Electricity + Control January 2018

CONTROL SYSTEMS + AUTOMATION

abbreviations DCS – Distribution Control System I/O – Input/Output P&ID – Piping & Instrumentation Diagram PES – Process Expert System PLC – Programmable Logic Computer SCADA – Supervisory Control & Data Acquisition TVDA – Tested, Validated and Documented Architecture VSD – Variable Speed Drive

Goal Modernise ageing control, automation, and electrical sys- tems in wheat mills. Solution PlantStruxure PES, the single process automation system to engineer and operate the plant. Results • Cost effective engineering • Advanced operation services that reduce downtime • Future ready solution • Improved energy management • Robust, scalable, and flexible automation architecture

The architecture implemented by Schneider Elec- tric is mature, has a proven track record, and is based on a wide range of Schneider Electric’s Ethernet devices. It is robust through the use of redundant Ethernet ring networks, as well as flex- ible and scalable for easy expansion in the future. PlantStruxure PES offers a single, object-oriented database that allows it to maintain consistency – both during engineering as well as throughout the system’s life cycle – for complete traceability and easy modification or extension during operation and maintenance. PES’ all-in-one configuration functionality also means faster system design from a single data entry point. Through the ap- plication manager, the application can be easily replicated as it is in real life, using any model. The design can be based on a hierarchical organisation, according to the P&ID definition, for easier evolu- tion of the installation. The system was engineered from scratch, with- out reusing existing code, to leverage the benefits of an object oriented platform. A multi-phased ap- proached was used to switch over the existing sys- tem to the new system during plant shutdown and maintenance periods so that only small portions of the plant were impacted at any given time. The flow of wheat and flour through each of the plant’s processes (in tons per hour) is continuously mon- itored and displayed on the supervision system. This system is integrated into Premier’s intranet, but not directly to the Internet. Remote access and control is available to limited users on the in- tranet, from any of their sites around the country. PlantStruxure PES collects process, quality, and energy data from the plant and generates detailed reports to support effective decision making. It seamlessly connects to the production and busi-

ness systems to ensure that the right people have access to the information they need. Reports have been configured to present plant management and accounting staff with the operations and pro- duction data from the plant. They can generate production and mass balance reports to determine the amount of wheat and flour processed by each section of the plant. The flexible reports allow anal- ysis over any desired time frame (e.g. hourly, daily, weekly, monthly, annually etc.). PlantStruxure PES also provides Premier with a mechanism to back up its system configuration, as well as process data like setpoints, tuning pa- rameters etc. PlantStruxure PES engineering li- cences are tailored to the size of the application. Its runtime licences are tailored to the instances’ objects count and architecture of the application, i.e. separate floating licences for servers, clients and web clients.

PlantStruxure PES, Schneider Electric’s innovative process automation system, played a key role in the customer’s selection for this modernisation project.

Electricity + Control

JANUARY 2018

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