Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Anchor Glass Corporation: Alarm Integra...
Chris Wild, Electronic Controls Specialist – Anchor Glass Container
Brad Downen, MES Project Manager – Stone Technologies
...
Agenda
 Introductions
 Anchor Glass Background
 Goals
 Why PlantPAx
TM
 Benefits realized
 PlantPAx Challenges
 Q &...
Introductions
 Chris Wild – Electronic Controls Specialist 
 Anchor Glass Container
 Brad Downen – MES Project Manager
...
COMPANYOVERVIEW
Anchor Glass Container ‐ Background
Anchor Glass
 A leading North American manufacturer of glass containe...
MAKINGAGLASSBOTTLE
Anchor Glass – What we are doing
 Convert crunched, recycled glass or raw materials into a liquid
 Cr...
GOALS
Goals
 Replace outdated DCS System
 Provide more intuitive operator interface
 Tighter Controls
 Configurable!!!...
PLANTPAX
What lead us to PlantPAx
 Sequence Object for Reversal
Inputs Outputs
Steps & 
Operation Status
PLANTPAX
PlantPAx valued benefits
• Note to self: “PlantPAx isn’t something you should try to 
partially implement!!!!”
Fr...
PLANTPAX
Architecture: Provide failover communication paths
 Data servers located in control 
room to eliminate possible ...
PLANTPAX–FULLFEATURED
Consistent Standards – Especially with PID zones
HISTORICALDATA
Data ‐ A wealth of knowledge
Alarming Analysis  ‐ Value Added
PLANTPAX–ALARMINGBENEFITS
 Quickly pin‐point areas of concern
 Determine if issues are ...
ALARMREPORTING
Alarming Data that IS useful
Challenges
 New Programming Scheme (could not re‐use any 
previous controls standards)
 Learning & dissecting all availa...
PLANTPAX
Questions
Chris Wild, Electronic Controls Specialist – Anchor Glass Container
Brad Downen, MES Project Manager – ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
 On the mobile app:
1. Locate ses...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
www.rsteched.com
Follow RSTechED on Facebook & Twitter.
Co...
Upcoming SlideShare
Loading in …5
×

Anchor Glass Corporation: Alarm Integration Enables More Manageable, Cost-Efficient Process System

477 views

Published on

Operating on an antiquated DCS and historian, a leading supplier of glass packaging was limited to a 14-day capacity for historical data storage. Hard-coded alarms were unmanageable by operators. The company upgraded to a PlantPAx® system with FactoryTalk Historian software. The new system pulls and stores many years of
data, freeing hours spent on manual collection and opening a new resource for system analysis and improvements. Alarm integration and remote access empowers operators to manage alarms at the HMI level and significantly lowers maintenance and support costs.

Published in: Technology, Business
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
477
On SlideShare
0
From Embeds
0
Number of Embeds
2
Actions
Shares
0
Downloads
13
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

Anchor Glass Corporation: Alarm Integration Enables More Manageable, Cost-Efficient Process System

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Anchor Glass Corporation: Alarm Integration Enables More Manageable, Cost-Efficient Process System
  2. 2. Chris Wild, Electronic Controls Specialist – Anchor Glass Container Brad Downen, MES Project Manager – Stone Technologies Choosing PlantPAx Alarm Integration Enables More Manageable,  Cost‐Efficient Process System
  3. 3. Agenda  Introductions  Anchor Glass Background  Goals  Why PlantPAx TM  Benefits realized  PlantPAx Challenges  Q & A CHOOSINGPLANTPAX
  4. 4. Introductions  Chris Wild – Electronic Controls Specialist   Anchor Glass Container  Brad Downen – MES Project Manager  Stone Technologies  Audience – How Many ...  End Users  System Integrators  Rockwell Automation  Distributor  Other CHOOSINGPLANTPAX  Experience with…  PlantPAx Operations  PlantPAx Development
  5. 5. COMPANYOVERVIEW Anchor Glass Container ‐ Background Anchor Glass  A leading North American manufacturer of glass containers with annual revenue  of approximately $550 – $600 million and employing approximately 2,000  people.    6 glass manufacturing facilities, consisting of 11 furnaces and 31 lines  2 Oxy/Gas furnaces, 9 Gas/Air Reversing furnaces  Lots and Lots of bottles!!!!  Up to 600/min => 300,000,000 bottles/yr Controls History  1986‐1995 – Deployed Leeds and Northrup Micromax DCS controls system  throughout the company  2003* – Established new corporate standard HMI and Controls with Rockwell  Software’s RSView32 and ControlLogix® processors  2012 – Adopted Rockwell Automation’s PlantPAx controls strategy layered with  Rockwell Software’s interface solution: FactoryTalk View SE, FactoryTalk Historian  SE, FactoryTalk Alarm and Events, FactoryTalk VantagePoint
  6. 6. MAKINGAGLASSBOTTLE Anchor Glass – What we are doing  Convert crunched, recycled glass or raw materials into a liquid  Create a stream of lava and condition the stream of lava to a consistent temperature  and weight  Physical items to control  Burners (many, many)  Pressure (helps prevent flames from shooting out)  Glass Level (weight of the bottle)  Electric Boost  Reversal (conserves heat) Furnace Forehearth(3) Hole located here  drops the gob of glass  to make the bottles
  7. 7. GOALS Goals  Replace outdated DCS System  Provide more intuitive operator interface  Tighter Controls  Configurable!!! (especially for reversals)  Better historical of data for analysis (both Process & Alarming)  Better Alarming.  Managable (Alarming without overwhelming noise)  Extendibility:  capable of expanding to other areas of plant  Remote access – Corporate viewing  Low maintenance
  8. 8. PLANTPAX What lead us to PlantPAx  Sequence Object for Reversal Inputs Outputs Steps &  Operation Status
  9. 9. PLANTPAX PlantPAx valued benefits • Note to self: “PlantPAx isn’t something you should try to  partially implement!!!!” Fringe Benefits  Standards!!!  Tightly Integrated with HMI – Minimal need to access PLC  code  Easily simulated and tested  Rich features and functionality available at HMI level  Historical Data – dependable, reliable, fast and DEEP….store  much, much more data than before.  Easily hold 1‐2 years of  data verses 10 days for operations  Alarming – Full control of alarms from HMI.  Configure,  disable, enable, and SNOOZE!!!!!
  10. 10. PLANTPAX Architecture: Provide failover communication paths  Data servers located in control  room to eliminate possible  infrastructure failure points   Virtual Server hosting 3 virtual  machines: HMI, Historian &  RDP Server  Data Servers configured for  failover of:  Linx Enterprise  Historian Interface Nodes  FactoryTalk Alarm & Events  HMI developed as direct tag  so dependence on HMI server  is minimal
  11. 11. PLANTPAX–FULLFEATURED Consistent Standards – Especially with PID zones
  12. 12. HISTORICALDATA Data ‐ A wealth of knowledge
  13. 13. Alarming Analysis  ‐ Value Added PLANTPAX–ALARMINGBENEFITS  Quickly pin‐point areas of concern  Determine if issues are caused by system or operator  Alarms configured to obtain important process data to  determine if issue was operational, electrical or mechanical  Focus maintenance on issue and not just a guess
  14. 14. ALARMREPORTING Alarming Data that IS useful
  15. 15. Challenges  New Programming Scheme (could not re‐use any  previous controls standards)  Learning & dissecting all available objects for new project  Understanding PlantPAx security   Added Screen counts  Operational Training PLANTPAX
  16. 16. PLANTPAX Questions Chris Wild, Electronic Controls Specialist – Anchor Glass Container Brad Downen, MES Project Manager – Stone Technologies
  17. 17. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 17 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  18. 18. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank you for attending our session!

×