Jiri Prochazka (BASF) & Jim Luffman (ABB), April 25, 2012 ... · Windsor, Canada – Paint Plant...

© ABB Inc. April 25, 2012 | Slide 1

APW – C551I BASF Windsor - Harmony system evolution success to System 800xA

Jiri Prochazka (BASF) & Jim Luffman (ABB), April 25, 2012 – Session 12

C551I BASF Windsor - Harmony system evolution success to System 800xA

Speaker name: Jiri Prochazka

Speaker title: Instrument & Electrical Engineer

Company name: BASF

Location: Windsor, Ontario, Canada

Co-presenter

Speaker name: Jim Luffman

Speaker title: Project Manager

Company name: ABB Inc.

Location: Burlington, Ontario, Canada


Agenda BASF Windsor

Introduction

About BASF – a brief overview

The BASF facility in Windsor, Ontario (Canada)

Evolution timeline summary

Project integration highlights

AC800M control

HPG (Harmony PCU Gateway)

Profibus

Intrinsic Safety

Project execution & coordination

Questions?

Key Learnings (Measureable Results)

© BASF April 25, 2012 | Slide 8

Introduction About the Speaker

Instrumentation & Electrical engineer at the BASF

Windsor, Canada – Paint Plant

18+ years experience in this position

Responsible for maintenance and new installation of

instrumentation, control systems as well as all mid &

low voltage electrical infrastructure for the facility

Mandated with the challenges of:

Enhancing overall installed base of electrical,

instrumentation and process automation

Increasing productivity and overall equipment

effectiveness

Balancing maintenance and operating costs

Maximizing equipment uptime

Maintain “Best-in-Class” approach through the

application of most up-to-date technology while

balancing best utilization of installed

infrastructure

Training staff

Jiri Prochazka


About BASF History and products

BASF The Chemical Company was first incorporated (as Badische Anilin & Soda Fabrik) in 1865 for production of coal tar dyes and other products.

Today, BASF is the world’s leading chemical company

We aim to constantly increase the value of company by

profitable growth and to remain the number one in chemistry.

We combine economic success with environmental protection

and social responsibility.

BASF is a publically traded company with ~ 111,000 employees and 2011 annual sales of 73.5 billion Euros

BASF is an innovative solutions provider, comprised of chemical, plastics, performance products, functional solutions, agricultural solutions and oil & gas segments

BASF is focused on sustainable development for long term growth and profitability

The automotive paint plant in Windsor, Ontario (Canada) is part of BASF’s Coatings Division, which is part of the functional solutions segment.


About BASF Paint plant facility in Windsor, Ontario, Canada

Products: OEM coatings, waterborne & solvent borne primers, and basecoats (automotive paints), and refinished products

Area: 8.5 acres, land locked

Site: over 100 years old

Floor space: 110,000 ft2

Total headcount: ~145

Average experience: 20 yrs

The site became BASF as part of the Inmont acquisition in early 1980’s


2007 (June) – Evolution implementation Operator consoles & engineering work stations

Conductor

VMS

Redundant

Servers

Conductor VMS

Clients

1994 2007 (June) 2007 (July)


2010 (September) Adding new controls for refinishing product line

In 2009 BASF made the strategic decision to expand the Windsor

facility to include refinishing products

Existing system has approximately 2000 I/O points for process

automation of blending, mixing, batch processes and dispersions

Project Scope:

New refinishing product line has ~ 600 I/O points

Addition of 800xA controllers to existing INFI 90 system including;

HPG (Harmony PCU Gateway)

2 x AC800M controller pairs

S800 I/O modules (with embedded intrinsic safety)

3 new operator client stations

New sequences implemented in AC800M controllers (using

Sequential Function Charts) and modified existing BATCH90

configurations

Addition of INFI 90 library into AC800M controllers

http://www.lzcd-cn.com/cn/upfile/200901092221.jpg


IS Interface

AC800M

2010 (September) Status Adding new controls for refinishing product line

2007 (June) 2008 2010 (March) 2010 (Sept.)

BRC400

HPG

AC800M

S800 I/O S800 I/O

Profibus to 3rd

party devices

(eg. VFD’s &

PLC’s)

Profibus to 3rd

party devices

(eg. VFD’s &

PLC’s)

System 800xA New refinishing line

Challenges and solutions HPG – Harmony PCU Gateway

Challenge:

Operators need to seamlessly control the new refinishing

products line while operating the existing blending, mixing,

batch processes and dispersions lines

Existing plant equipment was moved to the new refinishing

products line, yet field wiring remained unchanged, therefore

INFI 90 needed to interface with System 800xA

Solution:

HPG (Harmony PCU Gateway) to connect the existing

BRC400’s to the new refinishing products AC800M controllers

The Harmony PCU Gateway (HPG 800) is designed to provide

a robust, peer-to-peer communications with AC 800M

controllers via CI867 Modbus TCP CEX modules

Operators have seamless control of the new refinishing line

with the addition of some new graphics


Challenges and solutions AC800M Controllers

Challenge:

New refinishing product line has ~ 600 I/O points. BASF

wants to adopt new control technology and integrate it with

existing control technology

Solutions:

Using AC800M controllers (part of the System 800xA) for the

new refinishing products inputs/outputs

2 x AC800M controller pairs (allowed us to communicate to

third party devices using Profibus DP), including interfacing to

variable frequency drives connected to motors

Using Profibus with AC800M allowed BASF to utilize remote

I/O distributed to many buildings, minimizing field cabling.

This saved many hours of labour and testing

Addition of INFI 90 library into AC800M controllers to maintain

operator interface standards



configurations


AC 800M Controller(s)

Motor

Variable Speed Drives

Challenges and solutions S800 Input & Output Cards

Challenge:

Our process operates in a Class I Zone I environment. We

were limited on real estate space with the addition of the new

refinishing product line

Solutions:

S800 I/O modules were added for the new refinishing product

line

S800 I/O has embedded intrinsic safety in the modules

Total of 6 I/O cabinets distributed throughout the process

areas

Solution minimized footprint required in limited real estate

space


Challenges Project execution and coordination

Challenges:

Time was a challenge. The equipment was received at site in June 2010 and commissioning with loop checks & sequencing needed to be started September 2010

Site equipment and configuration had to be phased in existing process which was still in operation (switched one line at a time)


Solutions Project execution and coordination

Solutions:

The project was planned and scheduled with configurations combined and tested ahead of time

The hardware was shipped ahead of time so the wiring could be completed

Planned loading of graphics and configuration was used as equipment came on-line, others phased out

The final installation was implemented during a weekend shutdown “plug and play”, once final equipment swing over was complete

The upgrade was transparent to the operators, eg. Faceplates, etc. looked the same and operated the same on either the INFI 90 or 800xA system.

ABB was able to pool their resources together, plan hardware, loop checks, final configuration and sequence testing


Evolution Can you see the difference?


INFI 90

Operator graphic

System 800xA

Operator graphic


2011 (December) Tank farm PLC replacement and power system upgrades

In 2011 BASF made the decision to replace the programmable

logic controller (PLC) on the tank farm and upgrade the INFI 90

power supplies to MPSIII power systems

Existing PLC had approximately 300 I/O points for automation of

tank farm

Project Scope:

Addition of 800xA controllers to existing system;

1 x AC800M controller pair

S800 I/O modules

1 x new operator client station



configurations

Replaced INFI 90 power systems with 2 x MPSIII power systems

Add 5 new VFD’s for mixer control.

http://www.lzcd-cn.com/cn/upfile/200901092221.jpg


IS Interface

AC800M

2011 (December) Status Adding tank farm PLC replacement and power upgrade

2007 (June) 2008 2010 (March) 2010 (Sept.)

HPG

AC800M

S800 I/O S800 I/O

Profibus to

3rd party

devices

(eg. VFD’s

& PLC’s)

Profibus to

3rd party

devices

(eg. VFD’s

& PLC’s)

System 800xA New refinishing line

BRC400

Tank Farm

AC800M

S800 I/O

2011 (Dec.)

Tank farm PLC replacement challenges Project execution and coordination

Challenges:

Time was a challenge. The tank farm need to be moved from existing PLC to 800M in a single weekend, including complete loop and functionality checks

Minimal training for Tank Farm operators.

Upgrade INFI 90 power systems without affecting operations or tank farm upgrade

Add 5 variable frequency drives (in phases) with minimal effect on system interruption


Tank farm PLC replacement solutions Project execution and coordination

Solutions:

Project design included I/O with pre-terminated field cabling, 100% tested before shipment

Interconnecting cabling was designed to match the existing PLC cabinet terminal block grouping

New cabinet was installed ahead of shutdown.

New I/O marshaling cables wired to existing PLC termination panel in less than 1 day (Saturday).

New 800xA client computer was installed and tested before replacement Controller, S800 panel installed

All control standards from previous project were used for PLC replacement. Complete plant now looks and controls to the same standards –> minimized training.


Tank farm PLC replacement solutions Project execution and coordination

Solutions continued:

INFI 90 power supply upgrade installed weekend before tank farm PLC replacement. This concluded the DCS migration planned since 2005.

New variable frequency drives added to Profibus segments with minimal new wiring requirements

Variable frequency drive logic copied from existing configuration with minimal effort adding logic, updating graphics and checking I/O


Tank farm PLC replacement solutions


Tank farm control panel Power supply system upgrade

Evolution Next steps

The BASF Windsor site continues to evolve

Next steps include existing (obsolete) PLC’s evolve to ABB’s AC800M controller and S800 input & output cards

and thus eliminating control islands.

Special reporting for Filler Machine using Information

Manager.

Expansion of existing pigging system.



Key learning's and conclusions

1. We made the right decision….

Protected original

investment

Innovative approach to

evolution as opposed to

replacement

Minimized staff retraining

2. The new System 800xA

systems are stable and

reliable

3. All process information is available to operators / management through a single interface, plant controls are transparent to site staff whether they operate an INFI 90 or 800xA system

4. The plant’s control system

technology is new and up to

date

Minimizing maintenance

costs

Easy expandability

Low cost hardware

Flexible licensing

5. Minimized footprint of new equipment

6. Intrinsic safety embedded

7. Integrated services provided with ABB single contact representative

Jiri Prochazka (BASF) & Jim Luffman (ABB), April 25, 2012 ... · Windsor, Canada – Paint Plant...

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Transcript of Jiri Prochazka (BASF) & Jim Luffman (ABB), April 25, 2012 ... · Windsor, Canada – Paint Plant...