simcoa system platform looking forward, looking...
TRANSCRIPT
SIMCOA Operations
SIMCOA System Platform
Looking Forward, Looking Back
Mike Chivers
Electrical Engineer
Simcoa Operations
Only Silicon Smelter in Australia
Commissioned 1989
Owned by Shin-Etsu Chemical (Japan)
160km south from Perth
Simcoa Operations - Site
Silicon Process
Simcoa Operations
24h 7d Operation
10h 5d Maintenance + Shift Roster
1 Process Engineer
1.5 Electrical Engineers
1 Mechanical Engineer
Plant Control System (2005)
7 x GE Series 6 PLCs
11 x ABB MOD300 Controllers
6 x ABB MOD 300 Consoles
1 x Citect HMI
3 x GE Series 6 Programmers
1 x MOD300 Configuration Node
1 x MOD300 History Node
1 x Serial DDE Link to Laptop (Hist Data)
Plant Control System (2005) - Issues
Reliability
Spares
Technical Support
Troubleshooting (Double Handling)
Engineering Efficiency
Expandability
Many HMI Pages / Colours
Plant Control System (2005) - Arch
Plant Control System (2005) - Scale
610 Analog I/O
3,100 Digital I/O
12,255 Rungs PLC Ladder
2,890 DCS Loops
1,550 DCS Devices
40,000 DCS TCL Lines
121 Graphic Pages
2005 Upgrade Project Assessment
Many One-One Between DCS and
System Platform
System Platform Customisable
Single Controller Architecture Advantage
Capital Cost vs Risk & Efficiency
2005 Upgrade Design - Philosophy
Redundancy
Combined DCS HMI/Controller Upgrade
Terminal Services
Redesign HMI Graphics
2005 Upgrade Design - Software
MS Windows Server 2003 (+ CALs)
Wonderware Application Server (25K I/O, 5
platform)
Wonderware InTouch TS View (10 user,
redundancy)
Wonderware Historian (5K tags)
Wonderware ActiveFactory (10 user)
GE GES OPC Server
Moxa SNMP OPC Server
GE Proficy Machine Edition – Logic Developer
2005 Upgrade Design – Plant Model
Hierarchical Function-Based Model
Plant / Area
Process / Line
Function
Sequence / Loop
Std Logic
2005 Upgrade Design – Plant Model
2005 Upgrade Design - HMI
Tag-Based PLC Access (OPC/Symbolic)
Review / Apply HMI Standards (also
Consider Colour Blindness)
Consolidation of Graphics
2005 Upgrade - Design
2005 Upgrade – System Platform
I/O Point Count: 9,107
Instanced Object Count: 3,119
Object Templates: 117
Historian Tag Count: 3,725
Implementation – Issues
Alarm Descriptions
Fetch Alarm Functionality
Priority Based Alarm Sound
Didn’t Leverage Containment
Alarm Management vs User/Logon
Too Many Templates
Furnace 3 Expansion (completed 2013)
Additional (3rd) Furnace & Grinding Plant
1 x New PLC, 1 x Expanded PLC
1 x Safety PLC (Triconex TriGP)
5 x New Operator Stations
2 x Server Upgrades (Win 2008 Svr)
Historian Upgrade (5K to 12K Tags)
NAS for 10y+ History Online
Widescreen Conversion (1920x1200)
Archestra Graphics (new Symbols)
2013 Expansion – System Platform
I/O Point Count: 13,714 (9,107)
Object Count: 4,894 (3,119)
Object Templates: 176 (117)
Historian Tag Count: 5,698 (3,725)
Wonderware Upgrades
Various Upgrades (in-house)
Beware Hidden Functionality Changes
Migrating SmartSymbols (on-going)
Various Continuous Improvements
Performance – System Platform
Engine Scan Period: 0.5s
Readback of Write: <1.0s
HMI Page Change: <2.0s
HMI Page Update: 0.5s
Retrieve 24h Trend <4.0s
Utilisation (Typical)
Ethernet Network: 2%
App Server CPU: 30% (2005)
5% (2012)
Terminal Server CPU: 10%
Historian CPU: 20%
Engineering Efficiency
Substantial Improvement in Engineering
Efficiency
Reliability
Downtime:
1 x Network Failure (config error)
2 x PLC Failure (prog, h/w fail)
No Significant Impact:
3 x Historian Failure (mem leak)
2 x PLC Hardware
5 x Operator Console Hardware
Numerous Operator Console Software
Lessons – System Platform
Adaptability – Painless Correction
Invest Time in the Model!
Set Standards
Experience Adds Value
Full Benefit Not Realised (Brownfields)
Lessons – Other
HMI Pages:
Many & Simple to Few & Busy
ActiveFactory Web and Excel
Tools in Hands of Users
Eliminated Old Data Bottlenecks
Support Tips
System Architecture Diagram
Servers & Roles
Network Connections (VLANs)
Clients
Controllers
Serial Comm Links
Locations
Network Addresses
Support Tips
Software Record
Server Specs (CPU, RAM)
Installed Software per Server
Versions
Licence Install Locations
Archive on Update (History)
Future Plans
Improved Alarm Descriptions
Alarm Inhibiting
Rollout Generic Object Alarm Status
Migrate $AnalogDevice to $UserDefined
Migrate to Archestra Graphics
Online Version Upgrades
Wishlist
Historian Summary Config in IDE
Log Operator Actions by RDP Client
Better Alarm&Event DB Performance
Enumerated UDAs
Hist Client Display Enum Label (not Int)
Method to Integrate IDE Security with Alarm Query (Ack Permission)
Optional Contained Name for Object in Area & Alarm Properties for Containers
The End
Thanks!