Using Manufacturing Intelligence for Wastewater Pre- Treatment Compliance
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1 Insert Photo Here Using Manufacturing Intelligence for Wastewater Pre- Treatment Compliance Marty Fallon EZSoft, Inc. Rockwell Automation Process Solutions User Group (PSUG) November 14-15, 2011 Chicago, IL McCormick Place West Copyright 2011 Rockwell Automation, Inc. All rights reserved.
2 Message Think Long Term Think Global Sell the Vision Copyright 2011 Rockwell Automation, Inc. All rights reserved. 2
3 About Colorcon US-based Excipient Manufacturer With International Operations Excipients Are Components Of Final Tablets Other Than The Active Ingredient Colorants and Dyes Binders Non-Toxic Inks Coatings Customers Include Major Manufacturers Of Patented Drugs, Generics, And Nutraceuticals Copyright 2011 Rockwell Automation, Inc. All rights reserved. 3
4 About Colorcon Founded In 1961 In The Food And Candy Business World Leader in Pharmaceutical Product Development Manufacturing Operations In US, UK, India, China, Japan Technical Service Laboratories: Globally Copyright 2011 Rockwell Automation, Inc. All rights reserved. 4
5 Business Challenge: Manufacturing Intelligence 2007, The Township Upgraded Their Treatment Facility Changing Colorcon s Discharge Permit New Requirements Discharge Water Must Be Monitored For ph, And CL, And Must Be Within Limits. Monthly reporting for Daily Discharge, CL and ph Average and Maximum. Cost Of Non-compliance Fines From Township (+$10K) Worst Case, Plant Shutdown Copyright 2011 Rockwell Automation, Inc. All rights reserved. 5
6 Lack of Intelligence Water Monitored At The Edge Of The Property Metering Installed With Chart Recorders Local To The Manhole, Not In Control Room Updated Requirements Monthly Reports Need to Contain ph, CL, and Daily Water Flow Rates Copyright 2011 Rockwell Automation, Inc. All rights reserved. 6
7 Lack of Intelligence Existing HMI Used To Acquire Data Using Trends Data Records Every 2 5 Min. Acquires About 7MB/Day Works Well For The Operators Copyright 2011 Rockwell Automation, Inc. All rights reserved. 7
8 Solution Definition / Evaluation Greater Accessibility To Data Eliminate Manually Creating Discharge Report Better Diagnostic Tools Needed Remote Visibility Of Pre-treatment Processes Better Reporting, Not Just In Control Room Infrastructure To Grow The System Tech Evaluation Attended Seminars Spoke With Solution Providers Attended FactoryTalk Historian & FactoryTalk VantagePoint Classes Copyright 2011 Rockwell Automation, Inc. All rights reserved. 8
9 Project Team Involved Work Groups Internal: Engineering and Quality Information Technology (IT) Environmental Health and Safety (EHS) Suppliers: Rockwell Automation Rumsey Integrator: EZSoft, Inc. Copyright 2011 Rockwell Automation, Inc. All rights reserved. 9
10 EZSoft Scope Documentation Functional Specification Factory Acceptance Test (FAT) Installation and Operations Qualification (IOQ) Integration Upgrade FT AssetCentre Implement FT Historian and FT VantagePoint Reporting Trend Reports from Analog Trend Data Daily Report for Regulatory Compliance Startup / Commissioning Copyright 2011 Rockwell Automation, Inc. All rights reserved. 10
11 Project Planning Kick Off Meeting with Engineering Engaged Quality & IT Departments Early Develop Plan / Model For Expansion Worked closely with Rockwell / Rumsey Copyright 2011 Rockwell Automation, Inc. All rights reserved. 11
12 FactoryTalk Directory Server W2K3 Server O/S (1) FT Directory Server Colorcon Initial Project Data Collection for Water Treatment Data Center Virtual Servers Harleysville, PA FactoryTalk VantagePoint EMI Server W2K3 Server O/S FactoryTalk VantagePoint MSSQL 2K5 Std. Edition MS Office 2007 (Excel) FactoryTalk Historian SE Server W2K3 Server O/S FactoryTalk Historian SE Server (5K RA Tags) MS Office 2007 (Excel) Managed Switch(es) Control System Ethernet Water Treatment Area Physical Computer West Point, PA FactoryTalk Historian Interface Node W2K3 Server O/S or Win XP Pro SP2 FT Hist. FTLD Interface (1) RSLinx Enterprise WAN VantagePoint Client.NET Framework Internet Explorer Managed Switch(es) Control System Ethernet Copyright 2011 Rockwell Automation, Inc. All rights reserved. 12
13 Colorcon - Vision Data Collection for Additional Building at West Point Data Center Virtual Servers FactoryTalk Directory Server W2K3 Server O/S (1) FT Directory Server FactoryTalk VantagePoint EMI Server W2K3 Server O/S FactoryTalk VantagePoint MSSQL 2K5 Std. Edition MS Office 2007 (Excel) FactoryTalk Historian SE Server W2K3 Server O/S FactoryTalk Historian SE Server (5K RA Tags) MS Office 2007 (Excel) VantagePoint Client.NET Framework Internet Explorer Firewall Managed Switch(es) Control System Ethernet Water Treatment Area Physical Computer FactoryTalk Historian Interface Node W2K3 Server O/S or Win XP Pro SP2 FT Hist. FTLD Interface (1) RSLinx Enterprise New Building WAN FactoryTalk Historian Interface Node W2K3 Server O/S or Win XP Pro SP2 FT Hist. FTLD Interface (1) RSLinx Enterprise Managed Switch(es) Control System Ethernet Managed Switch(es) Managed Switch(es) Control System Ethernet ~15 Controllers Copyright 2011 Rockwell Automation, Inc. All rights reserved. 13
14 Colorcon - Vision Data Collection for Additional Sites Data Center Virtual Servers FactoryTalk Directory Server W2K3 Server O/S (1) FT Directory Server FactoryTalk VantagePoint EMI Server W2K3 Server O/S FactoryTalk VantagePoint MSSQL 2K5 Std. Edition MS Office 2007 (Excel) FactoryTalk Historian SE Server W2K3 Server O/S FactoryTalk Historian SE Server (5K RA Tags) MS Office 2007 (Excel) VantagePoint Client.NET Framework Internet Explorer Firewall Managed Switch(es) Control System Ethernet Water Treatment Area Physical Computer FactoryTalk Historian Interface Node W2K3 Server O/S or Win XP Pro SP2 FT Hist. FTLD Interface (1) RSLinx Enterprise WAN New Building Physical Computer FactoryTalk Historian Interface Node W2K3 Server O/S or Win XP Pro SP2 FT Hist. FTLD Interface (1) RSLinx Enterprise Managed Switch(es) Control System Ethernet Managed Switch(es) Managed Switch(es) Control System Ethernet ~15 Controllers WAN Remote Sites FactoryTalk Historian Interface Node W2K3 Server O/S or Win XP Pro SP2 FT Hist. FTLD Interface (1) RSLinx Enterprise FactoryTalk Directory Server W2K3 Server O/S (1) FT Directory Server Managed Switch(es) FactoryTalk Historian SE Server W2K3 Server O/S FactoryTalk Historian SE Server (XXX Tags) MS Office 2007 (Excel) Copyright 2011 Rockwell Automation, Inc. All rights reserved. 14
15 FactoryTalk VantagePoint EMI Data Connectors FT Live Data FT Historian Alarms & Events History 3 rd Party Real Time Data (OPC DA) 3 rd Party Historian (OPC HAD) SQL Server ORACLE SAP Portal Visualization Reporting Analysis Copyright 2011 Rockwell Automation, Inc. All rights reserved. 15
16 Factory Talk VantagePoint EMI Functionality Dashboard KPI s Integration with Excel Trend Tool XY-Plot Tool Composite Reports Start with Key Performance Indicators Drill Down to Underlying Calculations Copyright 2011 Rockwell Automation, Inc. All rights reserved. 16
17 FactoryTalk VantagePoint EMI Reduces Engineering Cost Reduces Time to Deliver Value No Programming Skills Needed Unified Production Model The Unified Production Model allows for a single source for data aggregation, analysis and reporting Connect to ALL plant floor, production and manufacturing business data sources Offers multiple-plant analysis of all manufacturing metrics in the organization Copyright 2011 Rockwell Automation, Inc. All rights reserved. 17
18 Who Uses The Information / Manager Manager Of Pre-treatment Access To Plant From Anywhere Created Simple Screens In Xcelsius Using Live Data Copyright 2011 Rockwell Automation, Inc. All rights reserved. 18
19 Who Uses The Information / Engineer Environmental Engineer Assisted Creating Monthly Reports Data Auto Populates Also Ability To Run The Report For Past Months Can Be Completed At EHS Engineer Desk Copyright 2011 Rockwell Automation, Inc. All rights reserved. 19
20 Who Uses The Information / Operations Operators Need To Complete Less Data Entry Upset Conditions Are Faster To Diagnose More Accurate Metering Water Discharge Issues Went From A Few A Year To Zero Data File Size Adjustment: Recording For 7 Months RSView32: 1,470 Mb, Historian: 32mb Copyright 2011 Rockwell Automation, Inc. All rights reserved. 20
21 Next Steps Qualifying The System Develop Plan For Future Deployment And Changes Create Install Plan For Production Plants System Is Scalable Modeling Data For Global Harmonization Move Remaining 2 - RSView32 Recording Systems To Factory Talk Historian Upgrade some Systems to ControlLogix Address The Needs Of Global Facilities Copyright 2011 Rockwell Automation, Inc. All rights reserved. 21
22 Next Steps Expand System To Production Plants At West Point Remove Data Collection From Batch Sheets HMI s Drive The Production Process Faster Data Analysis From Engineering Copyright 2011 Rockwell Automation, Inc. All rights reserved. 22
23 About EZSoft Systems Integrator Malvern, PA 12 Year Old Company ControlBuilder Services Specification Development Control Programming HMI/SCADA Programming Database Design/Programming Web-Based Reporting Manufacturing Execution Systems - MES Validation GAMP5 Startup Supervision, Support and Training Copyright 2011 Rockwell Automation, Inc. All rights reserved. 23
24 About EZSoft Applications Batching Systems Liquids, Solids, Creams and Ointments Tank Farm Systems Storage Systems Water /Wastewater Systems Clean/Steam In Place (CIP/SIP) Bioreactor Systems Packaging Machine Systems Data Collection & Monitoring Systems Motion Control Systems Granulation Systems Copyright 2011 Rockwell Automation, Inc. All rights reserved. 24
25 EZSoft, Inc. A Few Parting Thoughts Copyright 2011 Rockwell Automation, Inc. All rights reserved. 25
26 Questions Martin J. Fallon Vice President Sales Cell Phone: Office Phone: Copyright 2011 Rockwell Automation, Inc. All rights reserved.
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