T12 — Case Study: Dubai Aluminium - Rockwell Automation · T12 — Case Study: Dubai Aluminium...

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Rev 5058-CO900B

T12 — Case Study: Dubai Aluminium

Jeff Krbec Business Manager, Global Solutions November 7-8, 2012 — 10:00AM

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Session Abstract

Dubai Aluminium (also known as DUBAL) is transferring its state of the art Reduction cell technology for the largest Aluminium Reduction line in the world currently being built at Abu Dhabi (EMAL). DUBAL selected the Global Solutions team at Rockwell Automation to develop and implement the control system for the reduction cells, which includes dozens of controllers and hundreds of I/O cabinets. This presentation will discuss best practices for large project control, as well as the complexities of managing a project which involves thousands of personnel.

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Dubai Aluminium DUBAL owns and operates the world’s largest modern

aluminium smelter with a captive power station.

Built on a 480-hectare site in Jebel Ali, Dubai, UAE,

the complex's major facilities comprise:

a one million tonne per annum primary aluminium

smelter

a 2,350 megawatt power station (at 30°C),

a large carbon plant, casthouse operations,

a 30 million gallon per day water desalination plant,

laboratories, port and storage facilities.

DUBAL also holds a 50 per cent share in EMAL.

Entirely state-owned, DUBAL is one of the largest non-

oil contributors to the economy of Dubai and widely

regarded as the industrial flagship of the UAE.

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Emirates Aluminium EMAL is a state of the art aluminium smelter complex

supplying the world with high quality metal. The advanced

smelter in Al Taweelah currently uses DX Reduction Cell

Technology to produce 750,000 tonnes of aluminium

annually. This will increase to 1.3 metric million tonnes by

the end of 2014 upon completion of Phase II and the

installation of the new generation DX+ Reduction

Technology, making it the largest single site smelter in the

world. Approval of a $4.5bn investment for Phase II,

combined with the original $5.7bn Phase I joint venture

between Dubai Aluminium and Mubadala Investment

Company, makes EMAL one of the largest industrial

projects in the UAE outside of the oil and gas sector and

one of the key projects leading the diversification of the

UAE’s economy. 4

EMAL Phase 1 (2009)

(2) 375K TPA Potlines

Casthouse

Carbon Plant


Global Solutions Bringing you a world of experience

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Consistent methodology deployed in all locations

The right team for your project from our worldwide talent

All major industries Any production environment Combining technology &

application knowledge

Based on PMI ® PMBOK®

Certified project managers Repeatable, measurable,

auditable Risk management

Domain Expertise

Global Execution

Information | Process | Discrete Automation | Power Motion | Sustainable Production | Technology Migration | Hardware Integration

80 Countries | 20 Languages | 3000+ Employees | Average 13+ Years Experience | Single point of contact

Project Management

Helping you exceed your business goals


How do we make Aluminium

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6–8 Million Tons of Bauxite 2-3 Million Tons of Alumina 1 Million tons of Aluminium


EMAL Phase 2

DUBAL is providing a 444 cell (pot) 550 K tpa system to their partailly

owned subsidiary EMAL Process design Technology License Automation & IT systems Startup Assistance

In order to maximise the line output, the line will have the most cells on a

single line ever built. Reduced Capital Investment Unique Electrical Challenges

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Project Overall Coordination

Rockwell Automation Project Management Hardware engineering Network Design Network Test FS Development / Documentation Level 1 &2 Consultancy FAT Cabinet Assembly Cable Provision Installation Management Commissioning

DUBAL Automation L1 Code HMI Screen design L2 Interface

DUBAL IT L2 Code, screen L3 Code, Screen, Reports Audio System

SNC Automation specifications Panel & Cabinet Installation Cable routing engineering Power supply Fibre network supply

DUBA

L Te

chno

logy

Dev

elopm

ent &

Tran

sfer

P

rojec

t Man

ager

EMAL Operation needs/requirements Operators

DUBAL Technology Development Process & Pot Design Process Definition Documentation Control

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 9

DUBAL EMAL

RA DESIGN TEAM

MFG TEAM


Original System Architecture

Note: Final network architecture is more complex than shown to facilitate phased implementation (redundant star in place of REP ring)


Pot Group Architecture

Looks easy right ? Maybe not if you need to connect (48) of these subsystems


System Scale

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550K ton per year potline 1500 meter length 2000VDC, 460,000 amp

power feed 1351 Cabinets ~2500 Cables > 10,000 Engineering & PM

Hours > 30,000 manufacturing and

test hours > 7,000 Commissioning Hours

(50) L7x Controllers (224) 10” PV+ (224) Point I/O Nodes (448) E3+ motor starters on Enet/IP (50) Stratix 8000s (448) ETAPs


Project Execution - iPM

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Integrated PM Methodology Based on PMI – a Global Standard

A Guide to the Project Management Body of Knowledge (PMBOK® Guide): PMI has become, and continues to be, the leading professional association in project management

– PMI has over 200,000 members in 125 countries – The PMBOK® Guide is the globally recognized standard

for managing projects in today’s marketplace – The PMBOK® Guide is approved as an American

National Standard (ANS) by the American National Standards Institute (ANSI)

Planning Closing Executing

Con trolling Initiating

Process Groups

Knowledge Areas


Project Management Methodology

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• Develop project charter • Identify Stakeholders

• Collect requirements • Define activities • Develop project

management plan: (cost, quality, risk,

communication, schedule, scope & change control,

procurement and staffing)

• Quality assurance • Manage resources • Communicate & report • Monitor and control risks • Manage & Control : (resources, scope, schedule & costs)

• Close project activities • Capture lessons learned • Survey customer satisfaction • Transfer to operations/support teams

• Pre-project planning • Front End Engineering & Design

(FEED)

* Blue denotes PMI® methodology

• Parts Management • Preventive Maintenance • Training • Embedded Engineer

OPERATE & IMPROVE

CLOSE

ORIGINATE

INITIATE

PLAN EXECUTION & CONTROL


Project Execution – Governance Model

It is very typical for Global Solutions to implement a Governance model on major projects.

This project includes a quarterly steering team:

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Middle East Sales Director

Heavy Industries Business Manager

Metals Business

Development Manager

Technology Development

& Transfer Director

Contract Manager

IT Manager

Automation

Manager


Risk Mitigation - Network test

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Network Test included:

(48) Logix CPUs (pot controllers)

(2) Logix CPUs (current distribution)

(26) Stratix 8000 switches (2) Cisco 3750x switches

I/O, PV+, E3+ on Enet for (5)

Pots

Network design, test and commissioning provided by RA Network Security Services team


Risk Mitigation - FAT

FAT System included: (32) cell system

(2) PLC Panels (16) Pot Control Panels Potline Current Distribution

System Network Infrastructure Level 2 / MIS Server

A FTView based network

diagnostic system (1650 nodes) to facilitate both startup and maintenance

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Risk Mitigation - Pilot

(10) pots from EMAL Phase 1 have been converted to the new technology

The existing lab line at DUBAL has a different electrical system

This will also provide a training system for operators

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Image courtesy of EMAL


Risk Mitigation – Life Cycle Support

Commissioning team is made up of local Field Service personnel to ensure a smooth transition for on-going support

The EMAL site has had Parts Management agreement and Techconnect support contract in place since phase 1 commissioning started in 2008

These contracts shall be expanded for scope and additional components L7x controllers and EtherNet/IP

infrastructure components

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• Develop project charter • Identify Stakeholders

• Collect

requirements • Define activities • Develop project

management plan: (cost, quality, risk,

communication, schedule, scope & change control,

procurement and staffing)

• Quality assurance • Manage resources • Communicate & report • Monitor and control risks • Manage & Control : (resources, scope, schedule & costs)

• Close project activities • Capture lessons learned • Survey customer

satisfaction • Transfer to

operations/support teams

• Pre-project planning • Front End Engineering &

Design (FEED)

• Parts Management • Preventive Maintenance • Training • Embedded Engineer

OPERATE & IMPROVE

CLOSE

ORIGINATE

INITIATE

PLAN EXECUTION & CONTROL


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Rev 5058-CO900B

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