Mosaic PotashIntegrating 3rd Party Vendor Control Systems into 800xABelle Plaine, Saskatchewan, Canada

Who Are We?• The World’s largest potash solution mine.• Located in Belle Plaine, Saskatchewan, Canada.• Produce over 2.5 Million Tonnes / Year

• “Help The World Grow The Food It Needs”

Who Are We?• The World’s largest potash solution mine.• Located in Belle Plaine, Saskatchewan, Canada.• Produce over 2.5 Million Tonnes / Year

• “Help The World Grow The Food It Needs”

Bailey Infi90Bailey Infi90 AB PLCAB PLC DeltaVDeltaV

PCVPCV Factory LinkFactory Link Active FactoryActive Factory

Control SystemControl System

HMIHMI

Where We Were

2007 2008 2009 2010 2011 2012 2013 20142007 2008 2009 2010 2011 2012 2013 2014

Why 800xA?- Legacy HMI replacement- Multiple control systems in one HMI- Reduce HMI system maintenance- New features

- Asset optimization- Alarm management- Documentation links

- Robustness and redundancy- Object-oriented design

- Templates- Parent-child objects

• Reduce control room clutter – One workstation per operator– 2 or 4 screens

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Bailey Infi90Bailey Infi90 AB PLCAB PLC DeltaVDeltaV

Harmony ConnectHarmony Connect

Where We Are

2007 2008 2009 2010 2011 2012 2013 20142007 2008 2009 2010 2011 2012 2013 2014

PLC ConnectPLC Connect

Domain ControllersDomain Controllers

Aspect ServersAspect Servers

Asset OptimizationAsset Optimization

ABB 800mABB 800m

PLC ConnectPLC Connect800m Connect800m Connect

System 800xA v5.0

Operator ClientsOperator Clients Engineering ClientsEngineering Clients

FlinkFlink AFAF

Remote ClientsRemote Clients

800xA Network

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Asset Optimization

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Asset Optimization

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Asset monitors for motors

- # of Starts- Run time

Bailey Infi90Bailey Infi90 AB PLCAB PLC DeltaVDeltaV

Harmony ConnectHarmony Connect

Where We Are Going

2007 2008 2009 2010 2011 2012 2013 20142007 2008 2009 2010 2011 2012 2013 2014

PLC ConnectPLC Connect

Maximo / SAPMaximo / SAP

AMSAMS

Asset OptimizationAsset Optimization

ABB 800mABB 800m

PLC ConnectPLC Connect800m Connect800m Connect

Operator ClientsOperator Clients

Aspect ServersAspect Servers

Domain ControllersDomain Controllers

Alarm ManagementAlarm Management

Engineering ClientsEngineering Clients

System 800xA v5.1

Remote ClientsRemote Clients

PLC ConnectAllen Bradley Control Logix PLC

Why PLC Connect for Allen Bradley?• Interface PLC control into same HMI.• Operators can operate motors, gates,

control valves, etc. from the same graphic interface.

• All process alarms in one system.• Asset monitors for motors.

AB Control

Logix PLCs

AB Control

Logix PLCs

PLC Connect 27PLC Connect 27

Allen Bradley Control Logix

PLC Connect 28PLC Connect 28

Ethernet I/P

Ethernet I/P

Ethernet I/P

Ethernet I/P

HardwareHardware

SoftwareSoftware

OPCOPC RS LinxRS Linx Data HighwayData Highway

PLC Control Structure

PLC Faceplates

Example of Bailey and PLC Objects

Bailey Level, Flow, Control Valves, PressurePLC Motor status, Motor amperage

DeltaV ConnectEmerson DeltaV

Why PLC Connect for DeltaV?• Replace existing IT solution

– Web based graphics– Security concerns– Issues with robust and reliable control

• Integrated with rest of the facility• Access information from refinery• Reliable remote clients• Redundant OPC connection• Bulk Data Manager for mass system

changes.

Emerson DeltaVControl Network

Emerson DeltaVControl Network

DeltaV Connect 40DeltaV Connect 40

Emerson DeltaV

DeltaV Connect 41DeltaV Connect 41

HardwareHardware

SoftwareSoftware

OPCOPC

App Station xA1App Station xA1

App Station xA2App Station xA2

DeltaV – Navigation

Remote Connectivity Server

(10 Sessions)

Remote Connectivity Server

(10 Sessions)

DeltaV – Remote Clients

Creating Objects from Templates

Creating Objects from Templates

Creating Graphics from Templates

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Creating Graphics from Templates

800xA ImplementationBelle PlaineMosaic Potash

800xA System Size

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Item Current Count

Future Count

Bailey Tags 6,000 6,000PLC Tags 5,000 15,000DeltaV Tags 12,000 15,000800m Tags 4000 4000Asset Monitors 160 160+Engineering Workplaces 6 6Operator Clients 10 15Remote Operator Clients 8 20# of Control Platforms 4 4

Mosaic Graphics

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• Bailey Feed gate position control, Weighbelt• PLC Motor status, Screen status, Bucket gate position

Mosaic Graphics

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Mosaic Graphics

Conclusion• Successful connection to 4 different

control systems• Graphic development still in progress• Utilizing new features such as:

– Asset monitoring for motors– Asset monitoring for network devices– Bulk data management– Documentation linking within graphic displays

• Simplified operations with one common interface

• More readily available data to all operations groups

• Increased system reliability

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