1. 1 The Process Control Room Upgrade Roy L. Costa

2. 2 WHERE WE ARE AT Currently I am in the early stages of start up. The delay in my start up Is as you surmised (driver problems) I was having driver problems from the beginning. First I could not even write to the PLC I could only read. They fixed the driver. (I had to send them one of our PLC-2 and a rack). Then I was having timing problems. (The integration timing was about 30 seconds in between writes) The update time from reads was 3 to 5 seconds. One of the support Engineers at NI instructed me to program as many tags as I could to cut down on errors generated by unrecognized tags during polling. I also created all my read indicators, (current, temps state changes etc.) I plugged in a 3 rd KG card and I was able to simultaneously operate the Panel Mates with the New HMI’s. Then, I disconnected the serial connector on the Panel Mate 2 (the one on the right) and ran some durability tests. The new HMI did all that the Panel Mate 1 & 2 did (as well as the other enhanced features). When ever I could get a window to do some write commands (on a Sunday or when they had down time) I would try and write to the registers. I could successfully write to any register but I was having some lag times from one wrtie to another. I knew write a way that it was a driver problem and that the OPC driver needed to be optimized. National Instruments basically washed their hands of the driver optimization. I met a person at a NI seminar who mentioned to me that there was company who had a driver that was created to work with PLC-2 (HighwayVIEW) he emailed me a link and after checking out the demo we ordered it.

3. 7/6/2016 3 The switch from HMI to Panel Mates is done in 3 minutes and at the most you may have to reboot the counsel power. ( Both the Panel Mates and the New HMI’s plug into the AB-1771 KG card using RS-232 serial interface.) The mimic boards and the Panel mates are combined Into one User Interface utilizing GUI (Graphical User Interface) Technology. The Panel Mates will be a back up This will not compromise the contract with the Client The hardware, software, installation, commissioning and training is and will be a savings of thousands of dollars. I designed, programmed and ran simulations in my office before I tried it in the field.

4. 7/6/2016 4 What is logged in the Citadel Database? Logs data (tag values) from tags configured for logging Logs alarms Logs all system events (I.e. engine starting) Logs tag events (I.e. change in alarm state) from tags configured to log events Engine must be logging events for events to be written Engine must be logging historical data for tag data to be written Now we have Citadel Database function

5. 7/6/2016 5 Retrieving Data from Citadel Historical Trend Viewer (HTV) –Application that Retrieves and graphs Citadel data. –A tag Must be configured for data logging before it can be displayed! Historical Trend Indicator –Front Panel Indicator you can customize for your own VI’s –A tag Must be configured for data logging before it can be displayed! –Use the wizard for easy configuration Historical VI’s –VI’s that will read the database returning an array of data. ODBC –Any ODBC compliant application (MS Query, MS Excel, MS Access) can query and retrieve data from Citadel

6. 7/6/2016 6 Using the remote panel feature in LabView, we can remotely control our LabView application over the Web -- with no additional programming. With only two mouse clicks, we have embedded our front panel in a standard Web browser. Then, designated users (managers etc.) can control your applications remotely without installing any additional software other than a standard Web browser. You can purchase additional licenses to enable 5, 20, or 50 simultaneous connections, depending on the needs of your application. Fred Jacobsen as well as other managers really like this feature. Currently we are only using this within the corporate LAN. There are tons of built in security features. The VI’s that we have been viewing remotely have been screens with strip charts. Any VI that is used on the Panel Mate replacement is capable of being viewed remotely as well as customized ones.

7. 7/6/2016 7 LED’s HMI’s HMI (Enlarged) PLC Local Rack Panel Mates Shared Desk Top

8. 7/6/2016 8 100 Line200 Line300 Line 400 Line HMI remains as is

9. 7/6/2016 9 7 Remote I/O’s From Serial port To AB 1771- KG Card 2-19”Monitors sharing the same desktop (using a special video card) 2 Field Point I/O for 16 Added Analog /INPUTS 485 PCI Card added for 485 interface to the MODBUS adapter for the 4 VSD controls We now could control the VSD’s with MODBUS but we can at least have 25 signals we did not have before (current, volts, rpm etc.)

10. 10 This area is where there will be Pop up screens where there is an error Each motor will have a label next to it And a button that will be a hyperlink to Another small screen for sub-vi controls. Pop-Up vi

11. 11 Financial Savings!!! UIS Programmable Services quoted $70,982.00 Venture Technology Groups quoted $73,340.00 Rockwell Automation (Allen Bradley) quoted $45,000.00 Galco Industrial Electronics quoted $58, 000.00 1.The above quotes combine all 3 PLC’s into one PLC 5/40 (Thereby we would lose our redundancy) 2.These companies would keep the source code and any changes in the future would be extra 3.The hard ware changes would eliminate the possibility to use the Panel Mates as back up. 4.In order to keep our redundancy we would need to triple the cost of the above quotes. (And even add Additional hidden costs for changes and future upgrades) $$$$$$$ (And even add Additional hidden costs for changes and future upgrades) $$$$$$$ UIS Programmable Services (Tripled) $212,946.00 Venture Technology Groups (Tripled) $220,020.00 Rockwell Automation (Allen Bradley) (Tripled) $135,000.00 Galco Industrial Electronics (Tripled) $174,000.00 Note: The above cost is enormous and does not reflect additional cost for the software to do upgrades or for requested customized changes.

12. 12 Benefits State the art software affording us to create our own HMI’s (Having full control of customizing our panels as well as having the capability of doing our own upgrades in the future) Along with: –Benefit #1 Redundancy & Back up –Benefit #2 Financial Savings  NI Software $14,000.00 (Included training)  HMI hard ware (3 PC’s & 6 19” Monitors & connection hardware) About $15,000.00 (Note: I am not sure about the total cost so far but I would make a guess that it is around $40,000 to $50,000) –Benefit #3 National Instruments software is very versatile and can apply to all of operations. (We can even use it to create programs to do all of our calibrations.)

13. 13 Close This upgrade brings us into the 21 st century many possibilities. –26 signals per VSD (4 VSD’s/line) –15 add ional analog inputs per line (all the major conveyors are now monitored, the primary and secondary bag house pressures are now monitored from the control room, the signal from the scale is also monitored.) –Every action (button pressed etc.) every analog and digital signal is being recorded into a data base (like the power blocks history node) –All panels are capable of being viewed as a remote panel anywhere on our company LAN and is also capable of being viewed from outside of our LAN on the internet (I have not configured this as of yet) –Training is a snap –Adds moral to the employees, self accountability and individual assertiveness, (this naturally happens because it is a new thing) –Saves time as it helps reduce down time because the potential plugs/jams it prevents with its monitoring system. (Already, the system in place has stoped plugs on the 29, 401, 402 & 404 conveyors.) –Tracks hammer ware as well as other devices as a preventive maintenance.