brennand & plantpax - rockwell automation · pdf fileplant expansion scheduled to february...
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Brennand & PlantPAx: Grass Roots Cement Plant
Eugênio Monteiro Neto Senior Automation Analyst, MBA Nov-12
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2
Agenda
Conclusion
Automation Project
The challenge
Brennand & Cement Market
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Brennand - History
Created in 1917, started its business in the sugar-alcohol market
Based in Recife, state of Pernambuco, in the Northern Region of Brazil
It expanded operations to different markets: Ceramics and tiles Glass Power generation Cement
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Brennand - Businesses
Ceramic & Tiles Home utilities, art objects Ceramic: different styles, shapes, sizes available Product line for exportation Personalized products developed
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Energy: 335 MW installed capacity 2 Hydroeletric Power Plants (HPP) 13 Small Hydro Power plants (SHP) 2 HPPs under construction (+21 MW) 3 Wind Power plants under construction (+90 MW)
Juba 2 HPP Diacal SHP Station
Glass: Float glass plant under construction (start up scheduled to Aug-13) Investment : ~US$ 400 million Production capacity: 900 tons / day Aimed to the civil construction
1st Float Glass plant in the Northeastern region
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Brennand – Other areas of investment
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Instituto Ricardo Brennand: since 2002 Museum, Ar Gallery and Library 200,000+ visitors per year Cultural activities and courses Educational programs for public schools
Gallery Inside
Educandário Nossa Senhora do Rosario Energy channeled to a better society Brennand Group maintains Educandario Children have constant medical, nutritional and educational
monitoring with music, art and education classes in early childhood
Brennand Plaza Building The Plaza has Brennand differentials that
come together in a place of tranquility and relaxation.
Castle
Reserva do Paiva Destination for tourism, leisure, housing
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Brennand – Cement Business
Cimento Nacional in operation since 2011.
Currently, the most modern cement plant in Brazil !
Cimento Nacional comes with the most advanced technologies available: Integrated plant with the latest technology machines and state-of-the-art automation
Results: superior quality and high performance cement
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Cement Market - 2011
Cement consumption in Brazil: 63.5 Mt (8.3% growth vs 2010)
Brazil is in 4th place in the world (behind China, India and USA) Prices went up 5.8% vs 2010
14 groups with 79 cement plants all over the country (2011) Current production level does not meet market demand
Huge investments in infrastructure underway: “My Home, My Life” Program from Brazilian Governement (homes for lower class) “Growth Acceleration Program” from Brazilian Government World Cup FIFA 2014 in Brazil, 2016 Olympics Games in Rio de Janeiro
Demand expansion expected in 2012: 8.1% Domestic consumption growth rate higher than GDP Production capacity already compromised even with new plants being built
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Agenda
Conclusion
Automation Project
The challenge
Brennand & Cement Market
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
The challenge
A cement plant build from scratch ! Total investment : US$ 300 million Capacity : 1,000,000 tons / year Start up : February 2011
Brennand was looking for : An automation solution for the optimal plant performance Open architecture (no proprietary networks) Infrastructure to support future plant expansion (less time, lower risk) Integration of plant data to support real time decision making by upper
management Lower cost of ownership
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Why did Brennand choose Rockwell ?
Process Optimization
Asset Management
Information Management
• Plant & HQ
• Control System • Instrumentation • Rotating Equipment • MCCIs
Process Control
• Control • Interlock • Safety • Power
x
x
Future
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Agenda
Conclusion
Automation Project
The challenge
Brennand & Cement Market
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Process Control
29 Controllers – 80,000 I/O points 12 ControlLogix; 17 CompactLogix
71 AC Drives DeviceNet (+20 units out of DN)
650 HART instruments
Infrastructure Redundant PASS 09 Operating Work Stations (OWS) – Dual Monitor 02 Engineering Work Stations (EWS) 06 Virtualized Physical Servers
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Virtualization – 06 Physical Servers
Installed in 2 different locations
29 VMs (Servers)
2 Storage Dell II (9 HDs of 600 GB SAS 6 Gbps in each storage)
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Alarm Priorization
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Web Visualization
Expands the ability of visualization Real time update, high quality screens, full animation,...
Expands the ability of visualization and real-time decision to remote users
Views screens, trend and alarms to simplify casual users access
Waives software installation and maintenance
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Web Client: Feed to Roller Mill
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Asset Management
Rockwell Asset Management tools cover large breadth of equipment
Control System Automated backup of logic/files Traceability (Developer, Operator, Engineer)
Error, Warning, Audit, Information
Instrumentation Field device configuration Calibration management of field devices
Regulatory compliance, Staff effectiveness improvement, More repeatable process, Lower production cost,...
MCCIs Remote diagnostics Documentation repository
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Asset Management FT AssetCentre
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Traceability
Automatic Backup
Field Device Configuration
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Information Management
Demand increase in cement requires real time tool to support quick & good decision making
Integration with different types of DataBases Connectors available (SQL Server, MySQL, Oracle,
devices in real time OPC DA, …)
Web based reports Trends, dashboards, XY charts,...
Information available throughout the plant
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Dashboards de Produção
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Equipamentos Críticos
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Energy Management
Full understanding of utilities consumption is key to deliver better results
Provides direct correlation of energy costs and production costs
Generates reports of a department, process area and entire plant
Allows real-time decision making
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Energy Management : Consumption Reports
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Agenda
Conclusion
Automation Project
The challenge
Brennand & Cement Market
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Next steps...
Plant expansion scheduled to February 2013 Production will increase from 1 Mton to 1.8 Mton
New cement mill
New packaging line
New pallet line
Evaluating MPC deployment in different process areas Raw Mix Blending, Raw Mill, Pyro-Processing, Finish Mill
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• PlantPAx infrastructure in place already supports expansion
• Minor changes required ⇒ smooth plant expansion expected
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PlantPAx - Key Benefits
High availability and Improved results with high performance controllers and software tools
Real time Automation Portal where upper management has easy access to KPIs like plant performance, energy consumption, process availabilty,… (decision support tools)
Lower maintenance costs Transparent integration of different disciplines (control, power, network,...)
reduces enginnering costs Remote access to operation screens simplifies manager task to track
process operation Integration of historical data with plant operation “ready”
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Final Conclusion
PlantPAx capabilities have delivered benefits in different areas allowing the
plant to operate at 115% of design capacity since start up!!!
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Questions
Eugênio Monteiro Neto Senior Automation Analyst, MBA Nov-12