sequencing solution with logix batch and sequence module (lbsm) & steam table solution
TRANSCRIPT
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WUNDERLICH – MALECENGINEERING l SYSTEMS l SERVICES
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COMPANY OVERVIEW
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Who is Wunderlich-Malec?
•Founded in 1982
•Headquarters in Minnetonka, Minnesota
•Full Service Engineering and Systems
Integration
•Professional Registration in 42 states
•Stability due to:
• Diverse Vertical Markets/Client Base
• 100% Employee Owned Corporation
•22 Offices in the US
•International Presence – LATAM, China
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APACS to PlantPaxSelection Process
• Moore APACS DCS to PlantPax conversion 2011-2012
• Dissatisfaction with Siemens due to product withdrawal
• Many subsystems with Rockwell PLC 5,SLC,Micro
• Maintenance comfortable with Rockwell
• Close relationship with the local distributor
• WM had previously implemented BOP systems
• Former employees worked at WM client site
• WM/RA Demonstrated reduced life cycle cost vs Siemens
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APACS to PlantPaxProject Background
• 5 LM6000 48MW gas turbines
• 1 Three drum Heat Recovery Steam Generator (HRSG) with steam turbine
• 4 Once Through Steam Generator (OTSG) HRSGs with 2 steam turbines
• 3 redundant L75 CLXs with approximately 2500 I/O
• Redundant Factory Talk, Redundant OPC, PDC, BDC, & Asset Centre Servers
• Asset Centre implemented to meet NERC/FERC compliance
• Servers in two locations for disaster recovery
• Narrow conversion window with rewiring to IFMs
• PlantPax objects matched up well with APACS objects simplifying conversion and significantly reducing implementation time
• Through the use of PlantPax steam tables and energy balance models provided by OTSG vendor the client was able to reduce the time to bring the OTSGs on line
• Installed fiber ring around the plant replacing APACS coax
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APACS to Plant PaxNetwork Overview
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OTSG Steam Table Logic
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HP Feedwater FB Logic
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Sample Screens
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LBSM Project
• Fast Track specialty chemical batch project
• Transition from manual pilot to production plant due to high product demand
• Good relationship with local distributor
• WM demonstrated process and electrical solution expertise
• 4 reactors with associated front end and back end equipment
• Expanded Rockwell content beyond PLC
• H/W included CLX, Versaview HMIs, Rockwell VFDs and MCC
• A proprietary interface to an analytical system critical to the end point detection of the batch was provided
• PlantPax and LBSM utilizing Phase Manager were implemented
• Approximately 200 I/O
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System Overview
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Simulation
• WM builds simulation into every PlantPax project
• Significantly reduces site start up time and cost
• AOIs created for different objects
• VFDs, Motors, Valves
• P_AIN analog inputs
• Psychometric data for air handler models (based on steam tables)
• PID loops based in parametric model (lead, lag, gain, bias)
• Rapid implementation of AOIs
• Extensive fault insertion testing that could not be tested on a live plant
• Fail to start / stop, Fail to open / close, PV alarms
• Analog simulation runs faster than real time to reduce testing time
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Ladder Simulation
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Rockwell Technology
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Design
FactoryTalk AssetCentre
RSLogix 5000/500/5
HMI
FactoryTalk View Site Edition (SE) / Machine Edition (ME) /ViewPoint
PlantPAx
Logix Batch and Sequence Manager
Manufacturing Intelligence
FactoryTalk VantagePoint / Historian
RSNetWorx for DeviceNet / ControlNet.
Connected Components Workbench and Drive Explorer for VFD and MCC
configuration.
GuardLogix
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INDUSTRIES SERVED
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WME’s stability can be attributed to diverse client base
and industry markets:
• Aviation/Aerospace • Mining
• Building Automation • Medical Device Manufacturing
• Brewery • Oil and Gas – Compressor Stations
• Chemical • Pharmaceutical
• Data Centers • Pulp and Paper
• Ethanol • Semiconductor
• Food Processing • Utilities
• Grain Storage/Export • Warehousing
• Material Handling • Water/Wastewater Treatment
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Company Culture
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Resources
Hire the best (industry subject matter experts)
Retain
Continuous education (technical universities, vendor training and
industry certifications (CSIA Audit, PMP, TUV, UL)
Collaboration
Share knowledge and project resources within the company
Vendor Channel management (invest with channel partners to be
current with new products, steering committee, user groups/forums,
beta testing, etc.)
Growth
Organic via new business unit locations and products
Acquisitions
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COMPANY OVERVIEW
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• Financially Strong
• Revenue Growth +250% since 2009
• Tracking 8% ahead of 2015 goals through 3rd Quarter
• Goal is maintained >5% Growth/Year (rolling average)
• Current Backlog is 55+M. Very Strong.
• Opportunities in Pipeline >100M. Good Diversity.
• Customer Focused
• Over 80% of project work is repeat business, long term customers
• We succeed together. On-time, on-budget solutions set up our
customers to be competitive and grow, which results in the next
project. Long term vision even in small projects.
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OPERATIONS
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Certifications / Organizations
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19Thank You!
WUNDERLICH – MALECENGINEERING l SYSTEMS l SERVICES