Making ISA-S-88

Control Systems More

Affordable
Insert Photo Here Randy Otto
ECS Solutions

Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL – McCormick Place West
Introduction

Evansville, Indiana

Founded in
1977
Overview

2009

• Overview of the project

• Size and scope
• Challenges
• Key Decisions
• Key Features
• Results
Overview
Overview (consolidate 3 pre-existing kitchens)





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Overview (relocate kitchen 3)



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Overview (clear area for initial kettles)



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Overview (installation of initial kettles)


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Overview (demolition kitchen 1 / continue installation)








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Overview (demolition kitchens 2 and 3)




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Overview (final configuration)
 Size of New System

70 Tanks / Kettles

120 Variable
Frequency Drives
Size of New System

1,200 Valves

Copyright © 2011 ECS Solutions, Inc. All rights reserved.

Size of New System

5 Clean-in-Place
Systems
 ECS Scope of Supply

Instrument
System
Hardware
Architecture
Specification
Design
ECS Scope of Supply

Controllers Motor Controls

Operator Terminals

Procure Materials

Solenoid Valves

Network Hardware / Servers

Instrumentation
/ Computers
 ECS Scope of Supply

16 Motor Panels

Operator
Procure
Valve
Motor Panels
Control Materials
Panels
Terminals
Panels
8 PLC Panels

50 Valve Panels

13 Operator Panels
ECS Scope of Supply

Software
ValveDevelopment
Panels
 Challenges
Short
Commissioning
Short Development Schedule Schedule
Hardware Design Procure Materials Panel Fab & Install Production
System
Trials
Architecture
Software Development (12 tanks)

10 weeks 1 week

Phased Implementation While Maintaining Production

Phased Startup and Commissioning (Remaining 58 tanks)

10 weeks
 Key Decisions

S88 Physical
Model

Process Cell
“SEPARATE”

Unit

Equipment Phase

Equipment Module

Equipment
Control Module Programming
 Key Decisions

S88 Physical
Model

Process Cell

Unit

Valve A Valve B Valve C Pump

Equipment Phase

Equipment Module

Control Module
 Key Decisions

S88 Physical
Model

Process Cell

Unit
Valve C
Valve A Valve B
Equipment Phase
Pump

Equipment Module

Control Module
 Key Decisions

S88 Physical
Model

Process Cell

Unit
Add Water
Valve C
Valve A Valve B
Equipment Phase
Pump

Equipment Module

Control Module
 Key Decisions

S88 Physical
Model

Process Cell
Water

Unit
Ingr A Ingr B Heat

Equipment Phase
Agitate
Equipment Module

Transfer
Control Module
 Key Decisions

S88 Physical Software

Model Development

Process Cell Recipes

• FactoryTalk Batch

FT Batch
• Software Innovations
Unit S88 Area Model

Equipment Phase Equipment Phase Graphics

FT View
ControlLogix
Equipment Module Equipment Module EM Faceplates

Control Module Control Module CM Faceplates

 Conceptual Overview

FactoryTalk Batch
• Recipes / Procedures
• Automatic Control
• Batch Management

ControlLogix PAC
• Equipment Modules
• Control Modules
• Software Innovations

FactoryTalk View SE
• Operator Interface
• Manual / Semi-automatic interface
Intelligent Equipment Module Faceplates

Equipment Module Faceplate

Simple Clean-in-Place

Clean-in-Place Faceplate
Cleaning
Procedure
Alert Navigator

Alert Navigator

Ingr A Ingr G Ingr M Ingr U

Ingr B Ingr H Ingr N Ingr V

Ingr C Ingr I Ingr O Ingr W

Ingr D Ingr I Ingr P Ingr X

Ingr E Ingr K Ingr Q Ingr S

Ingr F Ingr L Ingr T

Ingr R
Pipe Animation

Built-in Pipe Animation

• 15 Colors
• Shows residue – most recent product
Device Animation

Acquired / Interlocked Status

• Acquired / Interlock status displayed

throughout
Electronic Work Instructions
Production Scheduler
Fully Simulated System
 Recap Challenges

Short • (10) weeks for development

Schedule
Short • (1) week commissioning for initial 12 tanks
Startup
Phased • Phased implementation during production
Install
 Recap Key Decisions

ISA-S88 • “Separate” Equipment from Process

Programming
Standard • Modular, building blocks

• Recipe Development / Automatic Operation

FTBatch • Performance Optimization

Software • Equipment Module / Control Module Devp

Innovations • Advanced Features / Advanced Diagnostics
Results Original Justification

Reduction in large
contracted staff

Increase in
efficiencies

Replacement of
obsolete controls

Increase in
capacity
 Results Unexpected Return from Software

$20M
Reduced
$18M
Development
$16M
$14M
$12M
FT Batch $10M
and Software $8M
Innovations $6M
$4M
$2M
Cleaning

2010

2012
2013
2014
2015
2016
2017
2018
2019
2011
Process time
reduction
 Better, Quicker, for Less

S88 Physical
Model
Speed to Market
Process Cell

Short Project
Unit Schedule

Equipment Phase
Flexible Solution

Maintain Production
Equipment Module Levels
Save Development
Control Module
Costs / Time
 Questions

Randy J. Otto
Vice President
Randy.Otto@ECSSolutions.com
812-431-7824
812-479-5170 x503