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Occupational
5 years with the Naval NPTU 7 years with Bama Companies 5 years maintenance 2 years as Corporate Controls Engineer Current responsibilities include plant floor controls and visualization for all Tulsa based plant locations
Personal
Married, 3 kids, one on the way; live in Tulsa, Oklahoma Interest include: Family activities, computers
Process Description
Ingredients Sheeting Line
Freezer Mixing
Packaging
Solutions Evaluated
All technology was to remain Allen-Bradley based
Installed base and familiarity with products
2)
3)
Vendor Selected
PlantPAx (FTBatch, FTView, ControlLogix) system delivered by Rockwell Automation Only one to formalize/organize a User Requirements Spec
(Was a billable activity but of value)
Dwayne McAlexander:
Lead Engineer
Nick Huddleston
Process Improvement Mngr. Operations Lead
David Keen:
HMI Implementation
John Blaylock
Networking and SW Installs
Jed Hepfner:
Field Support, Training, Testing, Startup support
Electrical Foreman
Functional Specification
Mapped out entire process (Blueprint) Completed and approved before design/coding started 9 revisions by Bama lead operators, engineering, maintenance (inclusivity) Contractually binds the deliverables and acceptance criteria
Copyright 2011 Rockwell Automation, Inc. All rights reserved.
22 Batch Units
105 Phases 25 Active Recipes
1 ESX Server
FTView SE VM FTBatch VM SQL VM Citrix Published Apps 10 Thin Clients Redundant HardDrives
Failover Scheme
Copyright 2011 Rockwell Automation, Inc. All rights reserved.
FTBatch
22 Units
Incorporated all Hand Adds, Equipment Checks, and SOPs through operator prompting Batch journal is dumped to a SQL database through an ODBC connection
SQL Database
Existing System prior to upgrade Uses Business objects (our ERP) Data table work required but ultimately working with our existing reports
Copyright 2011 Rockwell Automation, Inc. All rights reserved.
Software
System originally built for existing IT/Business infrastructure Process system added with minimal changes
New VLAN and a few switches standard growth
Not completely new concept (running RSView32 Virtually for 3 years) Ten (10) Thin clients being managed by single terminal server image
Install once, use multiple, replace easily Only ini file needs to be updated with MAC ID of new hardware
Three (3) virtual servers dedicated to the PlantPAx system Fourth virtual server (SQL) offsite Three (3) Citrix Applications
This was a lifesaver for startup because it eliminated hurdles that would have existed otherwise
Factory Acceptance
Performed At Bama :
Brought to Bama at our request; standalone simulated process so we could have a large audience and increased exposure Difficult to segment between familiarization, training, and, testing Left active in the off hours so others could interface with system Eventually used the virtual test rig from FAT for startup and cut install time (just redirected communications) Remote access for Rockwell Automation allowed so that FAT punch list and initial installation steps could be done before install
Lessons Learned
Not all Units are Created Equal:
Typical Units = mixers, hoppers, slurry tanks, etc We found others such as a Salt Chute.
FAT:
Was short as we were trying to train at the same time we were checking out; should not have tried to address issues all at once instead of working on a fix at the time.
Virtual Servers:
Use Snapshots to keep fresh rollback points.
Benefits Seen
Still in the evaluation processes but
Looking to see about improvements around power outages Flexible recipes trials (no salt) completed without interrupting production Found a lot of hardware and material deficiencies as part of the process i.e. RPM sensor preventing packing flour sifter at least once since install Double signoff now needed which improves/enforces QA involvement on signoff Eliminated paperwork for hand add tracking Improved manual equipment control capabilities that did not exist before Improved alarming and troubleshooting capabilities from the plant floor Inclusivity of system selection and deployment improved plant adoption
Rockwell Automation Process Solutions User Group (PSUG) November 14-15, 2011 Chicago, IL McCormick Place West
Copyright 2011 Rockwell Automation, Inc. All rights reserved.