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Operating on an antiquated DCS and historian, a leading supplier of glass packaging was limited to a 14-day capacity for historical data storage. Hard-coded alarms were unmanageable by operators. The company upgraded to a PlantPAx® system with FactoryTalk Historian software. The new system pulls and stores many years of data, freeing hours spent on manual collection and opening a new resource for system analysis and improvements. Alarm integration and remote access empowers operators to manage alarms at the HMI level and significantly lowers maintenance and support costs.
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Anchor Glass Corporation: Alarm Integration Enables More Manageable, Cost-Efficient Process System
Chris Wild, Electronic Controls Specialist – Anchor Glass ContainerBrad Downen, MES Project Manager – Stone Technologies
Choosing PlantPAxAlarm Integration Enables More Manageable, Cost‐Efficient Process System
Agenda
Introductions Anchor Glass Background Goals Why PlantPAxTM
Benefits realized PlantPAx Challenges Q & A
CHOOSIN
GPLAN
TPAX
Introductions
Chris Wild – Electronic Controls Specialist Anchor Glass Container
Brad Downen – MES Project Manager Stone Technologies
Audience – How Many ... End Users System Integrators Rockwell Automation Distributor Other
CHOOSIN
GPLAN
TPAX
Experience with… PlantPAx Operations PlantPAx Development
COMPAN
YOVERVIEW
Anchor Glass Container ‐ Background
Anchor Glass A leading North American manufacturer of glass containers with annual revenue
of approximately $550 – $600 million and employing approximately 2,000 people.
6 glass manufacturing facilities, consisting of 11 furnaces and 31 lines 2 Oxy/Gas furnaces, 9 Gas/Air Reversing furnaces Lots and Lots of bottles!!!! Up to 600/min => 300,000,000 bottles/yr
Controls History 1986‐1995 – Deployed Leeds and Northrup Micromax DCS controls system
throughout the company 2003* – Established new corporate standard HMI and Controls with Rockwell
Software’s RSView32 and ControlLogix® processors 2012 – Adopted Rockwell Automation’s PlantPAx controls strategy layered with
Rockwell Software’s interface solution: FactoryTalk View SE, FactoryTalk Historian SE, FactoryTalk Alarm and Events, FactoryTalk VantagePoint
MAKIN
GAGLASSB
OTTLE
Anchor Glass – What we are doing
Convert crunched, recycled glass or raw materials into a liquid Create a stream of lava and condition the stream of lava to a consistent temperature
and weight Physical items to control
Burners (many, many) Pressure (helps prevent flames from shooting out) Glass Level (weight of the bottle) Electric Boost Reversal (conserves heat)
FurnaceForehearth(3)
Hole located here drops the gob of glass to make the bottles
GOALS
Goals
Replace outdated DCS System Provide more intuitive operator interface Tighter Controls Configurable!!! (especially for reversals) Better historical of data for analysis (both Process & Alarming) Better Alarming. Managable (Alarming without overwhelming noise) Extendibility: capable of expanding to other areas of plant Remote access – Corporate viewing Low maintenance
PLAN
TPAX
What lead us to PlantPAx
Sequence Object for Reversal
Inputs Outputs
Steps & Operation Status
PLAN
TPAX
PlantPAx valued benefits
• Note to self: “PlantPAx isn’t something you should try to partially implement!!!!”
Fringe Benefits Standards!!! Tightly Integrated with HMI – Minimal need to access PLC
code Easily simulated and tested Rich features and functionality available at HMI level Historical Data – dependable, reliable, fast and DEEP….store
much, much more data than before. Easily hold 1‐2 years of data verses 10 days for operations
Alarming – Full control of alarms from HMI. Configure, disable, enable, and SNOOZE!!!!!
PLAN
TPAX
Architecture: Provide failover communication paths
Data servers located in control room to eliminate possible infrastructure failure points
Virtual Server hosting 3 virtual machines: HMI, Historian & RDP Server
Data Servers configured for failover of: Linx Enterprise Historian Interface Nodes FactoryTalk Alarm & Events
HMI developed as direct tag so dependence on HMI server is minimal
PLAN
TPAX–FU
LLFEATURED
Consistent Standards – Especially with PID zones
HISTO
RICALDATA
Data ‐ A wealth of knowledge
Alarming Analysis ‐ Value Added PLAN
TPAX–ALARM
INGBEN
EFITS
Quickly pin‐point areas of concern Determine if issues are caused by system or operator Alarms configured to obtain important process data to
determine if issue was operational, electrical or mechanical Focus maintenance on issue and not just a guess
ALARM
REPO
RTING
Alarming Data that IS useful
Challenges
New Programming Scheme (could not re‐use any previous controls standards)
Learning & dissecting all available objects for new project
Understanding PlantPAx security
Added Screen counts
Operational Training
PLAN
TPAX
PLAN
TPAX
Questions
Chris Wild, Electronic Controls Specialist – Anchor Glass ContainerBrad Downen, MES Project Manager – Stone Technologies
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