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PlantPAx Objects for Chemical Processor
ECS Solutions, Inc. (ECS) recently executed an increasingly rare upgrade for a midwestern chemical processor. The application was rare in that the facility and its controls were neither a brand new, greenfield design nor an upgrade from existing, controller-based automation. This grain processor utilizes volatile hexane in their oil extraction operations so the facility has classified locations throughout. Thus, the legacy control system leveraged pneumatic integration, and hard-wired, and hard-plumbed control loops. That system served them admirably for years and was left in place until this was replaced with a modern electrical system at the direction of ECS.
To facilitate a clean project that could be adopted easily by seasoned operators, ECS built the automation using Rockwell Automation ControlLogix hardware and PlantPAx objects for the code. The robust library of process objects made the code generation very straightforward, and the controller code coupled seamlessly to the Rockwell FactoryTalk View SE SCADA. ECS’ high-performance HMI design focused on a simple, flatter overall concept that leveraged color and animation effectively to drive efficient user interaction. Information from code easily passes to the newly deployed FT Historian system, sharing the same information to the long-term storage.
Interwoven in the control system are other elements that leverage the PlantPAx technology like Rockwell Automation variable frequency drives connected via Ethernet and encompass partner instrumentation. The design specifically kept the products homogeneous so that detailed information from these devices is shared with the operators. System control items, alarms, and even the ability to see underlying code are used throughout the design. Thanks to the PlantPAx objects, this information is presented in a clear and concise manner with enough detail for critical decision-making without overloading the operators.
“From a project development standpoint, using PlantPAx objects reduces development time since a good deal of the component code for them is pre-validated,” says Ryan Muller, project manager from ECS. “Ironically, the objects deliver more by way of information and control about most of the automation equipment so the user experience is enhanced in that regard”, Muller continues. “Further, each instance of similar equipment looks and behaves exactly the same so operators’ learning curve is reduced and they have more confidence when using the control system”.
The Plant PAX architecture provides an additional benefit for simple upgrades or migration in the future. The processing element of this client’s system is complex and involves quite a bit of time and effort to stop and restart. Thus, it is only stopped when absolutely necessary, typically once annually during a shutdown. The PlantPAx objects used within this system were unmodified by ECS during implementation and, thus, can upgrade automatically, if desired, when an updated object is released. This provides a simple scalable upgrade path with the least risk.
The operators adopted the new system readily. They were among the most seasoned of the site’s operators and they had proudly controlled the legacy system via its manual controls for a long time. A few later admitted they were skeptical that the revised system would suit their needs. The ECS Team’s pragmatic design and methodical approach to project management ensured that the operators were involved in the review process and, via pre-deployment training, that they were anxious and supportive by system startup. Today they execute the process control with the same confidence they have for the decades prior to the system upgrade.
Posted In: Case Studies, Chemical Industry