cs15 industrial automation-caloris engineering

Copyright © 2014 Rockwell Automation, Inc. All rights reserved.

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Industrial Automation Group PlantPAx Evaporator

Levi Upham

Project Manager

Industrial Automation Group

November 17-18, 2014

Niniv Tamimi

Sr. Controls Engineer


Bruce Skinner

Sales Manager

Caloris Engineering


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Agenda

Project Outcome

Development

Design

Project Scope

Project Team


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Industrial Automation Group; Modesto, CA Rockwell Recognized System Integrator

CSIA Certified

Project Team

Levi Upham, Project Manager (B.S.E.E)

Niniv Tamimi, Sr. Controls Engineer (B.S.ChE/MSE)

Ruben Marroquin, Project Engineer Intern (Electrical Engineering Student)


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Caloris Engineering

Caloris Engineering, LLC; Easton, MD Evaporator and Thermal Process Systems – Design and Supply

Dairy, Juice, Food and Waste Water Applications

New Custom Design Evaporator Systems – All Sizes, Capacities and Capabilities

New Pre-Engineered Evaporator Systems Designs – MVR and Steam Heated

Rebuilds/Modifications of Existing Evaporator Systems

Evaluate Existing Process Systems to Optimize Thermal Efficiency and Capacity

Project Team:

Daniel Neth, Engineering Manager, Founder (A.A.S., Drafting and Design)

Barry McFarland, Process Development Manager, Founder

(B.S.M.E)

Bruce Skinner, Sales Manager (B.S.ChE)

Derek Phillips, Project Engineer (B.S.M.E)


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Caloris Engineering

Concentrix™ Compact Falling Film MVR Evaporator

Turbofan Heated

500 PPH to 100,000 PPH Evaporation

Cubix™ Compact Forced Circulation Evaporator

Rotary Lobe Compressor Heated

200 PPH to 2,500 PPH Evaporation

Agilix™ Mobile MVR Evaporator

Forced Circulation


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Caloris Engineering

Caloris FlexMode™ – Compact

Steam Heated Falling Film

Evaporator System Juice Evaporator

100,000 PPH Water Evaporation

18°Brix to 70°Brix

Compact Design and Assembly Minimum installation costs for

foundation

No structural support steel required

Short installation time with pre-

fabricated primary components


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Project Scope

Caloris Engineering system requirements

ControlLogix PAC Flex IO HART Protocol Distributed IO panels

End User system requirements

Distributed FactoryTalk View SE Utilize PlantPAx library of process objects Segregated Network Levels

SCADA, VFD, IO

Provide a flexible, expandable, affordable all-in-one controls solution for a new Evaporator installation.


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Project Scope

Control System Magnitude

Evaporator IO count: 130 Digital Inputs

60 Digital Outputs

70 Analog Inputs

20 Analog Outputs

22 EtherNet/IP Drives

Control Components

Evaporator main sequence and sub-sequences 30 control loops Sequence and device alarming


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System Design

Design Considerations

What is my system architecture? What are my system elements?

The PlantPAx system uses a combination of standard Rockwell Automation Integrated Architecture (IA) products configured in a prescribed way for optimal performance for your process automation system.


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System Design

System Architecture

Distributed - Multiple PASS (Process Automation System Server) Servers

Multiple PASS servers and multiple OWS

Utilize existing HMI Server and system architecture of end user

System Elements

PlantPAx Software Components RSLogix5000, Version 20

FactoryTalk View SE, Version 7.0


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System Design

System Elements Continued

Process Controller 1756-L75 Simplex controller (Non-redundant controller)

Process Automation System Servers FactoryTalk Directory Server

HMI Server

Redundant Data Servers

Alarm and Event Server (Hosted on HMI Server)

2 OWS’s (Operator Workstations) dedicated for the Evaporator


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Sizing Control Strategies

PlantPAx System Estimator (PSE), which is a part of the Integrated Architecture Builder (IAB) software tool, was then used to define the PlantPAx system.


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Control Strategy definitions (Defined in PlantPAx reference manual)

Simple regulatory: This is a simple PID loop with a single analog input and analog output.

Complex regulatory: This is a more complex regulatory look such as PID controllers in a cascade configuration with two analog inputs and one analog output.

Simple 2-state discrete: A simple valve or motor with basic interlock logic and a single digital input and output.

Complex 2-state discrete: A valve or motor with complex interlock, permissive, and restart inhibit logic that can have two digital inputs and two digital outputs

Complex regulatory non-PID: This can be a complex control strategy, such as a loss in weight feeder, that can include an analog input, valves, and a motor.


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PlantPAx Library of Process Objects

Library Elements

Controller code (Add-On Instructions) Display elements (global objects) Faceplates

Determining Library Objects appropriate for our application

Reference Manual Publication PROCES-RM002B-EN-P

The PlantPAx library of process objects is a predefined collection of coded objects that offer proven strategies, functionality, and known performance for your process control system.


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Main process objects used to build the Evaporator controls.


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System Development Life Cycle

Kickoff Meetings

Requirements

Design

Development

Unit/Module Testing

Factory Acceptance Testing

Commissioning

Site Acceptance Testing


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Development

Periodic Tasks configuration

Fast task for discrete control Medium task for control loops and analog Slow task for sequence control

Download and Import Process Object Library

Utilize library object documentation Defines parameters and display elements specific to each object

Configure library objects for our application

Alarm and Event Server Configuration

Develop Application Specific Logic


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Screen Shots – Evaporator Screen


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Screen Shots – Condensate Screen


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Screen Shots – Command Screen


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Screen Shots – Alarm Screen


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Conclusion

Benefits Provided

Proven functionality and known performance Characterized control system Standard logic and templates Process objects configurable for all standard control strategies Streamline development Scalable Increased throughput


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Questions

Levi Upham

Project Manager


November 17-18, 2014

Niniv Tamimi

Sr. Controls Engineer


Bruce Skinner

Sales Manager

Caloris Engineering

cs15 industrial automation-caloris engineering

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