Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

PCS Phosphate Automates Reporting to Liberate Process Engineers and Improve Accuracy

Derek Hyde

Systems Analyst

PCS Phosphate

PotashCorp.com

PCS Phosphate White Springs, FL

Presented By Derek Hyde

PotashCorp.com

• Systems Analyst

• .NET Web Form Applications

• SQL 2010

• Hired to assist with the growing need for

application support and in-house

solutions.

• FactoryTalk® VantagePoint® reports was

some of the first work that I performed for

the company

• Process Engineers

• Training

About Derek Hyde

PotashCorp.com

Company Background

Issue to address

Technologies used

Results

Next Steps

Agenda

PotashCorp.com

PotashCorp's White Springs facility is one of six

operations in our phosphate division, with facilities

located throughout the United States.

Phosphorus is extracted from ancient sea fossils

and used in agricultural and industrial products like

fertilizers, animal feed, food additives and other

applications. At White Springs we process

phosphate ore into phosphate rock which we

convert into phosphoric acid - the feedstock for all

our phosphate products. Products are shipped by

rail and road to customers around the world. We

are committed to the health and safety of our

people, the protection of our shared environment

and the economic and social well being of our

community.

About PCS

Phosphate Division

PotashCorp.com

• Production

• Annual Capacity – 3.6 million tonnes

phosphate rock, 1.0 million tonnes

phosphoric acid, 0.3 million tonnes

phosphate feed.

• Products

• Monoammonium Phosphate

• Phosphogypsum

• Superphosphoric Acid

• Uses

• Solid fertilizers and animal feed

supplements are used in agriculture.

Phosphates are used to manufacture

downstream industrial products.

About PCS

Phosphate Division

PotashCorp.com

Company Background

Issue to address

Technologies used

Results

Next Steps

Agenda

PotashCorp.com

• Hired to address the reporting bottlenecks

at the time

• Automate some of the manual reporting

• Large Piles of paper log sheets

• Statisticians would crunch the data into

Excel spreadsheets.

• Seen as non-essential

• Round of layoffs

• Moved a process to a different facility –

catalyst to re-engineer the reporting

process

• Too many high-value people doing low-

value work

Issues that needed

addressing

PotashCorp.com

State of Affairs of

Production Reporting

Operator

President

Statisticians

Accountants

Wrote values

in Log Books

Typed Values into

various spreadsheets

Crunched Data in

additional spreadsheets

Received reports

eventually which were

very error prone

PotashCorp.com

• Consultant came in and mapped the work

flows

• Marked the reporting process deficiencies

• They looked into where the data was

• Historian

• LIMS – Oracle

• Mineware – collects data on the Drag lines

- SQL Server

• Paper Log Sheets

Multiple Data Sources

PotashCorp.com

• Had an old process and then laid off all of

the statisticians

• We have a corporate process engineer at

the corporate office that has OSI PI, which

he stewards.

• Eventing engine is the heartbeat.

Project Justification

PotashCorp.com

• Process Control Engineers who were

familiar with FactoryTalk VantagePoint

gave it as a recommendation

• Recommended because of the strengths it

has in connecting to multiple

databases/datasources

• Simple to leverage time-series data from

our already in-place historians.

Finding the Solution

PotashCorp.com

Company Background

Issue to address

Technologies used

Results

Next Steps

Agenda

PotashCorp.com

• FactoryTalk VantagePoint

• Connected to 3 Historians (In SQL)

• Connected to Oracle and SQL Databases

• Paper Log sheets were replaced with a

dynamic, asynchronous manual data entry

form (OLS)

• ASP Web Forms (VB.NET)

• Recreated from existing paper log sheets

Identified Middleware

• Powered by FactoryTalk VantagePoint®

• Web Interface to MS-SQL Data,

FactoryTalk® Historian etc (HMI or

management)

• View alarms / production reports / SP

changes etc.

• Supports data entry, e.g. lab results

(secured by permissions)

• Customizable web environment,

supports standard and custom reports

Web Reporting

• Key issue to obtaining data was legacy systems lacked correct instrumentation and

control systems to provide accurate data

• Example of LoMag process control system, installed PlantPAx® to replace legacy

DCS Moore APACs

Process Control System Data

PlantPAx Mining Solution

• Controller based logging, reporting,

alarming

• Industry specific control modules

• Advanced control modules

PlantPAx

• High performance faceplates

• Color / language switching

• FDT DTM Integration

• Status monitoring

INT

EG

RA

TIO

N

DIA

GN

OS

TIC

S

MA

INTA

INA

BIL

ITY

Network Architecture

PotashCorp.com

Company Background

Issue to address

Technologies used

Results

Next Steps

Agenda

• Month end closures used to take 6 days. Now, they take ½ a day. Only slow

parts are getting some of the manual data. Do so with the 1/3 man hour

equivalents.

• Freed the engineers from being mired into creating reports from the days

before. The first 2 hours of each day was wasted working on old data. Now

they start the day working on the day’s activities.

• 25% additional bandwidth usage from Engineering staff and Supervisors

• Field staff built their own OEE calculations for their area without input from

the System Administrator (Prentiss Adams).

• He’s a business analyst, not a chemical engineer

Benefits from the organization

• The engineers love the fact that they can trend lab values directly

out of the QA databases.

• Lab values calculated into production reports automatically.

• Eventing services get data into the hands of supervisors without any

additional work.

• After minimal training, users/engineers are actively creating reports.

• Drastic decrease in the amount of time taken to generate a report

and consolidate data.

Added benefits

• Production Inventory in P2O5 Tons

• Totalizer x Quality x Lab Values = P2O5 Tons Production

• Inventory = Tank info, Lab info (quality) strappings/level indicators

Final need was the Total Production

•Used to be done manually, now generated automatically.

• Production engineers actively improving and expanding upon the

system to generate the reports demanded of them.

•80 reports run automatically every night.

•Prentiss unavailable but happy to give out the contact

information.

Material Balance Reports

FactoryTalk VantagePoint Report – Branded Inventory

FactoryTalk VantagePoint Report – Nitrogen Dashboard

FactoryTalk VantagePoint Report – Phosphate Dashboard

Online Log Sheets (OLS)

HemiHydrate Tank Levels via strapping

FactoryTalk VantagePoint

/ OLS Marriage

• Provides nice overview

• MTD

• Adjusted Production

• Forecasts

• Consumption

• Rock Input

PotashCorp.com

• Word got out of the capabilities

• Use and success of FTVP in White Springs

led to the roll-out of the technology in other

sites:

• Expanded to Aurora, NC

• Expanded to Augusta, GA

• Researching solutions:

• Web Service times out. If that happens, the

event engine stops running. It happens

about once a week.

Future for PCS

There’s more online:

PotashCorp.com

Visit us online

Facebook.com/PotashCorp Find us on Facebook

Twitter.com/PotashCorp

Follow us on Twitter

Thank you

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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