plant modernization project. By the time the modernization project started in 2009. Due to new circumstances higher emission standards and the skyrocketing energy resource prices, the ineffective energy generation presented a serious threat to the business. The Power plant modernization plan projected construction of two new boilers, each with an overall steam output of 160 t/h, a new 60 MW turbogenerator
94

Power
throughout the entire duration of the project, which took several years to finish. The system was upgraded to MESH and I/A version 8.4.2. HIMA, Allan Bradley and Siemens PLC systems were all running under the I/A system, fully integrated. The installed I/A system had approximately 5000 I/Os and the PLCs had over 15000 I/Os. Invensys Operations Management provided maintenance support and ongoing service. In 2009, Invensys participated on the Flue Gas Desulphurization Unit project and TPP Revamp (two new boilers, one new turbo generator and new cooling water circulation centre). This was all possible due to the previous successful upgrade of the system, which was then ready to be improved with the implementation of new technology. The modernization project resulted in the system growing further and to fitting a few more thousands I/Os in addition to 25000 existing ones. In the near future, a Triconex Emergency Shutdown (ESD) system will be implemented to resolve the last maintenance constraint - a total shut down.

Foxboro Distributed Control System, I/A series Version 8.4.3

Shift to a new era. Delivered.

Slovnaft refinery is supplied with energy a power plant running on a robust and stable system. The burning process is optimized and all flue gas emissions are below the allowed limits. The new Central Control Room became the heart of the power plant enabling our customer to employ fewer operators. Real-time production data is available non-stop to ERP and business intelligence systems for evaluation. The system is entirely integrated with all components supplied by different OEM manufacturers and the corporate IT infrastructure. New issues can be easily traced and evaluated, the heat and energy generation effectiveness continuously improved and emissions further reduced. Operators can proactively maintain and improve the power plant operation.

This document was realized thanks to the support of: CM European Power Slovakia s.r.o. 95

INDUSTRY: POWER

China Huaneng Group

www.chng.com.cn

Invensys Operations Management has been an important partner, offering us a cost-effective process control solution and has helped to sharpen our competitive edge.
Mr. Jinjian Operations

China Huaneng Group Powers up for Growth

Goals Build a power plant in the Anhui Province to service its high commercial and industrial energy demands. Challenges In light of Chinas rapid economic growth, there has been inadequate construction of power plants, resulting in shortages. Rapid expansion in capacity is required to service demands and avoid additional shortages. Connect thousands of stations at data speeds up to 1GB between switches. Solutions and Products Foxboro Distributed Control System - I/A Series Foxboro Mesh Network Results The plant reduced the power shortage risks in the Anhui Province and has helped accelerate the development of its economy. The digital control system reliably monitors and controls the power plants 19,000 I/O points, production and process optimization. The fault-tolerant system design provides continuous and reliable power to the province. The more advanced control system improved equipment and unit performance

96

Power
Chaohu, China In 1978, after years of state
control, the government of China embarked on a successful program of economic reform. As Chinas economy grew, the Chinese workforce slowly began to evolve. Prior to the 1978 reforms, nearly four in five Chinese worked in agriculture; by 1994, the ratio was one in two. Economic growth and the changing demographic of the Chinese worker have gone a long way to create unprecedented demand for power and electricity. In 2006, Chinas electricity demand grew by 14% over the previous year, while installed capacity increased by approximately 100,000 Megawatts (MW) to reach 622,000 MW, a 20.3% increase over the previous year. Looking ahead, the growth in power demand is expected to remain strong. Unfortunately, power plant construction rates have been unable to keep pace with the growing demand for electricity. With power plants in 23 provinces, China Huaneng Group (CHNG) had already supplied more than 70,000MW of electricity by 2007, making it the largest power generator in China. With a market share of 10% of national installed capacity, CHNG is still expanding extensively. In accordance with the national economic development plan, Chinas industry policies and the market demand, CHNG has identified its development strategy that by the year 2010, it will increase its generation capacity to 80 Gigawatts (GW), becoming one of the worlds top 500 power companies. To meet the ever-growing power needs in China, CHNG is accelerating its market expansion plans. The new Huaneng Chaohu power plant is its first digitally automated plant. CHNG has chosen Invensys Operations Management, one of the worlds leading names in the automation industry to provide a range of advanced control and safety solutions services.

Foxboro Distributed Control System - I/A Series, Foxboro Mesh Network

construction is divided into two phases with the first two units completed in 2008. The plant is located in Chaohu City, Anhui province. This region is enjoying the most vigorous economic growth in China and, therefore, the highest demand for power. The goal of this new plant is to not only reduce the risk of power shortages, but to facilitate the economic growth of the province. In order to achieve these goals, CHNG required a partner who could effectively implement an automation solution under an aggressive timeframe while keeping an eye on safety. To do so, CHNG forged a mutually beneficial and strategic relationship with Invensys. Invensys consultative service, advanced technology and customer-centric solution proved to be a perfect fit. Invensys provides a reliable and advanced automation solution that enables a real-time convergence of plant operations and enterprise performance.

Overcoming Obstacles
More than just a product-provider, Invensys was a strategic partner to CHNG. As a global technology, software and consulting firm leading significant change in process manufacturing, plant optimization, business operations and enterprise performance, Invensys supplied CHNG an integrated automation consulting service backed by critical technical support and training. Invensys critical insight helped CHNG to maximize their return of assets through balancing the availability and utilization of equipment, energy, and fuel optimization.

A Bright Road Ahead

CHNGs Huaneng Chaohu power plant is a new, technologically advanced, digital power plant that is specially designed to house four supercritical generating units, each with a capacity of 600 MW. The
97

Power
We are very pleased with Invensys successful process control implementation as this is the first digital power plant for CHNG. Invensys has been an important partner, offering us a costeffective process control solution and has helped to sharpen our competitive edge, said Mr. Jinjian from CHNGs Operations Department. The fast data communication in real-time and the systems open architecture helps to preserve CHNGs original investment. This solution included an advanced Foxboro I/A Series Distributed Control System of more than 19,000 I/O points. It was used to control the new plants boilers, turbines and generators. Subsystem applications included Data Acquisition System (DAS), Furnace Safety Supervisory System (FSSS), Boiler and Turbine Sequence Control System (SCS), Turbine Digital Electro-Hydraulic (DEH) control system, Feed Water Pump Mechanical ElectroHydraulic (MEH) control system, and Environmental Control Systems (ECS). Dedicated to digital communication effectiveness, Foxboro I/A Series Distributed Control System used a 1 Gigabyte (GB) Mesh network that provided highavailability and self-healing network performance. Moreover, Invensys supplied a general interface, which could communicate with other systems equipped with Modbus, Profibus and Hart protocol. This open system revolutionized how Invensys sold, delivered and serviced its clients, exceeding even CHNGs automation and information needs.

Foxboro Distributed Control System - I/A Series, Foxboro Mesh Network

This best-in-class approach involving superior technology, reliable and accurate information was implemented enterprise-wide. The success of Phase I has been applauded by CHNG. Invensys highperformance culture coupled with the unified project implementation team resulted in the successful implementation. The results are impressive. Invensys provided a fault-tolerant system design which extended unit availability, advanced control that improved equipment and unit performance and control optimization that improved unit and station performance. Overall installation costs were reduced and the open architecture preserved CHNGs initial hardware investment. Working together, Invensys and CHNG are paving the way to a brighter future for China.

A Brighter Future
By the end of August 2008, Phase I of this power plant project had passed successfully through 168 stringent tests. This resounding success demonstrated the ease and reliability of the Invensys solution.

This document was realized thanks to the support of: China Huaneng Group 98

INDUSTRY: POWER

ESKOM
www.eskom.co.za

Our primary decision was that we wanted the new system to be based on Wonderwares Historian and InTouch HMI/SCADA ... the choice of other elements in the implementation would be influenced by their degree of compatibility with that platform.
Abdul Gaffaar Hoosain, Senior Advisor for ESKOM Peaking Generation

Eskom Peakings power stations now more ready than ever with a little help from Invensys
Goals Upgrade control systems of peak-demand power stations to the latest technology Rapid determination of the root cause of failures Remote control of stations from head office Challenges Uninterrupted operation in mission-critical support of national grid Solutions and Products Wonderware InTouch HMI Wonderware Historian Software Wonderware Historian Client Results Successful upgrading of mission-critical power stations Enthusiastic response from operations, maintenance and engineering Enhanced in-house skill set Ability to implement any enhancements requested after the upgrade

99

Power
Acacia Power Station is situated on the outskirts of Cape Town in the Western Cape and Port Rex power station at East London in the Eastern Cape. Each station has three 57MW gas turbine generator units where each unit is a twin-pack FT4 Pratt and Whitney Gas Generator Set incorporating turbines that are similar to Boeing 707 engines. The result is that each of these stations can generate a total of 171MW that can be channelled to the national grid at a moments notice. The Port Rex power station is at the end of a very long transmission line and its main purpose is to stabilise the voltage on that line by running in what is known as synchronous condenser mode for most of the time and only switching over to its generating mode on demand. Acacia also provides line stabilisation but its most important role is as off-site back-up electrical supply to Koeberg Nuclear Power Station, an important licensing requirement. If Acacia does not have sufficient generating capacity and redundancy available, Koeberg has to be shut down, so it carries a huge responsibility. Both Acacia and Port Rex can be operated by remote control from Eskoms National Control Centre in Germiston to provide back-up and black-start capability (the ability to start operating without the need for external power). Since their commissioning in 1976, the control systems for Acacia and Port Rex had remained largely untouched and consisted of hardwired relay logic and analogue power governors which had since become obsolete. Electrical protection was implemented through electromechanical relays and this was simply no longer good enough as Senior Advisor for ESKOM Peaking Generation, Abdul Gaffaar Hoosain explains.

Wonderware InTouch HMI, Wonderware Historian Software, Wonderware Historian Client

make sure that the conditions which caused it are not only understood, but are not repeated in the future. To this end, SCADA systems can contribute enormously to our knowledge of the cause of incidents. The obsolescence of the control systems, coupled with the very limited availability of expert knowledge to keep them running as well as the absence of historical plant information (i.e. for troubleshooting) and the impossibility of remote engineering support prompted ESKOM to review its options and in 2007, the company decided that an upgrade of these critical resources was in order. If there was ever a time to be ready for peak power demands, it was during the 2010 World Cup held in the heart of a South African winter. Thankfully, ESKOMs Acacia and Port Rex gas turbine power stations were ready for action well ahead of schedule thanks to a rigorous upgrade programme.

How it was done

We contacted the OEMs that installed the original system and they indicated that they were able to implement what we wanted and offered solutions based on a number of alternative options, says Hoosain. Our primary decision was that we wanted the new system to be based on Wonderwares

For example, when a plant is brought on-line, which often needs to happen in just a couple of minutes (in fact, it takes just 4 minutes for either power station to reach full-load power) it is vital to avoid trips or mode-change failures as this would defeat the rapid response requirement. However, if the system does fail, it is vital that we determine the root cause of that failure as soon Figure 1: System overview of one of the power stations as seen on an InTouch display. as possible and, more importantly,
100

Power

Wonderware InTouch HMI, Wonderware Historian Software, Wonderware Historian Client

Historian and InTouch HMI. Our good relationship and experiences with Wonderware as well as the excellent level of support and training we have received in the past meant that we had adopted a specific platform and the choice Figure 3: InTouch screens showing the operational overview, electrical mimic and the vibration of other elements in the monitoring system. implementation would be parties involved in this project collaborated to help influenced by their degree of us achieve our information goals, adds Hoosain. compatibility with that platform. The OEM was appointed as the responsible party for the building and factory testing the entire control system which was initially implemented at their facility in Colorado. The OEM was also to supply ESKOM with a commissioning engineer during the installation phase of the project. Figure 1 shows an overview of the system at any one of the power stations where the switches, controllers, PLCs, protection relays, vibration monitors, InTouch HMIs and the Historian all get their timing information from the TimeSync Server (top right). The fault-tolerant ring network (shown in blue) will continue operating should any of its segments fail thereby maintaining communications between the InTouch HMI and other segments of the network. ESKOMs responsibilities included the design and installation of the Ethernet Network and time synchronisation system as well as the design of the protection system and implementing the historian. ESKOM would also provide Wonderware software support during commissioning and would be responsible for the installation of the entire delivered system. The adoption of the IEC-61850 OPC interface software standard (figure 2) allowed us to have far more control over the information we wanted and all The supplied HMI application was based on an old version of InTouch and this was immediately upgraded to the current InTouch version, which involved creating new graphics and implementing standards. Perhaps the most important development was making the application unitindependent, says Hoosain. This meant removing all the hard-coded unit-specific details and creating a standardised environment that would accommodate all the individual units in both Acacia and Port Rex. The implementation of the new system came complete with its own set of challenges ranging from getting operator buy-in to the fact that, in Acacias case, only one unit was allowed to be unavailable at any time without jeopardising Koebergs status.

Benefits
Successful upgrading of mission-critical power stations through the installation of the most up-todate SCADA facilities without interruption to service or the black start capabilities of either site Enthusiastic response from operations, maintenance and engineering Enhanced in-house skill set Ability to implement any enhancements requested after the upgrade

Conclusion
Information is obviously the key to improved control and when that control can influence the way of life of millions, then it better be applied with great care. ESKOMs Acacia and Port Rex power stations, when compared to their coal and nuclear colleagues, are diminutive but equally vital to contributing to a way of life that none of us can do without.
This document was realized thanks to the support of: ESKOM 101

Figure 2: The migration from a proprietary to an open approach of information delivery helped put ESKOM in control of its own information needs

INDUSTRY: POWER

Ontario Power Generation

www.opg.com

By choosing to go with Invensys, we made the decision to utilize their products for future modifications or upgrades... We expect that it will also ensure a high degree of reliability in the future.
Mike Considine Project Leader

Invensys Operations Management solution helps Ontario Power Generation revitalize Nanticoke plant
Goals Complete a controls integration and performance improvement project to help the plant meet the energy demands of its customers todayand position it to meet future demands Challenges Improve energy efficiency, lower product costs, and ensure cleaner electricity production while meeting customers energy demands Solutions and Products Foxboro Distributed Control System - I/A Series Results Assist in providing continuous power, producing 20 to 24 billion kilowatt-hours (kWh) of energy to run nearly 2.5 million households for a full year. Increase boiler efficiency and responsiveness Reduce maintenance and fuel costs Reduce emissions through the use of advanced control Provide the responsiveness to market demands that Ontario Power Generation needs to compete effectively in its competitive environment Position OPG to meet future demands

102

Power
Ontario, Canada Ontario Power Generation
(OPG) is a major North American electricity generating company, based in Ontario, Canada, that operates a fleet of nuclear, hydroelectric, and fossil generating facilities. Each of these facilities along with its expanding portfolio of green power sources plays a unique role in meeting its customers energy needs. OPGs goal is to be a premier North American energy company, providing customers with reliable, clean, and competitively priced power while operating in a safe, open, and environmentally responsible manner. OPG supplies about 85 percent of all electricity consumed in Ontario through a portfolio of 80 efficient and relatively low cost generating stations. As electricity demands grow worldwide, energy providers must maintain highly efficient and modern facilities that can produce the energy their customers requireor risk losing the competitive battle. That explains why OPG focuses on continually improving its plants to improve energy efficiency, lower product costs and ensure cleaner electricity production. That focus has resulted in a recent revitalization project at its Nanticoke Generating Station in Ontario, Canada. OPGs Nanticoke Generating Station is one of the largest coal-burning stations in North America. Its eight generating units annually produce approximately 20 to 24 billion kilowatt-hours (kWh), which represents enough electricity to run nearly 2.5 million households for a full year. In 2000, legacy management turned to Invensys to help them complete a controls integration and performance improvement project that would help the plant meet the energy demands of its customers todayand position it to meet future demands. Mike Considine, Project Leader, said, The legacy control systems at Nanticoke were designed and installed in the early 1970s and were no longer supported by the vendor, which was a great concern to us. In addition, the control systems had limited or no expansion capability. We began experiencing deterioration in reliability, and we had limited diagnostics capabilities, which delayed our ability to make necessary repairs. So we knew we had to make significant improvements in our control systems.

Foxboro Distributed Control System - I/A Series

Hydro. But with this project, Invensys went a step further signing a corporate alliance agreement that ensures OPG will receive the support it needs to cost-effectively complete the control integration and performance improvement project, which will be phased in over a five-year period. We originally requested quotes from a few vendors, with the intent of choosing the vendor that offered hardware maturity, reliability, backward compatibility, and a mature and proven software design. We visited other utilities that used Foxboro control systems and were impressed with their excellent track record, said Considine. Invensys is moving forward aggressively on this project, which will entail replacing the plants current control systems with a Foxboro I/A Series Distributed Control System on all eight units. In fact, Invensys delivered and installed 4,000 points of control in a nine-month period an accomplishment that is virtually unheard of in the industry. Invensys also supplied new operator control interfaces, advanced control packages, engineering, integration, installation, and commissioning services. Considine said, While this project was justified as a sustaining effort to deal with obsolescence, we also wanted to provide a solid base for future technological/operating improvements like artificial intelligence, optimized soot blowing and smart annunciation. By choosing to go with Invensys, we made the decision to utilize their products for future modifications or upgrades that will allow us to avoid a mix of technologies and black box interfaces with different systems. This will simplify our training and help us avoid the need for employing a host of experts that understand different systems. We expect that it will also ensure a high degree of reliability in the future.

Addressing Future Needs

When completed, the project improvements are expected to help increase boiler efficiency and responsiveness, enhance productivity, reduce maintenance and fuel costs, and reduce emissions using advanced controls. This will provide the responsiveness to market demands that OPG needs to compete effectively in its competitive environment.
This document was realized thanks to the support of: Ontario Power Generation 103

Delivering a Cost-Effective Solution

For 40 years, Invensys has provided solutions to OPG and its predecessor company, Ontario

INDUSTRY: POWER

RK Powergen

The Foxboro PAC System is perfect for RK Powergen because it provides the power plant with a distributed solution that is effective, redundant and just the right size and price for its control requirement.
Terry Minns Director PAC Systems Portfolio Invensys Operations Management

Invensys Solution Helps Provide Clean, Reliable Electricity in India

Goals Support a biomass power plant that would generate clean power in an area that previously had limited and unreliable electricity Automate plant operations to maximize efficiency and productivity while reducing downtime Facilitate accurate control and monitoring of plant equipment to ensure consistent output as well as safety and security. Provide a solution that can be easily expanded as energy demands increase Challenges The plant had to meet strict requirements for sustainability, environmental monitoring and safety while conserving operating costs The solution had to integrate various processes into one control solution that would encompass the entire plant Operators needed real-time data to accurately control power generation, steam production and chilled water distribution Solutions and Products Foxboro Programmable Automation Controller (PAC) System Results The plant provides electricity to area residents and has improved local agricultural and industrial opportunities Sustainability goals such as decreased air pollution, water conservation and optimized fuel consumption are being met through the solutions monitoring and control capabilities Operators can now view plant-wide processes in real-time, so they can react immediately and make changes to maintain power output and plan for maintenance The Foxboro PAC System simplifies the rapid addition of new devices through preconfigured and tested applications and plug-in modules

104

Power
Chennai, Tamil Nadu, India When RK
Powergen won the contract to build a new power plant in an area of India where the residents previously had very little electricity, choosing the right technology was critical. But even more importantly, the company committed to sustainability goals and to improving the social and economic well being in the region.

Foxboro Programmable Automation Controller (PAC) System

World-Class Process Control

In all energy-generation activities, ensuring control, safety and compliance is paramount. Thats why RK Powergen partnered with Invensys Operations Management to configure and install the powerful, yet flexible, Foxboro Programmable Automation Controller (PAC) System. With the Foxboro PAC System, the power plant benefits from a distributed control system that enables accurate monitoring and control. Without it, the plant would not be able to provide reliable power. Data from the boiler, tank farm and other control points is transmitted from plant subsystems to the PAC. Accurate control of these processes results in consistent, quality steam output, which optimizes fuel consumption. Another fundamental requirement is redundancy to ensure both high availability and safety. Operators can perform live replacement of processor modules within the Foxboro PAC System so that there is little or no interruption of plant operation. Additionally, the system compiles data and provides management with both real-time and historical information. With these reports, plant supervisors can make equipment and personnel adjustments to increase efficiency and productivity while reducing downtime.

Unique Sustainability Opportunities

Several features of the project were central to meeting RK Powergens multiple goals. The first was that biomass fuel is considered a zero-emissions power source, so the plant would not generate greenhouse gases. Next, it created new sources of work and income for local residents. Local wasteland trees like the mesquite tree and shrubs as well as husks such as tamarind, sunflower stalks and other trimmings would be burned to generate steam. These abundant solid waste resources were unused before the power plant was built. But now, collecting and selling them has become a reliable business and has enhanced local agricultural and industrial activities. Additionally, the plant uses air-cooled condensers rather than relying on water cooling. Water-cooled condensers are more typical for facilities of this type because they are initially less expensive. However, it was more important for this project to reduce environmental impact. The air-cooled condensers use 93% less water, conserving it for the use of the residents as well as for irrigation. The biomass power plant not only supplies clean power to the southern regional grid of India, but it also provides substantial employment to the local population and increases the income levels of the people, said Terry Minns, Director PAC Systems Portfolio at Invensys Operations Management.

Biomass Fuel Source - Mesquite

105

Power
Operator Ease
Engineers appreciate the Foxboro PAC Systems superb visualization components (HMI) with high resolution graphics that enables the engineers to control the plant better. With it, they get a complete picture of the power plant. On-screen views show boiler, turbine, steam, fuel and air systems with standardized graphics that are easy to learn and intuitive to understand. Operators can make changes quickly and no training is needed when they move from one system to another. The Foxboro PAC System not only gives a redundant and efficient control system, but the historian and visualization components also provide capabilities that allow the plant operators to perform better. This makes the plant more productive, said Minns. Maintenance of the plant is another important consideration. The live data and historical reports that come from the Foxboro PAC System enables operators to schedule maintenance as well as to recognize possible problem situations and correct them before they impact productivity or the output of electricity.

Foxboro Programmable Automation Controller (PAC) System

Biomass Fuel Source - Tamarind Husks

it continues to provide one source for all plant data. As development continues in southern India, the need for more electricity will grow. Industrial customers will require it, and it also will be essential for all residents to have access to power. Fortunately, the RK Powergen plant has been designed to meet these diverse needs, while continuing to generate reliable, clean and environmentally sensitive power.

Planning for More Power

The solution also makes configuration and development for plant expansions rapid and easy. When applications are added, they are deployed across the network with simple-to-implement distribution features and standardized algorithms that eliminate the need to duplicate data. These additions are integrated into the solution so that

This document was realized thanks to the support of: RK Powergen

106

INDUSTRY: POWER

Southern Mississippi Electric Power Association

www.smepa.coop

Depending on the load, potential heat rate improvements up to 1.5% are expected. This benefit will provide a project payback of less than one year.

Optimization System Increases Profitability of Southern Mississippi Electric Power Association

Goals Improve the performance of the Riley turbofired units Improve the mills impact on the energy efficiency of the furnace Lower NOx emissions Challenges Improve heat rate and boiler efficiency while maintaining low NOx emissions Solutions and Products SimSci-Esscor Connoisseur Online Optimization Results Expected heat rate improvements of 1.5% , providing a project payback of less than one year Expert System at soot blower maximizes heat transfer area in the furnace Model Predictive Control provides increases boiler efficiency while maintaining steam temperatures and remaining within NOx specifications

107

Power
Hattiesburg, Mississippi The Southern
Mississippi Electric Power Association (SMEPA) uses the Model Predictive and Neural Network Based controller, Connoisseur to improve efficiency at their Hattiesburg station. At SMEPAs R.D. Morrow Generating Station, improving heat rate while maintaining low NOx emissions was extremely important. To this end, a supervisory control system was installed over the modern DCS to improve performance for these Riley turbo-fired units with ball mills. Both furnace and ball mill controls were optimized with coordinated multivariable control. Heat rate improvements were achieved through reduced dry gas losses and lower loss-on-ignition (LOI). In addition, the improved mill regulation increased maximum generation capability, particularly for lower grade coal.

SimSci-Esscor Connoisseur Online Optimization

The objective of the Optimizer is to determine the most profitable operating point for the boiler and mills, as defined by a set of values for the controlled and manipulated variables in the process model. To drive the process to this point, the optimizer passes these values to the controller the optimum values of the controlled variables (CVs) become set points for the CVs in the controller and the optimum values for the manipulated variables (MVs) become targets for the MVs in the controller. An Expert System Soot Blower Advisory supplements the heat rate benefits of applying Connoisseur by suggesting which blower to activate in order to maximize heat transfer area in the furnace. Ball mill optimization improves the grind in the mill, lowers LOI and improves the mills impact on the energy efficiency of the furnace. Connoisseur runs in a separate platform so that the security of the existing DCS is not compromised. The application at SMEPA is designed to revert to the DCS based control seamlessly, with minimum disruption to the process, in case the operator decides to take over control.

An Optimizer is to determine the most profitable operating point

The SMEPA generating plant in Hattiesburg utilizes two parallel boiler-turbine units with a capacity of 204 MW at 2400 psig. The Riley Stoker Corporation manufactures each steam generator unit. Each has a turbo-furnace design with balanced draft operation, and is front and rear fired. Nominal steam conditions at HP turbine inlet are 2400 psig at 1005 DEGF and 1000 DEGF at the IP turbine inlet. Maximum continuous steam rate is 1,575,000 lhs/hr. The fuel is pulverized coal from three Riley doubleend ball tube mills fed by six Stock Gravimetric feeders. There are twelve Riley diffusion burners. Two forced-draft fans and two induced-draft fans deliver combustion air and provide balanced furnace draft to the scrubber. Dampers at each fan regulate airflow. One recirculation fan returns flue gas to the bottom of the furnace combustion zone, also regulated by a fan damper.

An Effective Technology for Increasing Boiler Efficiency

For this application, Model Predictive Control has provided an effective technology for increasing boiler efficiency while maintaining steam temperatures and remaining within NOx specifications. Operator acceptance has been excellent due to the stable performance of the system and the smooth interface with the existing ARC controls on the boiler. Depending on the load, potential heat rate improvements up to 1.5% are expected. This benefit will provide a project payback of less than one year.

This document was realized thanks to the support of: Southern Mississippi Electric Power Association 108

INDUSTRY: POWER

Tucson Electric Power Company

www.tucsonelectric.com

I cant believe how smoothly the actual unit startup went; especially with this complex interaction between Invensys Operations Management and Alstom.
Mike Puzzi Administrator for the DCS upgrade project

Tucson Electric Power upgrades with a Foxboro Solution

Goals Install new turbine control system that include overfire air, low NOx burners, and new hydraulic actuators for the turbine stop/ control valves Install new DCS and simulator to minimize errors and train employees on the system Challenges Upgrade the plant, identify and minimize control system errors that can delay the unit startup and return to service, without creating lost generation costs Solutions and Products Foxboro Distributed Control System - I/A Series Results Prevents lost generation costs calculated at $250,000 to $500,000 a day Helped provide continuous service to more than 375,000 customers in Southern Arizona Identified and fixed over 350 errors before plant the plant even started up Reduced startup time by seven days due to the operators familiarity with the controls

109

Power
Tucson, Arizona Tucson Electric Power
Company (TEP), the principal subsidiary of UniSource Energy, serves more than 375,000 customers in Southern Arizona. TEP is the backbone to UniSource Energys success. In 2000, TEP exceeded $1 billion in revenues for the first time in its history. That same year, Tucson voters approved a 25-year extension of TEPs franchise agreement, launching the next chapter of a productive relationship that began more than 110 years ago. Today, UniSource Energy is parent to a growing family of energy companies serving more than 1.5 million Arizona residents. As TEP enters its third century of operations, it continues to discover innovative ways to provide safe, reliable energy to homes and businesses while maintaining its historic commitment to community service. The Tucson Electric Power (TEP) Springerville Station consists of two 380MW net combustion engineering drum boilers that are coal fired with an ABB steam turbine. Constructed in the early 1980s, the plant was still using the original Leeds and Northrup analog control system and ABB Turbotrol turbine control system, which was nearing obsolescence. Furthermore, the unit required an upgrade to include overfire air, low NOx burners, and new hydraulic actuators for the turbine stop/control valves in 2004.

Foxboro Distributed Control System - I/A Series

approaching retirement age, TEP selected Invensys to provide a high-fidelity simulator for operator training and detailed control system checkout prior to the unit coming back online. Invensys pioneered the Virtual Stimulation approach by simulating the control system using the FSIM Plus simulation of the Foxboro I/A Series Distributed Control System. This approach uses the actual I/A Series controller algorithms, man-machine interface, and DCS configuration tools to provide the most accurate representation of the control system. TEP now has the capability to move the controls and graphics back and forth between the simulator and control room, making the simulator a complete I&C workhorse. As the project unfolded, a unique challenge emerged. In order for the new Alstom turbine control valve actuators to be guaranteed, an Alstom turbine control system had to be part of the configuration. This led to questions about interfacing to the Foxboro I/A Series Distributed Control System, I/O, turbine protection, and operator controls. Using FSIM Plus, the project was modified to include a connection to GE Fanuc PLC 90-70 and 90-30 controllers, which ran the Alstom turbine control system programs. The simulator and DCS design went through concurrent development with major DCS loops tested and pre-tuned in the simulator. Feedback from operators using the simulator was then used to fine-tune graphics and make control function changes based on TEPs operating procedures.

Plant Upgrade Challenges

Like all major plant upgrades, there are inherent risks with the project. In this case, control system errors, even minor, could delay the unit startup and return to service. In extreme cases, control system errors could cause catastrophic equipment damage. Therefore, the decision to include control checkout on the simulator was justified with a simple economic analysis. Assuming lost generation costs of $250,000 to $500,000 a day, saving two to four days of outage time will pay for the cost of the simulator project. However, the benefits of the simulator do not end there. As the unit returns to service, the simulator will become an invaluable training tool.

Positive Results and Benefits

Simulator Factory Acceptance Testing identified and fixed over 350 errors before going into the plant. Chris Wallace, Simulator Project Manager, said, The majority of problems found were minor, such as graphics configuration errors, simple point misconnections. However, without the simulator, these errors would have been found during critical testing on the live unit. Even simple configuration errors take significant unplanned downtime to find and fix; especially in that high-pressure environment. The real value in the simulator was merging the Foxboro I/A Series Distributed Control System and Alstom control systems. Even though the running

Implementing the Solution

TEP selected a Foxboro I/A Series Distributed Control System for its new automation system. This new Distributed Control System (DCS) was a major shift from the current, bench-mounted analog control. With TEPs main operator workforce
110

Power
turbine and simulator were not connected, initiating the Alstom turbine using the simulator uncovered dozens of interfacing problems, saving valuable time and money. One error in particular could have caused repeated turbine trips or damage on startup as the initial control valve demand caused runaway turbine roll-up. The simulator saved at least one week of startup time due to the operators familiarity with the controls and advanced understanding of how they should interact with the unit, said Rex Brown, TEP Project Manager for DCS Retrofit Project.

Foxboro Distributed Control System - I/A Series

Furthermore, Plant Manager, Andy Hoekstra, commented that the simulator paid for itself due to the fact that his operators went through simulator training during their normal training cycle, and in addition, they all feel more confident about unit startups. As a result, TEP will experience fewer unit trips in the future now that operators fully understand how the unit and controls react using Invensys Intelligent Runbacks. The simulator was on site for six months of testing before the new DCS was put into Unit 1. As a result, TEP uncovered over 300 necessary changes and will now use the simulator for more than just training.

This document was realized thanks to the support of: Tucson Electric Power Company 111

INDUSTRY: POWER

Vectren Corporation
www.vectren.com

Being able to track info about planned and unplanned work was one of the key performance indicators we were trying to improve on. Because of the way Avantis interfaces with the workforce timetracking program, we are able to get to this data much more easily.
David Reherman Reliability Engineer

Avantis assists Vectren to attain new heights in Maintenance, Planning and Cost Tracking
Goals Eliminate inefficiencies in scheduling maintenance Track completed work Reduce operations, maintenance, and capital spending Challenges Reduce overall operations, maintenance and capital spending, while maintaining high availability within plants and continuously and efficiently serving customers. Solutions and Products Avantis Enterprise Asset Management Software Avantis InRIM Results Supplies continuous and efficient power to two-thirds of Indiana and 16 counties in Ohio Enabled management to capture and analyze data about maintenance work. Efficiently tracks 6,000 unique assets and more than 33,000 individual spare parts, keeping track of work orders and labor time Ascertains key performance indicators and benchmarks throughout the maintenance operation

112

Power
Evansville, Indiana For those in the
basketball-crazy Hoosier state and surrounding areas, Vectren Resources is what you might call a power forward. From its base in Evansville, Indiana, on the extreme southern tip of the state, this $2 billion utility provides electricity or natural gas to nearly two-thirds of Indiana and 16 counties in Ohio. A merger of two companies, Vectren today plays an integral part in the dayto-day lives of more than one million energy users.

Avantis Enterprise Asset Management Software, Avantis InRIM

Streamlining the Maintenance Process

The process of revamping maintenance operations at Vectrens electrical power facilities began in mid-1999 with an evaluation of procedures. Complicating matters was the fact that data, labor, and parts were all managed in two separate locations, about 30 miles apart in the Evansville area. The A.B. Brown and F.B. Culley facilities combined use more than 6,000 unique assets and more than 33,000 individual spare parts. Changing the management procedures for these assets and parts could have a potentially significant impact on the daily work activities for some 225 maintenance personnel at the two plants. According to company officials, the evaluation process was driven primarily by the need to streamline maintenance work and equipment processes rather than by any explicit requirements for software functionality. We werent necessarily looking to switch from our legacy Champs software, said Gary McCarty, Maintenance Supervisor. It was really more a case of asking ourselves how we could develop a maintenance model that would help us drive down the cost of doing unplanned work, and allow us to improve the ratio of planned to unplanned work. At the end of the process, though, it did become clear that a new maintenance software solution was in order. The trick was to find a tool to help us do this without compromising the process. After evaluating several competing offerings, the Vectren management team selected the Avantis software and Avantis InRIM (Industrial Rapid Implementation Methodology). One important

Customer Challenge
Vectren operates two power plants, which together use five coal-fired units and six gas turbines to produce about 1,400 megawatts of generating capacity. Keeping these plants running continuously and efficiently is vital to Vectrens mission to serve customers. Vectren is also in the wholesale market for power sales where availability has tremendous financial implications. David Reherman, Reliability Engineer, said, We invest in maintaining our plants to be sure that they are available when the demand calls for it. Our challenge is to reduce our overall operations, maintenance, and capital spending, while keeping the availability high. As a key part of its strategy for meeting this challenge, Vectren management set out to eliminate inefficiencies in scheduling maintenance, ordering parts and keeping track of completed work. It accomplished this with the help of Invensys Operations Management Avantis enterprise asset management software. Avantis gave Vectren an enterprise database that enabled management to capture and analyze data about the current and historical maintenance work. It also helped track the cost of maintaining any given piece of equipment, keeping track of work orders and labor time, and ascertaining key performance indicators and benchmarks throughout the maintenance operation.

113

Power
reason was the way in which the Avantis solution has enabled maintenance personnel to interface with other key programs notably Oracle for financial reporting, procurement and accountspayable and the companys workforce time and resource planning/utilization software. The Windows look and feel of the Avantis software also played into the decision. With all of the people we have working in this from janitors to mechanics to supervisors to planners to management the familiar Windows interface was a huge plus. There was not a lot of redevelopment of skill sets in learning to use it, said, Randy Simon, Manager of Technical Services, A.B. Brown facility. The ease of use also helped Vectren to implement one of the cornerstones of maintenance practice: the rapid acquisition of replacement parts. According to McCarty, Previously, we would buy a part, and it would just sort of disappear. Now, using Avantis Purchase Item Catalog feature, its easy to find that part, to purchase it if it is not in our stock, and to keep track of it afterward.

Avantis Enterprise Asset Management Software, Avantis InRIM

A Benchmark for Continuous Improvement

Measuring the benefits of preventive maintenance is a long-term proposition, but the Vectren team is already gathering information that will help improve operations continuously. We publish what are called Avantis Key Performance Indicators every two months. These look at work task backlog trends. They track the priority of work completed, tell us whether it was an emergency, a break-in, or scheduled. They tell us whether the work was preventive or corrective. We also get the top ten system costs year-to-date and top ten entity costs year-to-date that help us determine how to spend our O&M (operations and maintenance) and capital dollars, said Reherman. For example, with this type of information, Vectren knows that since July, it completed 12,000 work tasks, 7,300 of which were corrective repairs and 3,500 were preventive maintenance work tasks. In addition, employees completed 250 safety work orders. In the future, Vectren will receive comparable benchmark information, which will guide continuous improvement of its operations and services. Vectren will be better equipped for more preventive maintenance, scheduling, or planning work ahead of time and will not be driven by an emergency, break-in, or a schedule-disrupting activity. Avantis software also helps track progress of metrics such as productivity of workforce or reasons for delays on work orders.

Breakthrough Repair and Labor Tracking

The Avantis solution also helped the Vectren plants achieve a breakthrough in tracking data at the work-order level. Previously, separating expenditure data from information about what planned and unplanned work was being done was the source of considerable frustration. Two other partners were key to Vectrens success. I.M.A. Ltd., an inventory management firm from Ontario, Canada, renamed and renumbered every part that Vectren uses, making it much easier to access and order both stock and nonstock items. Performance Consulting Associates (PCA) of Atlanta conducted the asset reliability improvement initiative. This combined assessment and implementation project stands as an excellent example of the kind of teamwork needed to make this kind of initiative a success, with Performance Consulting Associates, I.M.A. Ltd., Avantis and Vectren all working together to provide the optimal solution for the Indiana utility.

114

Power
As planners and supervisors, we want to provide to the workforce the means to efficiently perform the task at hand by giving them all of the resources and information needed to do the job. Avantis facilitates this and allows us to track what work was completed, the costs involved, failure analysis, and even statistical information for us to do this job smarter if it shows up again. As the reliability engineer, I will be looking at and doing failure analysis using Avantis to improve equipment performance and life expectancy, said David Reherman, Reliability Engineer. The success at Vectren is a strong testimony to the value of approaching asset management

Avantis Enterprise Asset Management Software, Avantis InRIM

solutions methodically with adequate up-front planning, collaboration, and the right software solutions. Vectren has completed and effectively transformed the maintenance operation at its electrical facilities. Its 225 maintenance workers have changed the way they work and are now actively engaged in the process of continuous improvement. They have better information about what work they have completed, what needs to be done, and what can be done to make the process better. The result will be lower cost to Vectren with greater availability that will pay dividends to the Indiana and Ohio customers that Vectren serves.

This document was realized thanks to the support of: Vectren Corporation 115

INDUSTRY: POWER

Endesa
www.endesa.es

Thanks to Wonderware technology, we are efficiently managing available resources, have reduced the costs of the ship/port interface, improved the ratios of unloading/ optimisation of times and have greater flexibility in communications due to the introduction of different interlocutors in the control platform, among many other benefits.
Ana Beln Paz Endesa Ferrol Harbour Terminal Manager

Endesa responds to the challenges of the energy market by optimising its logistics processes with Wonderware
Goals To optimise the logistics process of the coal terminals owned by the company in Spain. To create a technological environment to automate processes, gather real-time information and analyse the activity at terminals in order to achieve greater operational efficiency. Challenges The process to optimise was being performed by Excel spreadsheets, which meant that the project included an element of cultural management as well as the technological complexity it involved. The particularity of the logistics industry at ports and the characteristics of the implemented process meant the need to have a system that could link up to a variety of devices and performed activities and be suitable for various types of users. The remote location of the facilities required a web-based development environment for easy deployment. Solutions and Products ArchestrA System Platform Wonderware Historian Wonderware InTouch Results Endesa now has a fully automated logistics process in which reliable, real-time information is gathered. The system helps to analyse the reasons for any inefficiencies and deviations by promoting constant optimisation of activities with a consequent reduction in costs. All the agents involved in the process have easy access to the information they need in a web-based environment, thus being able to become directly involved in the improvement process that Endesa is implementing.

116

Power
Madrid, Spain. Endesa is the largest electric utility
company in Spain and the leading private electricity company in Latin America, as well as also having a presence in the Mediterranean area of Europe. As one of the major Spanish listed companies, the multinational is firmly committed to growth as a way of bringing value to the company and its investors. Consequently, it has approved a strategic plan for the period 2011-2015 that includes investments tailored to market conditions, allocating 53% to Spain, Portugal and others and 47% to Latin America. In addition to its services of generating, distributing and marketing electricity, the Spanish natural gas market is also an important area of its development. With a socially responsible vocation, as well as being efficient, competitive and committed to safety, health and the environment, the company applies a strict process of continuous improvement and innovation in order to achieve the highest quality products and services based on criteria of profitability. In this context, process management linked to the generation of electricity is one of the areas in which the company has been involved.

ArchestrA System Platform, Wonderware Historian, Wonderware InTouch

Responding to Environmental Challenges

The production of electricity from thermoelectric power plants, corresponding to 35% of Endesas total electricity generation, uses coal as the raw material for the process. Despite positive developments in the extraction of this fossil fuel throughout the world, which currently stands at around seven billion tons, transportation of this mineral is becoming increasingly complex. As of July 2008, the price of coal rose by 100% over the same period last year and transport costs increased to 70% of the total price of the product. The rise in imports by China and India, existing bottlenecks in port infrastructures and the low availability of bulk carriers are among some of the reasons that have driven up the prices of this mineral. Based on a thorough analysis of the situation, Endesa anticipated by evaluating that one of the factors that could contribute to offset the high costs of this raw material was to minimise and optimise times and operations at ports: Reducing the costs of the process between the port and ship means improving the efficiency of the entire logistics chain of cargo handling and

transhipment, explains Intermark Technologies, the systems integrator responsible for the design and deployment of the project. Increasing the efficiency of loading and unloading results in a shorter stay for ships at port, thus allowing for a greater number of annual trips and, ultimately, increased operational efficiency by reducing the transport cycle times. Using this as a starting point, the multinational identified other areas in which it was possible to improve the process: A detailed analysis of bottlenecks, which produce deviations in unloading performance compared to theoretical forecasts, would lead to eliminating these, thus minimising the time spent in port and optimising operational costs, explains the team involved in the project. They also point out that Endesa understood from the beginning the importance of having available all operational information in real time: Immediate availability of data in the event of incidents occurring would allow for rapid decision-making, thus decreasing any non-productive times. Once the improvements paths were identified and the state of the process used was checked based on Excel spreadsheets from work reports, archive folders for historical data and other various informational elements the decision was made for an ambitious project entitled Ulysses that would radically change the way of implementing control of the logistics activity of receiving the coal and helping both local management at each terminal and global management in terms of all facilities. Ulysses was designed as a computerised integrated management system for the coal terminals that Endesa has to supply its thermal power plants, according to Intermark Technologies. Some of its main objectives were to reduce and optimise the

117

Power
costs of logistics operations, improve performance of unloading coal, optimise the management of the facility by analysing the length of stay in port, facilitate coordination between the different internal and external agents involved in the procurement process and provide immediate availability of data from the process, thus promoting decision-making in real time and, consequently, decreasing nonproductive times. The magnitude of the project to be implemented which would begin with the Ferrol port terminal, with the idea of extending it to Endesas other port terminals and the information requirements that the energy company established for the new system led to the need to search for a technology supplier that was able to communicate with the multitude of devices in the loading terminals, handle multiple user profiles local, remote, internal and external and offer real-time information through a shared system for all involved. Wonderware conformed to these system requirements and also offered full analytical capabilities to comprehensively handle the optimisation process that had begun.

ArchestrA System Platform, Wonderware Historian, Wonderware InTouch

From Manual Management to a Fully Analytical Environment

As explained by Intermark Technology, the project was designed in three main stages based on the premise of leading to a turnkey system for Endesa. The complexity implied by the move from management based on information gathered by Excel spreadsheets to full automation led to the need to carry out an in-depth design process for the resulting technological architecture of Ulysses. This was how the first stage of defining function consisted of a detailed breakdown of each of the activities that were taking place at the terminal. Firstly, there was an analysis from the beginning to the end of the process chain of everything related to activity planning, in other words, unloading, lifting, shift work, calendar management, volume of material and calculation of forecasts, among other aspects. Next, attention was focused on everything related to the unloading process itself, analysing parameters such as types of cargo ships or the requirements of berths, and finally in relation to freight forwarding, with parameters such as the control of stock and space available. Once all the processes involved were identified, it was decided which indicators should be considered and gathered to ensure full monitoring and analysis of the activity. The key was to conduct a thorough study of informational needs to design a
118

technological architecture that would help achieve the goal of optimising the process, explain the project managers. The large number of inputs/ outputs offered by Wonderware technology, along with its networking capabilities, helped to create a system that truly responded to each of Endesas needs. The system was configured in a 100% web-based environment for easy deployment in the farthest reaches of the logistics network of the coal transportation process. It consists of a System Platform server in which the functional logic of the system resides, a Historian server for storing data and two databases, one in real time and the other transactional. This web-based environment connects to web clients at each unloading port through computers, mobile devices, tablets, etc, with Wonderware InTouch or with remote clients in the case of suppliers or other agents outside the system. At a higher level, the entire architecture is monitored from an Endesa control centre located in Madrid. User definition was one of the most important aspects when designing the system, as the aim was to ensure complete consolidation of the information for all staff involved. Four types of user needs to which Ulysses should respond were identified: terminal user, where the key was facility management, coordination of customers and suppliers and the improvement of performance and planning; logistics user, with special emphasis on reporting for transport and planning; broker, responsible for compliance with legal obligations, ship documentation and information, etc, and carrier, in which not only legal aspects were involved, but also the control of activity. A general user was also set up in the event that an agent was not represented by any of these predefined profiles. Once Ulysses was actually down on paper, the critical stage of deployment began. The application was prepared to collect data and analyse information during an unloading process at the port of Ferrol.

Power
The control of the process that had been carried out would at the same time be maintained in order to confirm that there was total reliability in the data collected. It was essential to ensure the correct acquisition of real-time information, explains Intermark Technologies. The results obtained in this first test were analysed and proved to be completely successful. The system was working well from the beginning, which quickly led to the commencement of exploiting the information collected there and initial data was obtained that indicated how to begin the process of improving the logistics management of coal. After this pilot test, deployment of the global technology infrastructure began. In less than a year, taking into account planning and deployment, Endesa now had a new control and automation system for its coal terminals that offered full visibility and control over the implementation of its operations.

ArchestrA System Platform, Wonderware Historian, Wonderware InTouch

Availability of Information, Analysis and Continuous Improvement

As the Intermark Technology team explains, results did not take long to emerge after the project was initiated. According to Ana Beln Paz from Endesa, one of the great benefits after the deployment of the control platform was real-time management of port activity: We know the state of the unloading process at each and every moment and we can easily know about changes in the facility at a future time based on activity forecasts we are handling. We can also immediately and easily obtain reports and statistics of past activity, such as ship unloading ratios, lifting of coal, etc, which allows us to make decisions in a short period of time. Intermark emphasises that Endesa now has reliable information available about its logistics processes revolving around the procurement of coal for its thermoelectric power plants. There is full traceability of the process in terms of planning, unloading and lifting of the material. A control panel of indicators for managing the operations has been introduced. It is possible to design improvement actions thanks to the exploitation of historical data and costs have been significantly reduced by an increase in operational efficiency, the team claims, adding that having access to all activity information in real time through a simple, shared interface for all users is one of the greatest operational benefits obtained. The project reveals its full potential by analysing each of the areas where Wonderware technology is being used today. In the planning stage, Endesa is able to make a complete forecasting and historical

analysis of its activity, as well as ship schedules or searches for unloading processes made by having immediate access to the documentation associated with each ship. The system also allows for the easy registration of new vessels, planning of calendar shifts and worksheets. Finally, it also has the ability to perform simulations of stock in the analysed area in accordance to the unloading processes made and intended lifting rate. The change has also been profound in regards to operations: In addition to the automation of all processes, monitoring of the activity in real time is a reality today. It is possible to view the unloading process in progress, monitor the state of the elements at the terminal, receive information about stoppages and breakdowns, perform a detailed analysis of their causes and manage the inventory of stock based on reliable and immediate information, the team points out. Alongside this, the benefits of carrying out remote unloading in a fully automated manner increased safety, reduced fatigue and increased team performance have resulted in another dimension of improvements in

the workplace. Ana Beln Paz further emphasises the ease of monitoring processes: Wonderware technology allows us to connect from anywhere, via Blackberry or PC and in real time, which allows greater mobility and availability in those periods of time when we are not present at the facility itself, she states. In terms of transport, the advantages result from an increased simplicity of management: Documentation management associated with contractors has been simplified and professionalised and the legal requirements of trucks, logistics operators and drivers have been guaranteed, explains Intermark Technology. In this sense, critical issues such as billing for both transportation suppliers and other external agents to Endesa have been included in the system so that it is easy to emit, check and approve invoices by minimising any possible incidents.
119

Power
Regarding reports, through Wonderware technology Ulysses helps users to report and exploit information for each of the process stages: preparing activity schedules and attendance sheets, predefined reports on unloading and lifting, reports on activity at each terminal and the possibility of carrying out enquiries that are adapted to the needs of each user. Finally, in relation to the environment, which is a key area in all the improvement processes undertaken by the multinational power company, the benefits have also been indisputable, achieving a significant reduction in atmospheric contamination both dust and noise and lower energy consumption for implementing the process. In terms of technological features, according to Intermark Technology the advantages are no less important: Endesa now has a flexible platform to create a model for any type of process by accessing information in a simple and intuitive manner. The large number of inputs/outputs, along with their ability to link up to other systems and devices, has helped to design and deploy a system that the company needed, without fear that future requirements would not be able to integrate with the architecture. Endesa is now undergoing a substantial change in response to the challenges established by the energy market and Wonderware is fully prepared to accompany the company throughout this process. Thanks to its technology, claims Ana Beln Paz, we are efficiently managing available resources,

ArchestrA System Platform, Wonderware Historian, Wonderware InTouch

have reduced the costs of the ship/port interface, improved the ratios of unloading/optimisation of times and have greater flexibility in communications due to the introduction of different interlocutors in the control platform, among many other benefits. The prospects of the projects future involve further improvements to the integration of different elements at the terminals so that they can provide new information and, consequently, maintain the process of continuous improvement, including electrical power consumption meters, water treatment plants, geolocation systems, etc. The plan is also to make more use of the information gathered through business intelligence tools that help to make even better use of the information processed by Ulysses.

This document was realized thanks to the support of: Endesa and Wonderware Spain

120

INDUSTRY: PULP & PAPER

Weldwood of Canada
www.westfraser.com

Many spare parts are no longer inventoried, but are simply ordered when a repair is scheduled and its work order is cut which is a new capability that we gained, since the new system combines both work scheduling and parts purchasing.
Hank Dickey Maintenance Superintendent

Weldwood of Canada uses Avantis.PRO solution to reduce operation cost and increase efficiency
Goals Enhance production efficiency with new computerized maintenance management system Challenges Update outdated management system did not integrate the maintenance functions with plant purchasing systems, which required larger inventories of spares to be on hand Solutions and Products Avantis.PRO Results Diverse operations in both type and geography are now tied together Enhanced productivity through more efficient maintenance activities, helping to produce nearly 230 million square feet of plywood each year Achieved ISO 14001 certification at Williams Lake

121

Pulp & Paper

Williams Lake, Canada Weldwood of Canada
Ltd. is one of North Americas leading producers of plywood and lumber products. To meet everincreasing demand for the companys products, this subsidiary of West Fraser Timber Co. Ltd. has made key investments in new technology in recent years to increase plant capacity at its facilities in western Canada. Weldwoods Williams Lake plywood plant, located about 330 miles north of Vancouver, British Columbia, is a good example of how an asset management system can help management enhance both maintenance and production.

Avantis.PRO

extensive maintenance assessments prior to installation in order to be sure their processes were optimized. They installed the Avantis solution first at the Williams Lake plant. Based on initial experience with the installation here, they then rolled it out to five additional plants in just over one year.

Integrating Multiple-Site Maintenance

The Avantis solution is now integrated tightly with all aspects of solid wood products manufacturing at plants in Williams Lake, Quesnel, 100 Mile House, Houston, Burns Lake and at Hinton, Alberta. It is used to track equipment and asset utilization, schedule manpower for maintenance and repair services, track and manage parts inventories and disbursements, and generate work orders automatically for preventive maintenance (PM) and on-demand for emergency repairs. The Avantis solution provides features that enable Weldwood management to tie together operations that are diverse in type and geography. It uses an entity concept to facilitate recording of costing and maintenance activity records for anything users wish to track. Parent-child relationships can be set up easily to build hierarchies for cost rollups and operating statistics. Work management features ensure that maintenance personnel have control of incoming work while providing a flexible way to track work in progress. Planning functions include information on labor, materials, tools, drawings, and instructions, plus subcontractor requirements, and this detail can be included on work orders. PM functions can be structured in libraries of standard jobs with automatic work order generation, inspection checklists, PM routine specs, and parts lists.

Project Scope
As part of its expansion program, Weldwood has done far more than just add capacity management has also streamlined operations to make existing facilities run more efficiently. Among the tools used to enhance production efficiency are new Computerized Maintenance Management Systems (CMMS) that have been installed at several of its plants in British Columbia and Alberta. These systems have helped make the plants more productive by streamlining maintenance procedures so they are more efficient and take less time from production schedules to perform routine Preventive Maintenance (PM) or emergency repair services. In addition to increases in production equipment uptime, the CMMS has increased the efficiency of scheduled maintenance work and has reduced costs for spare parts inventories. At the same time, improved maintenance practices have also led to production of more consistent and uniformly high quality wood products. The Williams Lake plywood plant, located about 330 miles north of Vancouver, British Columbia, is a good example of how an asset management system can help management enhance both maintenance and production. The company previously had used a mainframe computing system for managing maintenance planning functions, but the system was outdated. One of the main challenges was that it did not integrate the maintenance functions with plant purchasing systems, which made it cumbersome for automating purchasing paperwork in ordering parts, which in turn required larger inventories of spares to be on hand. Weldwood management reviewed several CMMS and selected the Avantis solution. The companys maintenance management team conducted

122

Pulp & Paper

Using the detailed equipment information history that is developed via day-to-day activities, supervisors can analyze failure histories, track failure causes, and take action accordingly. Maintenance parts inventories can be better managed, especially when dealing with large numbers of unique and low unit value items that can often be subject to unpredictable demand. Workflow can be better planned and purchasing and procurement functions can be tied directly into maintenance programs. Don Gibson, Mobile Equipment Supervisor, said, We monitor odometer readings and fuel consumption statistics on all the trucks and mobile equipment, and we track actual hours of equipment operation in the plants. We enter weekly readings into the Avantis solution, and the program tracks the average use of each machine, then predicts and schedules PM based on that data. The Avantis solution database that facilitates maintenance planning at Williams Lake is designed to handle data on equipment usage from large entities down to the smallest from division-level entities down to departments, then machinery type and parts lists. The database has 2,365 entities defined, with 4,615 inventory items in the catalogue that identifies specific equipment. The master purchasing catalogue has 66 parts lists with a total of more than 15,000 items that can be generated instantly on a work order, for any repair. About 115 PM jobs are predefined in the system, with nearly 1,200 PM tasks and 240 safety procedures. Similar databases are maintained for five other Weldwood plants, and coordinated and monitored at head offices in Vancouver.

Avantis.PRO

According to Rick Brandson, Maintenance Supervisor, We have a maintenance meeting every Thursday to schedule our PM and other service. The normal window is seven hours, but if we need more time we can add to it as needed. Its all based on production needs. We know ahead of time when we have bigger jobs. We then adjust those maintenance windows accordingly so we can minimize the impact on production. The new system has been an important tool in Weldwoods achievement of ISO 14001 certification at Williams Lake. It helped the company meet stringent audit requirements for environmental systems because of the performance audit trail it provides on all equipment and maintenance operations. The plant is just about 100% self-sufficient, almost a perfect balance of incoming and outgoing materials for both fuel purposes and environmental issues. The bark and waste are used to produce heat for drying lumber as well as for heating buildings. The only exception is in the summertime, when there may be a bit of excess waste, so the chips are trucked to a Northwest energy plant that burns it to generate steam, producing power for British Columbia Hydro. The Avantis solution has also proven to be a valuable tool to help Weldwood maintenance management achieve a good return on investment at Williams Lake.

Enhancing Production Efficiency

The Avantis solution has become a valuable tool for Weldwood because it has helped the company enhance productivity through more efficient maintenance activities. This is critical for managing service of sophisticated equipment so that production keeps humming at the Williams Lake plywood plant. This single plant produces nearly 230 million square feet of plywood each year from spruce, pine, and fir logs brought in from Crown lands throughout British Columbia.

This document was realized thanks to the support of: Weldwood of Canada 123

INDUSTRY: SEMICONDUCTOR

Texas Instruments
www.ti.com

Flowthrough conductivity sensing technology has allowed TI to take a proactive role by heading off problems before they happen
Foxboro Flowthrough Conductivity Sensing helps TI improve Productivity while reducing Material and Maintenance Costs

Foxboro Flowthrough Conductivity Sensing helps TI improve Productivity while reducing Material and Maintenance Costs
Goals Reduce costs for materials and maintenance by improving ST-26 monitoring in real time Challenges Accurately monitor and analyze process material quality to achieve reliable monitoring, without interrupting production or jeopardizing worker safety, for profitable semiconductor production Solutions and Products Foxboro Measurement & Instruments Results Reliable monitoring of ST-26 in real time Online determination of critical process solution viability Reduced costs for materials and maintenance Increased productivity

124

Semiconductor
Dallas, Texas Headquartered in Dallas, Texas,
U.S.A., Texas Instruments (TI) has manufacturing, design or sales operations in more than 25 countries. TI is a company with a history of firsts, including the first commercial silicon transistor and the first integrated circuit. Located just 20 miles outside of Houston, TIs Stafford facility is the companys worldwide Digital Signal Processing center, with design and development facilities that collaborate to produce the semiconductors used in computers, automobiles, PC games and wireless telephones.

Foxboro Measurement & Instruments

Conductivity Sensor Solution

After evaluating many other analytical approaches, engineers at TI Houston concluded that conductivity sensing would be the right solution if they could find a sensor with the right combination of measurement capability and process-compatible components. After discussions with the conductivity product manager at Invensys Operations Management, they selected the Foxboro FT10 conductivity sensor. The FT10 sensors feature all virgin PFA for compatibility with TIs requirements for measuring water in ST-26. By monitoring the change in conductivity as an index of percent water, the sensors make an on-line, real-time determination of their process solution viability. TI installed the FT10 flowthrough sensor in their process on a 3/4-inch line using TIs preferred Flaretek connections. TI has found that the allowable range of water content is between 400 and 500 S/ cm. When conductivity reaches the lower limit, the FT10 sensor, with the Foxboro 875EC intelligent analyzer, triggers an alarm; the process is then remedied to restore the ST-26 solution back to acceptable parameters with no loss of production. The TI application requires a measurement capability in the 500 S/cm range, but the FT10 is suitable for numerous semiconductor applications including acids with measurements ranging from less than 50 S/cm to 2000 mS/cm.

Monitoring Quality
Semiconductor fabrication involves a carefully orchestrated sequence of intricate procedures, in a pristine clean room environment. Maximizing yield of acceptable product requires keeping all process materials at their precise original specification, from the point of delivery through application. Frequent and accurate monitoring of process material quality is important to profitable semiconductor production. Reliable monitoring, without interrupting production or jeopardizing worker safety, is an ongoing challenge for the industry. TI met this challenge at its Stafford, Texas facility in monitoring the quality of the photo resist stripper ST-26, which is a key material in its wafer production applications. The on-line process viability of the ST-26 solution is dependent on its water content. Thus, it is critical to monitor the ongoing viability of the solution during production, especially given that TI uses hundreds of gallons of ST-26 a day, at approximately $30 per gallon. If undetected and used, ST-26 that has unacceptable water balance can cause substantial material loss as well as significant lost production. Traditionally, analyzing ST-26 water balance required taking samples to a processing lab, where results might not be available for hours or sometimes-even days. When the results did arrive, they could show unacceptable water balance only after the fact. TI has now found the right solution using flowthrough conductivity sensing technology from Foxboro.

125

Semiconductor

Foxboro Measurement & Instruments

into the line, with associated costs and safety concerns. The FT10 calibration plugs permit quick, precise calibration with a shirt-pocket tool, which significantly reduces scheduled maintenance time and related exposure of personnel or the environment to aggressive and dangerous chemicals.

Eliminating Lost Product and Improving Productivity

Since installing the FT10, TI has eliminated lost product resulting from unacceptable water levels. Material and maintenance costs have been reduced, while productivity has improved. Flowthrough conductivity sensing technology has allowed TI to take a proactive role by heading off problems before they happen.

Another significant advantage of Foxboro FT10 sensors is in-line calibration. The FT10 features a calibration port that eliminates the need to break

This document was realized thanks to the support of: Texas Instruments 126

INDUSTRY: TRANSPORTATION

Ferrocarrils de la Generalitat de Catalunya

www.fgc.cat The challenge we have set ourselves as a company is that of excellence in customer service. Trains have to be punctual, stations must be kept clean and fully operational and any complaints or suggestions should be addressed and resolved. Each year, we seek to achieve higher satisfaction levels from our users and Wonderware technology is an essential tool in achieving this.
Alicia Coca, head of the Systems Development Department at Ferrocarrils de la Generalitat de Catalunya

Wonderware enables new management model for rail system providing service excellence and user accessibility
Goals To deploy a supervisory control system for a railway system in Spain that involves the remote control of rail station operation (ticket sales, opening and closing of doors, lighting, etc) that is able to meet the high standards of excellence and reliability required by the company. To integrate existing automated processes in order to obtain the most out of previous technological investments Challenges To maintain a high level of customer support by improving service despite an increase in processes in the network being controlled. To integrate multiple units of servers and owner PLCs into a single supervisory environment with a common interface for all processes. To complete the deployment of the new supervisory system without halting plant services and to ensure the smooth functioning of the countless remotecontrolled operations at each station: ticket vending machines, escalators, access control, etc. Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware Historian Software Results The new control architecture has helped Ferrocarrils de la Generalitat de Catalunya improve its customer satisfaction by providing a excellent seamless service, a strong policy for preventing incidents and better response times for passengers. Management of the remote-controlled operations by professionals in the control centre is carried out in a simple, fully automated manner and with total process reliability.

127

Transportation
Rub (Barcelona), Spain. Ferrocarrils de
la Generalitat de Catalunya (FGC) is a public company managed by the Catalan Regional Government providing rail transport services to over 80 million passengers (data from 2010). With 1,300 workers and two transport lines BarcelonaValls and Llobregat-Anoia, which together add up to 76 train stations and 200 kilometres of rail tracks FGC is committed to a model that constantly innovates, has excellent service and respects the environment. As a public company, the mission of FGC is to manage its rail services and infrastructure efficiently and effectively. FGC was transferred in 1979 by the Spanish Government to the Catalan Government to improve the mobility of its citizens and to make available to them, a range of leisure activities that meet their level of expectations. Under this premise, the company began an ambitious organisational and technological reform of its operational management in 1996. FGC was the first public rail transport company in Spain to opt for the remote management of stations by automating its operations and ensuring a high quality of service to its customers by taking care of such details as ticket sales, access control, lighting and air-conditioning. However, the companys key contribution is proving that the greater the commitment to process innovation and automation, the greater the customer satisfaction. Today, FGC has impeccable management that delivers unprecedented service excellence in the industry.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian Software

Innovate by Creating a New Concept of Rail Management

Although FGC had already been providing rail transport services to citizens before 1996, that year it launched a new operational model for stations by providing new value added services that went far beyond traditional ticket sales. Consequently, the automation of ticket sales through vending machines enabled the station personnel to focus on direct customer support. For example, if users required any information or had an emergency situation, the station personnel would be able to provide immediate support. As the head of the Systems Development Department at Ferrocarrils de la Generalitat de Catalunya, Alicia Coca, explains that: By eliminating ticket offices, which are an essential part in the functioning of each station, a supervisory architecture had to be developed to
128

help control each of the functions that had until that time been handled by the permanent staff at each station. Customers could not feel that they were being deprived of services because of the change, but quite the opposite, she explains. Little by little, the automation began to replace the functions previously performed by station staff. The creation of the Station Monitoring Centre, operating 24 hours a day, 365 days a year, enabled FCG to operate all stations in the network from a central location. Through the new remote-controlled model for the facilities, the Centre began overseeing the proper functioning of everything related to the station: ticket vending machines, CCTV, public address system, opening and closing of entrance doors, air-conditioning, lighting and pump shafts, among countless other functions. Despite being a pioneering system that marked a turning point in how train stations were managed in Spain, explains Alicia Coca, the supervisory system operated in a completely distributed manner, with every function controlled through an individual proprietary system whose functioning was not linked with other operations at the station. We had as many islands of information as controlled processes and this made things very difficult. The need to integrate all controlled operations into a single supervisory system through a common management interface was the next stage of the project. As a change to the railway operational model, it was decided to create the Integrated Command Centre (CCI) for the joint management of the two network lines, Barcelona-Valls and Llobregat-Anoia, which had hitherto been supervised separately. Thus, the Rub Operational Centre (COR) was created, housing both the Station Monitoring Centre and Traffic Control Centre, responsible for the operational running of trains, as well as the Customer Information Centre. Coinciding with the creation of the new CCI, a complete renovation was undertaken of the integrated station management system to improve and advance system features and incorporate the new multi-line concept. Following a public tender, it was decided that system upgrading of the Station Monitoring Centre would be carried out by SICE using Wonderware technology. The open architecture of its solutions provides it with unique interconnection capabilities and fitted in perfectly to the requirements of integration and operational reliability required by Ferrocarrils de la Generalitat de Catalunya.

Transportation
The Challenge of Interconnection and Reliability
The first objective established to update systems was to ensure the reliability of the control architecture. The dynamics of our service oblige us to have systems that are always operational, that do not return to zero, because any incident in our remotecontrolled operational model implies an extraordinary deployment of technical and human resources, explains Alicia Coca. We wanted an open system that would allow us to develop specific drivers for units that did not always work with traditional PLCs. Wonderware gave us the flexibility we required and guaranteed us a seamless link to each of the network systems, providing us with a common management interface for controlling all operations, she explains. According to the integrator involved in the project, Julio Martnez at SICE, the challenges were varied and complex. He points to the fact that the new architecture had to replace an operational SCADA, which meant that tests had to be done in parallel without interfering with operations. Alongside this, he also refers to the challenge implied by working with diverse facilities: Some of the communications equipment that provided information on the state of facilities, and that also helped to send commands to them, had been in operation for a long time, but it had its own private communications protocols, without any detailed documentation and sometimes the manufacturer no longer existed, he explains. The first stage of the project began with the team analysing how the system should be based on experiences gathered over the more than 10 years that the previous control architecture had been operating. The premise was to design before constructing, says Alicia Coca. Once we knew how the system worked, we decided what functions we wanted to change, what functions we wanted to improve and what functions we needed to add. The only way to ensure successful implementation was by working closely with the operational team at FGC, as they were the ones who would ultimately use the solution. This was how the Multi-Line Integrator System (SIM) was designed: a supervisory environment using Wonderware technology that for the first time linked together, the management of the two lines operated by FGC.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian Software

The second stage of the project was the implementation of the Barcelona-Valls line and this was no less complex. The inability to halt the service meant that the development of the new control architecture had to be carried out simultaneously with the existing one without any shutdown. In terms of engineering, the hardest part was getting the two systems to coexist simultaneously by capturing field signals without interference, explains Alicia Coca. After three days of operations with double the staff in the old and new command centres, as well as a week with backup personnel in case the new system failed, the new architecture to control and monitor stations with Wonderware was fully operational. A year after implementation, the operation was repeated with the Llobregat-Anoia line, thus concluding the third stage of implementation. Technologically, the control system was structured into two servers, the first being an ArchestrA System Platform, communicating information online and operating simultaneously because of the security requirements of FGC, and another server with a Wonderware Historian server, that connect to seven operator stations loaded with InTouch. The plan also included a development server where new software versions and solutions can be installed, run and validated. This simple and transparent architecture was determined by the functional requirements of the network, which were detailed in the first stage of the project, according to Julio Martnez at SICE: On the one hand, the users, their functions and location or way of accessing the system were defined. In terms of the servers, we knew the number of signals, equipment and type, as well as the degree of reliability required. Therefore, the solution was based on two servers functioning as input/output servers, with load distribution and redundancy, as well as a database server, he explains. Currently, the system architecture has evolved towards a solution based on four servers, following extensions that have been carried out that improved availability. In terms of functionality, the Multi-Line Integrator System (SIM) interacts with the various third-party subsystems, connecting in the back office with each of the servers or PLCs that control the various operations, but delivering to the front office, a
129

Transportation
common management interface to control CCTV, internal and external telephony, station intercoms and the many remote control features such as escalators, station lighting, outdoor shutters, station entrances, extraction and ventilation shafts, remote control of vending machines or barriers at entrances and exits. According to Alicia Coca, Wonderware currently provides integral management for about 50,000 signals from the most diverse existing units. Thanks to the capacity of the supervisory system, only three operators are required for the BarcelonaValls line and two operators for the LlobregatAnoia line to ensure excellent service to the 300,000 people using our services every day.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian Software

Excellence in Customer Service

This investment in technology using Wonderware at FGC has resulted in greater customer satisfaction. The supervisory infrastructure that has been Multi-Line Integrator System Operations Controlled by Wonderware Technology
Stations - Information and SOS points where users can contact FGC staff - Remote support for sales operations in ticket vending machines - Analogue and IP video to monitor facilities through closed-circuit TV (CCTV) - Services: lighting, escalators, automatic doors at station entrances and shutters, ticket barriers, airconditioning, elevators, etc - Ticket vending machines - Informational screens with train times - FGC information panels - Reception of alarms from station facilities - Management of incidents arising from alarm signals received Central Systems - Access control at stations: locking/unlocking of station entrances - Real-time camera footage at stations - Intercoms - Data usage: creation of reports (intercom calls, alarms and incidents, operator actions) and consultation of historical data Command Posts - Intercom voice recording systems - Video recording systems - Rear projection systems - Corporate telephone systems The response time of the integrated control system for operational actions required by stations is between 2.5-3 seconds.

implemented helps to ensure prevention protocols in virtually all areas: Today, the SIM knows when a machine is about to run out of change or is about to run out of the roll of paper on which the tickets are printed. As soon as the alarm sounds, the responsible control centre operator notifies the station agent and he or she resolves the problem before it has even occurred, explains Alicia Coca. Year after year, through customer surveys, Ferrocarrils de la Generalitat sees the degree of user satisfaction increasing: The model of centralised operation at the stations has strict criteria of excellence, for example, in relation to maximum response times for incidents. The fact that the system built on Wonderware provides full real-time visibility about what happens in the network is undoubtedly one of the key elements that ensures maximum passenger satisfaction, she claims. Closely linked to this desire for improvement, Julio Martnez at SICE highlights the ability of Wonderware to adapt itself to the requirements of a continuously developing management environment: FGC stations are in a process of constant renovation and growth. Proper design of the adopted solution and Wonderware platform architecture based on objectives helps the system reflect changes and introduce new equipment at the stations. The benefits are innumerable for system management. Today, we have absolute security and reliability about what is happening at each point of our network because the system provides us with information 24 hours a day, seven days a week, 365 days a year and always in real time, points out Alicia Coca. Satisfaction goes beyond the technological aspect of the project, and right through the quality of

130

Transportation
support received from Wonderware and the system integrator. To have the immediate support of the integrator and by Invensys, this is important when working with critical systems, in an environment that has an increasing level of demand. At the technology level, Julio Martnez is clear when it comes to the advantages provided by Wonderware: The ArchestrA System Platform provides the elements for overall integration. It is dynamic in terms of client and server architecture and allows for growth. Today, we can adapt the system architecture to design requirements with such useful features as creating non-standard drivers that can be incorporated into the system as if they were native, he explains. Alicia Coca also refers to the fact that the supervisory system has simplified the daily work of the operators at the Station Monitoring Centre. The integrated system has given us the ability to automate logical tasks that were previously carried out manually. If

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Historian Software

a passenger uses a station intercom, the operator receives the signal, answers and, because the machine also has a camera, the signal is automatically sent to the video wall at the control centre so that the operator can see what is happening instantly, assess the incident and directly manage the machine to resolve the issue. The Wonderware solution has also helped to guarantee system availability, reduce response times and improve the operation of operators at the Station Monitoring Centre, thus achieving impeccable management, explains Alicia Coca. The challenge we have set ourselves as a company is that of excellence in customer service. Trains have to be punctual, stations must be kept clean and fully operational and any complaints or suggestions should be addressed and resolved. Each year, we seek to achieve higher satisfaction levels from our users, and Wonderware technology is an essential tool in achieving this.

This document was realized thanks to the support of: Ferrocarrils de la Generalitat de Catalunya and Wonderware Spain 131

INDUSTRY: TRANSPORTATION

SALT Societ Autostrada Ligure Toscana p.a.

www.salt.it

Adopting an industrygrade automation solution was the first step to the successful implementation of a project characterized by a large number of controls, and mostly, by the need to guarantee uninterrupted operation.
Eraldo Benedetto Automation Manager Giordano & C. S.p.A.

Using remote control on A12 motorway has helped reduce energy costs and increase drivers safety.
Goals Improve safety, reduce energy and maintenance costs of the AI2 Motorway Obtain real-time information about status and alarm conditions of toll gate and tunnel equipment Enable the automatic control and operation of tunnel lighting and ventilation systems Challenges Manage a critical infrastructure with 24 tunnels and 75 km classified as B-class mountain motorway Deploy an application featuring a large number of control units and ensuring uninterrupted operation Immediately identify possible anomalies or malfunctions along the motorway, providing diversified information and access to each role within the organization Use high-performance automation solutions to guarantee real-time data collection and system monitoring Solutions and Products ArchestrA System Platform Wonderware InTouch for Terminal Services Wonderware Historian Results Safe operation of the A12 highway Optimization of energy consumption is realized through the automated management of tunnel lighting and ventilation systems Preventive maintenance system based on the centralized real-time monitoring of installed equipment enables savings in cost of spare parts

132

Transportation
Viareggio, Italy - Driving on a motorway requires
a great deal of attention, as due to high speed, you have to react promptly to any abnormal or unexpected situation. Attention must be further increased when you drive along the 155 km asphalt belt that leads from Sestri Levante to Livorno. The A12 highway includes as many as 24 tunnels and 75 km of B-class mountain roads, taking the track up to the 348 meters above the Bracco pass. It is a challenging route not only for the drivers, but also for the motorway management company, who must handle a flow of 50 million vehicles annually. For this reason, in 2007, Salt (Societ Autostrada Ligure Toscana), the company that manages this critical motorway, decided to invest in a remote control system with two goals: improve safety and reduce energy and maintenance costs. These requirements could be met only with solutions and expertise from the industrial domain, explains Paolo Pierantoni, CEO, Salt As they are characterized by high reliability and have the capacity to handle large-scale applications. To face these challenges, Salt selected Giordano & C., a Cuneo-based solution provider specializing in industrial automation, using and technology provided by Wonderware. Adopting an industry-grade automation solution was the first step to the successful implementation of a project characterized by a large number of controls, and mostly, by the need to guarantee uninterrupted operation, says Eraldo Benedetto, automation manager of Giordano & C. A motorway is always open and any failure of technology systems might endanger the lives of dozens of people. In the design stage - Benedetto underlines - we focused on the reliability and redundancy of all installed systems, in order to guarantee optimal control under any circumstances.

ArchestrA System Platform, Wonderware InTouch for Terminal Services, Wonderware Historian

at high speed covers a few meters, with the driver basically blinded. This situation endangers the safety of people and, for this reason, requires a proper adjustment of the tunnel lighting system. When visibility outside the gallery is excellent, the entrance to the tunnel must be daylit. Then, lighting intensity may decrease gradually towards the inner section of the tunnel, to grow again towards the exit. At night, the opposite approach should be adopted: as you drive from the dark outside into a lit gallery, and vice versa, the tunnel lighting must be dimmed at the entrance and exit. Traditionally, this activity was entrusted to a worker, with consequent risks related to human errors. This was combined with delays that, besides affecting safety, also had an economic impact. A delay by even few minutes when the lamps are turned on and off may result into significant energy saving or additional costs. For this reason, the automated management enabled by ArchestrA System Platform was a substantial technological leap. Time scheduling is based on an astronomy calendar where sunrise and sunset timetables are stored, including possible corrections triggered by a network of twilight sensors and light meters, which detect real weather conditions.

Wind in the tunnel

Inside a motorway tunnel, crossed by thousands of vehicles every hour, exhaust gas concentrations may rise quickly, reducing visibility and making air unbreathable, with devastating effects in case of long stops.

Light in the tunnel

On a motorway with 24 tunnels, lighting is one of the most critical elements, because the proper level of visibility must be guaranteed according to weather conditions, and because maintenance and power consumption have a significant impact on the balance sheet of the managing company. It takes a few fractions of a second for a drivers visual apparatus to adapt to sudden changes in lighting conditions. Galleries General Overview Within this time lapse, a vehicle running
133

Transportation

ArchestrA System Platform, Wonderware InTouch for Terminal Services, Wonderware Historian

Application Architecture

Proper ventilation is therefore essential; for this purpose, accurate management is required both to avoid useless operation that reduces the operating life of systems and increases consumption, and to determine the proper air extraction direction according to environmental conditions outside the tunnel. Basically, you should not go against the wind flow, while taking into account specific atmospheric pressure conditions that can affect the efficiency of the system. In case of fire, fan rotation speed and direction must be adjusted to support the extraction of smoke without further feeding the flames. So, its a matter of delicate balance, especially in tunnels like Saturnia, equipped with 14 fans. In this respect, a complex measurement system has been installed, which can perform smart calculations based on exhaust gas concentration, smoke opacity, wind and atmospheric pressure, in order to optimize the operation of every single fan.

to fans, is monitored remotely from a control room in Viareggio, where two redundant servers are installed. A dedicated optical fiber link, information is collected by 40 PLCs that supervise the operation of each system locally. In this way, the control room staff knows the conditions of any piece of equipment in real time, including power switch cabinets, as well as detailed information about the operating hours of each element. Knowing the useful life of installed equipment, they can plan maintenance operations in advance, enabling subcontracting companies to work during low traffic hours and minimizing inconvenience for drivers. A key element to support preventive maintenance and centralized management is the visualization system Wonderware InTouch HMI, operating in Terminal Service mode. Silvana Pettiti, Project Manager at Giordano & C., explains: Wonderware technology is also flexible as relates to operating system and basic remote management services (RDP/ICA), so it is particularly suitable for the implementation of hybrid client/server or peer-topeer architectures, which can be modified in the course of project deployment without restarting development from scratch. Engineering is also effectively supported by the object-oriented programming logic of Archestra; the possibility to duplicate previously developed and tested systems and models, quickly and reliably, ensures the rollout and cloning of controls in record time. For instance, we have developed almost the entire project over a remote connection to the application servers in Viareggio from our offices in Boves near Cuneo! .

Right on time
While energy is the most apparent cost factor, the financial impact of maintenance should also be evaluated accurately. Any traveller has experienced the inconvenience that is due to road works.. This is annoying for drivers and expensive for the management company, in terms of human resources, equipment and organization. Such conditions can be further worsened by the fact that, in case of extensive works or emergency situations, it might be necessary to close down the motorway, with a consequent loss of revenues. In view of this situation, maintenance requires special attention. All technology equipment, from lamps
134

Motorway alarm
Of course, safety is a factor that a motorway management company cannot neglect. For this reason, even before analyzing the cost effectiveness of a system, all the necessary solutions to safeguard travellers must be adopted. On a complex motorway like A12, Salt managers demanded to be informed promptly about any anomaly. Such request is not always compatible with the detailed analysis of each technology component, which is mostly relevant for ordinary management operations. In this respect, the flexibility of ArchestrA System

Transportation
Platform was a decisive factor, as it allows to provide diversified information and access to each person, including the possibility to access through a common browser. The control room operator, in charge for launching rescue operations in case of emergency, is informed about current events through a highly intuitive alarm system. Wonderwares HMI software graphics can visualize a failure on the operator panel, but also a car crash or other abnormal situations. In case of a similar event, the operators task is just to request the intervention of rescue squads or skilled workers. Detailed analysis, instead, is performed in the Viareggio control room, where all details of any situation can be examined to identify the required technical action or to modify specific parameter settings remotely.

ArchestrA System Platform, Wonderware InTouch for Terminal Services, Wonderware Historian

HMI Screenshot - Motorway Toll Station

To comply with the strictest safety standards, any change is automatically recorded and stored in the Historian database, so that it cannot be edited any further. This procedure makes each operator aware of his/her responsibilities and enables to analyze the effects of any action at a later time. Such capacity, supported by explanatory charts and the possibility to compare highly heterogeneous parameters, is a success factor for a motorway controlled by over 40 thousand I/Os. The number of I/Os keeps growing, says Benedetto, as energy bills are showing to Salt managers that energy savings achieved have paid back the entire investment in a very short time. The openness of Wonderwares Historian database and the virtually unlimited capabilities of System Platform, the software platform where all industrial automation applications converge adds Pettiti, have proved to be very useful during programming. We have also been able to create data exchange tables towards other systems, tailored to our needs, and to meet all customer demands during development. And dont forget that some functionalities were added later on, as soon as operators started to appreciate the benefits of remote control. Due to the complexity of the plant, using a remote control system supported by industrial automation technology has turned out to be very effective, as it enables the real-time management of a system that, with less performing solutions, would take minutes even for simple data collection. Under emergency conditions, such delay would put many lives at stake. And every day, it would cause delayed actions that, spanned across one year, would have a negative impact on profitability.

This document was realized thanks to the support of: SALT - Societ Autostrada Ligure Toscana p.a. Giordano & C. S.p.A.

135

INDUSTRY: TRANSPORTATION

Wuxi Transportation Tunnel System

en.wuxi.gov.cn

The Invensys solutions use advanced component object-based technology that enable us to reuse templates from previous projects allowing faster implementation of new processes.
Dr. Wu Zhichun Mayor of Wuxi

Invensys Technology Enables Remote Monitoring of Wuxi Transportation Tunnel System in Chinas Rapidly Growing Industrial and Technology Business Hub
Goals Remotely manage the series of tunnels, roads and pedestrian paths that connect the citys residential area, industrial zone and central business district Ensure the effective management of tunnel conditions and operation equipment including power, lighting, ventilation and drainage, as well as emergency response operations Challenges The control center has to rapidly react to emergency events such as accidents, fires and floods in accordance with contingency plans Respond to tunnel operations management issues including effective operation of equipment, maintenance of road conditions and management of energy use Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware Information Server Wonderware Historian & Historian Clients Results The management team can now efficiently monitor various systems, achieving full deployment of the entire road Reduced engineering costs, improved overall operation efficiency and decreased travel time through the central city The system now supports more than 10 clients as compared to the previous six clients and achieved a lower headcount

136

Transportation
Wuxi, China Wuxi earned its nickname of little Shanghai for its proximity to Chinas most populous city and for its booming economy and rapid growth of business and industry. According to Forbes magazine, Wuxi was ranked as the third best city for business in China in 2008. The industrial focus includes technology, electronics, machinery, pharmaceuticals and chemical processing. With the rapid growth in industry came an explosion of jobs and more people moving to the city and surrounding areas. As with other metropolitan areas experiencing this type of growth, traffic congestion became an issue.
In 2005, the Wuxi city government established plans to connect the citys residential area, industrial zone and central business district via a series of tunnels that would alleviate traffic congestion and streamline travel for the citys residents. In 2008, the 50 square kilometers of tunnel work was completed and includes the Inner Ring Road loop which connects five interchange tunnels, three general traffic tunnels and three bridges. This unique traffic management design enables residents and the business community to save an extra 15 minutes when traveling through the central city. To manage the complex series of roads, bridges and tunnels, city officials required a technology management system that could monitor traffic conditions, tunnel functions and emergency situations. After reviewing the offerings of several technology providers, Wuxi selected Invensys Operations Management solutions because it could fulfill all the requirements needed to remotely monitor the complex tunnel transportation system. The city required an open architecture software solution that would enable operators to quickly and easily modify the remote monitoring system to address the continually changing conditions of the tunnel and road conditions, said Dr. Wu Zhichun, mayor of Wuxi. Because the Invensys solution uses a component object-based model, operators can quickly develop templates that can be easily replicated and revised as needed. This significantly cuts down on the cost associated with engineering development of technology applications.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Information Server, Wonderware Historian & Historian Clients

Visualization Enhances Traffic Management

Monitoring the traffic paths and conditions of one of Chinas major industrial and business districts is no easy task. However, Invensys turned a potentially complex and difficult undertaking into a streamlined operation. The Wuxi tunnel and Inner Ring Road loop project required a software system that could successfully manage the Wuxi transportation corridor via a remote monitoring system. The solution was required to observe and manage tunnel conditions, manage equipment operations including power, lighting, ventilation and drainage, and handle emergency response procedures. Wuxi implemented ArchestrA System Platform along with InTouch and Wonderware Historian to provide a variety of remote monitoring capabilities and data collection operations. Wonderware System Platform provides a single, scalable platform that enables system managers to control and supervise operations using object-based technology which enables configuration, logging, delivery and maintenance of real-time and historical information. InTouch is the HMI solution which operates in conjunction with System Platform and provides graphic visualization of the entire Wuxi tunnel operations for easy tunnel management, control and process optimization. The combination of these standards-driven systems maximizes productivity, optimizes user effectiveness, increases quality, and lowers development, maintenance and operational costs.

137

Transportation
The monitoring system is responsible for a wide range of complex operations and safety activities, said Zhichun. Effectively viewing, analyzing and processing a variety of tunnel data is extremely important to the overall operation of the transportation system. Knowing that Invensys software is providing accurate, real-time information on tunnel conditions is a reassuring factor in management of the transportation system.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Information Server, Wonderware Historian & Historian Clients

Advanced Analysis and Reporting Capabilities Boost Operations & Safety Processes
Not only are traffic and tunnel conditions important to monitor, emergency services rely on the remote command center to provide details on fires, flooding, or other crises that occur within the Wuxi tunnel system. Because the control center is responsible for monitoring emergency situations, it must relay information immediately in accordance with the citys contingency rescue command plans. Wonderware Historian using Historian Clients provide historical data relating to activities in the tunnel environment. The use of InTouch added a great deal of power and flexibility to the system design, allowing us to efficiently and cost-effectively integrate an enormous amount of system information, said Zhichun. This enabled us to concentrate on the real-time control portions of the monitoring and emergency systems. Wonderware Historian is designed to assist users to visualize improvements in operational effectiveness and efficiency, analyze the best means to achieve their objectives and optimize existing investments in software and equipment. By combining process analysis, predefined trend charts and reporting into a single, integrated package, transportation engineers can more easily troubleshoot operations and obtain a better understanding of their process based on detailed, accurate information.

Online Access to Information Improves Departments Response Time

The backbone of the Wuxi tunnel technology solution is the Wonderware Information Server, which provides enhanced Web-based, enterpriselevel reporting capabilities. Information Server is integrated with Historian Clients, enabling department managers and operators to analyze operation trends and provide highly informative production and performance reports. These reports can be customized and tailored to the information needs of specific operations management users. Information Server also connects operations personnel with other open data sources so they can access the systems entire performance record. Information Server enables our team to access information and content anywhere at anytime, said Zhichun. Online access to critical data from all locations within the control command center allows us to make better operations decisions and immediately address problems as soon as they occur. Wonderware Information Server provides an interactive, open method of delivering critical operating information to workers engaged in a variety of industries including transportation infrastructure processes, utilities and water/ wastewater. Its ability to provide data in other forms compatible with corporate portals expands its usefulness to a wide range of users within an organization.

138

Transportation
As a unified portal and content server, Wonderware Information Server enables flexible access to applications, reporting and visualization information using a Web browser. Managers and operators at all levels can obtain an enterprisewide view of production operations and KPIs, providing the enterprise with a common real-time information dashboard.

ArchestrA System Platform, Wonderware InTouch HMI, Wonderware Information Server, Wonderware Historian & Historian Clients

Providing a single, comprehensive solution for management of the Wuxi tunnel system enables us to rapidly reuse and deploy process components providing tremendous cost savings and streamlining engineering practices, said Zhichun. The Invensys solution enables us to easily deploy the same process in other locations without the need for recoding. The scalability and reusability of the Invensys solution enhances the Wuxi transportation management teams ability to effectively manage its advanced tunnel system. Invensys software enables the department to continue to cut costs through use of the component object-based technology and update the tunnel surveillance system with customized software templates. Soon Wuxi may also be known as the city of tunnels.

Lower Engineering Costs Benefit Departments Operations Budget

By using Invensys software, the Wuxi transportation department is able to reduce operating costs by reusing component templates. Designed for operations intelligence, the use of these templates significantly reduces engineering time and costs as well as the overall total cost of ownership.

This document was realized thanks to the support of: Wuxi Transportation Tunnel System 139

INDUSTRY: WATER AND WASTEWATER

Southern Nevada Water System

www.snwa.com

In addition to eliminating paper shuffling, we avoid problems related to lost or inaccurately completed forms. We save cost of producing, filing, and sorting work orders, and we have better tracking of employee performance and equipment status.
Jeffrey Deitch Business Systems Analyst with the Technology and Special Projects Division

PDA-Based Planning and Scheduling Solution cuts costs and paperwork for Southern Nevada Water System
Goals Improve maintenance project and equipment status tracking Reduce inaccurate recordkeeping Increase employee performance Challenges Automate the maintenance planning and scheduling system, reduce paperwork and free field technicians from costly, time consuming, and potentially inaccurate paper recordkeeping Solutions and Products Avantis.PRO Results In its first year of operation, expected savings is about $17,000 in work order processing and $33,000 in reduced administrative costs More efficient work order processing and timely maintenance project tracking Improved accuracy in form completion, employee performance management and equipment status tracking

140

Water and Wastewater

Henderson, Nevada The Southern Nevada
Water System (SNWS) refers to the system of treatment and distribution facilities that diverts raw Colorado River water from Lake Mead and delivers potable water to Southern Nevadas municipal water providers. Water is treated at the Alfred Merritt Smith Water Treatment Facility, located on the shores of Lake Mead, and at the River Mountains Water Treatment Facility, located in Henderson, Nevada.

Avantis.PRO

free field technicians from costly, time consuming, and potentially inaccurate paper record keeping. A single planner/scheduler coordinates use of Avantis VIP Advanced Scheduling software on HP IPAQ handheld computers. The software ensures that all required people, tools, assets, parts, and other resources are lined up and available to the technician. A calendar wizard, for example, helps schedule the maintenance and measures schedule compliance. Therefore, instead of receiving a stack of paper work orders for the day, technicians now receive a PDA, which the planner/scheduler has already docked to the network and loaded work assignments for the day. At the end of the technicians shift, the PDA is returned and synced with Avantis.PRO, which consolidates all activity into a single database view. The planner/scheduler can then see the status of all existing and pending work orders instantly, including emergency or break schedule work that came in during the day. The planner/scheduler then uses the VIP tools to coordinate sick calls or any other schedule changes that are required and reconciles them with new work orders so that the updated PDAs are ready for crews when they report to work the next morning.

Streamlining Management Operations and Reducing Paperwork

SNWS, a department of the Southern Nevada Water Authority, manages treatment of up to 900 million gallons of water every day. Thirty pumping stations distribute water across 163 miles of pipeline to users throughout Southern Nevada. Maintaining a system of this magnitude is an enormous undertaking, requiring mechanical skill, system performance monitoring, information analysis, and efficient resource deployment. Efficient planning and scheduling is the key, said Jeffrey Deitch, Business Systems Analyst with the Technology and Special Projects Division. SNWS took its first step toward automated maintenance planning and scheduling (automating work order, entity, and inventory management) with the installation of the Avantis.PRO enterprise asset management software. According to Deitch, Our primary objective was to reduce paperwork. Less paperwork means more wrench time for the technicians and that means more availability of equipment and better service to the Authority. Also, less paperwork in the back office frees administrative staff to perform other value-added activities to improve the efficiency of our operation.

Savings and Impressive Results

SNWS now has 12 technicians on PDAs. This helps to plan and schedule field maintenance,

Advanced Scheduling Solution

When Deitch learned that Invensys Operations Management offered an Avantis planning and scheduling client for personal data assistants (PDAs), he saw the opportunity to

141

Water and Wastewater

Avantis.PRO

in work order processing and $33,000 in reduced administrative costs. Through the display, I can see daily or weekly availability of my entire crew in a single Gantt-style chart, said Deitch. Color-coding tells me where they are, what work has been started, and what has been completed. It is accurate up to the preceding day. Getting that kind of information would otherwise require a tremendous administrative effort, which would take away from wrench time. The software also helps make better use of the new time they have available. communicate schedules to the technicians on a timely basis, and obtain accurate and timely records back into the enterprise system. In its first year of operation, SNWS is expecting to save about $17,000 Running Avantis VIP advanced planning and scheduling software on PDAs has proven to be a multi-part solution for SNWS.

This document was realized thanks to the support of: Southern Nevada Water System 142

Leading magazines in the automation end electronic sectors

For more information please contact the Sales Manager: Giuseppe De Gasperis - tel. +39 02 4997.6527 - email:giuseppe.degasperis@eramilanoeditore.it

www.ilb2b.it - www.eramilanoeditore.it

Video Success Stories

INDUSTRY: FOOD AND BEVERAGE

Beam Global Spirits and Wine

www.jimbeam.com
Solutions and Products ArchestrA System Platform InTouch HMI Wonderware Historian Wonderware InBatch software ActiveFactory Trending, Analysis and Reporting Software

INDUSTRY: FOOD AND BEVERAGE

Chr. Hansen
www.chr-hansen.com
Solutions and Products Wonderware Information Server

INDUSTRY: FOOD AND BEVERAGE

New Belgium Brewing Company

www.newbelgium.com
Solutions and Products ArchestrA System Platform Wonderware Historian Wonderware InTouch HMI Wonderware ActiveFactory

INDUSTRY: LIFE SCIENCES

Xcellerex
www.xcellerex.com
Solutions and Products ArchestrA System Platform Wonderware InBatch Wonderware Historian Wonderware InTouch HMI

INDUSTRY: METALS, MINERALS & MINING

Nucor Steel
www.nucor.com
Solutions and Products ArchestrA System Platform Wonderware ActiveFactory Software Wonderware InTouch HMI Wonderware Historian Software

INDUSTRY: MOTORSPORTS

Hendricks Motorsports
www.hendrickmotorsports.com
Solutions and Products Avantis Asset Management Software Avantis Industrial Rapid Implementation Methodology (InRIM)

INDUSTRY: POWER

9REN
www.9rengroup.com
Solutions and Products Wonderware InTouch HMI ArchestrA System Platform

INDUSTRY: TRANSPORTATION

China Ministry of Railways

www.china-mor.gov.cn
Solutions and Products ArchestrA System Platform Wonderware Historian Wonderware Toolkits Wonderware InTouch HMI Device Integration Servers

INDUSTRY: WATER AND WASTE WATER

Ontario Clear Water Energy

www.ocwa.com
Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware ActiveFactory Software Wonderware Historian Software Wonderware SCADAlarm Wonderware Information Server

INDUSTRY: WATER AND WASTE WATER

Pinellas County
www.pinellascounty.org
Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware Historian Software

INDUSTRY: WATER AND WASTE WATER

Puerto Rico Water and Sewage Authority

www.acueductospr.com
Solutions and Products ArchestrA System Platform Wonderware Historian Wonderware Information Server Wonderware Industrial Computers ActiveFactory Trending, Analysis and Reporting Software

INDUSTRY: WATER AND WASTE WATER

Yellow River Conservancy Commission

www.yellowriver.gov.cn/eng/
Solutions and Products ArchestrA System Platform Wonderware InTouch HMI Wonderware Historian Software Wonderware Information Server Wonderware Device Integration Servers

NOTES

146

NOTES

147

NOTES

148

NOTES

149

NOTES

150

NOTES

151

NOTES

152

NOTES

153

Leading magazines in the mechanics and project engineering sectors

For more information please contact the Sales Manager: Giuseppe De Gasperis - tel. +39 02 4997.6527 - email:giuseppe.degasperis@eramilanoeditore.it

www.ilb2b.it - www.eramilanoeditore.it

THIS SITE CONTAINS GRAPHIC DEPICTIONS OF PERFORMANCE

Join the journey

WARNING
InFusionJourney.com

May be suitable for audiences unaccustomed to high performance.

Avantis

Eurotherm

Foxboro

IMServ

InFusion

SimSci-Esscor

Skelta

Triconex

Wonderware

Real Collaboration. Real-Time Results.

TM

Copyright 2011. All rights reserved. Invensys, the Invensys logo, Avantis, Eurotherm, Foxboro, IMServ, InFusion, Skelta, SimSci-Esscor, Triconex and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be trademarks of their respective owners.