holcim macuspana implements plantwide automation with plantpax system

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Holcim Macuspana Implements Plant-wide Automation

with PlantPAx System

Fernando Hernández

Automation and Control Supervisor

November 2014


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Agenda

Challenges and lessons learned

Advantages & Benefits

Upgrade to PlantPAx

Precedents


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Holcim Highlights

• Holcim Mexico produces and sells cement, aggregates, ready-mix concrete and other products and services for construction.

• Currently, is one of the leading companies in the production and commercialization of cement and concrete in México.

• The company was founded in 1928, in the town of Apaxco (State of Mexico), and since 1964 is part of the Swiss cement group Holcim. To date, has the capacity to produce 12.6 million tonnes of cement capacity in this country.

• About 4,000 direct employees working in Holcim México. One of the world's leading suppliers of cement, aggregates,

concrete and asphalt.


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Holcim Highlights

• It has an extensive infrastructure, which translates into a total of eight cement plants in Mexico: Apaxco (State of Mexico); Acapulco (Guerrero); Macuspana (Tabasco); Orizaba (Veracruz); Ramos Arizpe (Coahuila); Tecomán, Colima and Hermosillo (Sonora).

• Moreover, operates 23 distribution centers, two marine terminals, more than 40 ready-mix plants, about 500 mixers pots and three plants producing aggregates

• Presence in over 70 countries on all continents and has approximately 80,000 employees.

• Since 2000 to date, Holcim has invested in Mexico over USD 2,200 million, equivalent to an average of 183 million dollars a year.


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Holcim Highlights

The eight cement plants of Holcim Mexico hold ISO

14001 and Clean Industry certificate.

In 1999 joined the World Business Council for

Sustainable Development (WBCSD), committing to

long-term progress, respecting the balance between

economic development, environmental performance

and social responsibility.

Named "Industry Leader" in the Dow Jones

Sustainability Index, 2005 to 2008 This was

recognized as the company with the best sustainability

performance of the cement industry for 4 years.


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Macuspana Facility Project Upgrade

Since the 80’s the complete control system of the plant has been

Allen-Bradley ®.

In 2012, the Holcim plant Macuspana conducted a migration of Allen-

Bradley PLC-5 ® Systems and RSView®32 visualization software throughout

the plant, due to the end of its lifecycle.

Corporate Holcim standard requires to update this type of systems each

determinated time; analyzing the lifecycle of our old system, that was the

right time to perform the migration,


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Precedents

Due to the age of the system, the operation was

becoming expensive and their performance was

not adequate to carry out the production process

of the plant.

The network performance was not optimal for the

changes that the plant was living and did not meet

to the speed of the current applications such as

EtherNet I/P, ControlNet and DeviceNet.

We initiate with the “Project Concept” in team

with local Rockwell Automation team since

2007

The quality and full support from Rockwell Automation® bring us the

confidence to continue working with the new Process platform.


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Rockwell Automation in Cement Process


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COP CANTERA

COAL MILL AUXILIARY

AFR’S KILN CRUSHER RAW MILL CEMENT MILL DISPACH

CNET/R 5 Mb DNET 250 Kbps DHRIO 57.6 Kbps DH+ FIBRA OPT. MODEM RF

Previous Architecture

PLC-22 APILADOR

COP

3 CCM

PLC-61

RACK

RACK

RACK

RACK

PLC-52

2 CCM

PLC-51

RACK

RACK

4 RTU PLC-31

RACK

RACK

PLC-32

RACK

RACK

PLC-5

PLC-46

RTU

FlexLogix

4 CCM

4 CCM

C-LOGIX

RTU

1771-ACRN15

CCM

PLC-AFRs

RACK

ENGINEERING

COP ENVASE

ControlNet ControlNet

COP CRUSHER

HIM RED SERVER

Ethernet Ethernet

ENGINEERING WS

ASSET CENTRE SERVER

TIS LINKMAN

19

.2 K

b

FlexLogix

3 CCM

PLC-41

RACK

RACK

2 CCM

PLC-42

RACK

RACK

CCM

PLC-43

RACK

RACK

PLC-21

RACK

RACK

RACK

PLC-61

RACK

RACK

COP DISPACH

WS

CCM

PLC-62

RACK

RACK

PLC-62

RACK

RACK

PLC-21

RACKS

Architecture w/first phase

PLC-31

RACK

RACK

Logix

PLC-32

RACK

RACK

RAW MILL WS

Architecture w/next phases

PLC-22 APILADOR

EXISTENTES

Final System Architecture


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Scope of Solution

Migration of PLC-5 System to PlantPAx

Using of MMCL (Cement Libraries)

RSView32 Migration to Distributed

FactoryTalk ® View Site Edition (SE)

4 redundant servers of HMI’s

TIS integration

1 domain redundant server

1 SQL data base server

1 FactoryTalk® Asset Centre server

Services for each stage:

Configuration and programming

Installation and commissioning

Training


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Process Graphics


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Advantage and Benefits

Standardization. One of the main goals, currently we sent online

information to corporate offices from the main operational data of the plant

and also alarms and events, a situation that has not happened before.

Optimization. The future is to leverage the capabilities that are not yet

exploited of the processors, to develop strategies to serve directly in the

plant process and achieve better power and thermal control, among other

variants.

Distributed Architecture. With the new HMI control system and diagnostic

tools, the plant will have fewer unplanned stoppages due to equipment

control.

Competitiveness. The new platform provides improved reliability of

equipment; more diagnostic tools in case of failure; lower maintenance costs

and downtime, result in higher level of competitiveness for the company.


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Challenges and Lessons Learned

The complete project needed to be implemented in 2 years. Was

completed in 1 year and 8 months

The main challenge was to have all the configurations in time and simulate

the sequence with the software previously to shorten the startups. The

time of commissioning were always shorter than those granted by the

plant

The commitment of integrators, Holcim and Rockwell Automation were

fundamental for success.

The service provided by Rockwell Automation for the implementation

of this project was excellent, was able to fully adapt to the corporate

guidelines required by the Holcim group.

"We have achieved concrete and efficient answers whenever we have required"


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Why Rockwell Automation?

Global Execution: The quality of products and the worldwide talent and

local expertise of Rockwell Automation was Key to select them to execute

the project.

Domain Expertise: Their industry and application experts give us the

confidence that the project will help us to increase productivity, lower

manufacturing risk, speed time to market, and reduce costs of quality and

compliance.

Project Management: The PMI certified personal of Rockwell Automation

use the Common Project Management methodology, based on the PMI®

PMBOK®, that helped ensure that we received consistent Project

Management for every stage.


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Questions

Fernando Hernández

Automation & Control Supervisor

November 2014

holcim macuspana implements plantwide automation with plantpax system

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