Land O’Lakes Modernizes with Complete Code Rewrite, Minimal Downtime

Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 2Rockwell Automation TechED 2017 @ROKTechED #ROKTechED
PUBLIC
Land O'Lakes
Modernizes with Complete Code Rewrite, Minimal Downtime

Speakers
Mark Visness
Engineering Manager
Cybertrol Engineering
Nick Paris
Maintenance Manager
Land O’Lakes

Agenda
Next steps
Benefits
Business Challenges
Introductions/Company Overviews
Path to Success

Agenda
Next steps
Benefits
Solutions
Business Challenges

 Three main divisions
 Dairy Foods
 Animal Feeds
 Crop Inputs
 Dairy foods division comprised of
11 facilities
 Melrose MN facility – Specializes
in the production of cheese and
dairy proteins

Cybertrol Engineering
 Control and Information Systems Integrator – Minneapolis, MN
 Rockwell Automation Solution Partner
(Control/Process/Information)
 Thousands of projects for over 400 clients
 Follow us!
@CybertrolEng cybertrol-engineering
Excellence Integrity Achievement

Agenda
Next steps
Benefits
Business Challenges
Path to Success

Reasons for server upgrades
 Physical servers on plant floor – slow, outdated
 Previous HMI upgrade attempt by another integrator
had failed
 Three PLC-5®s nearly 100% full
 Unsupported server operating system
 Servers not virtualized
 Software versions not kept current
 Need for process data
Business Challenge
2015

Reasons for control system upgrades
 Code developed by various vendors with
entirely different code structures
 High cost of maintenance
 Little visibility into the operation
– no historian; minimal reporting
Business Challenge
2015
 Legacy PLC and HMI System – no longer supported
 PLC programs with many hands in them over 20+ years

Agenda
Next steps
Benefits
Path to Success
Business Challenges

History of the upgrade
Path to Success
Server upgrade – physical to virtual
 Network infrastructure upgrade
 Software and operating system upgrade
 Visibility and support additions
2015

Virtualization
Solution
 VMware Virtual Server Infrastructure
 High Availability
 Shared Storage and Scheduled Backups

Virtualization
Solution

History of the upgrade
Path to Success
Upgrade to the FactoryTalk® View SE
and ControlLogix® Platform
 PLC-5® to ControlLogix®
 RSView®32 to
FactoryTalk® View SE
 Complete code rewrite
 Reporting and Information
Server upgrade – physical to virtual
 Network infrastructure upgrade
 Software and operating system
upgrade
 Visibility and support additions
2015 2016

Upgrade to Rockwell Automation ControlLogix
Solution
 PLC Upgrade –
Migration to
ControlLogix®

Program Conversion
Solution
 The existing PLC-5® code was converted “as-is”, with no changes, in
order to get the old code running in the new processor
 This allowed for minimal shutdown time as it only took a few hours to
swap out the 14 PLC-5® racks
 After this, a quick spot check of I/O
 Verification of production operations on water
 Back to full production in less than 48 hours

New Program Commissioning
Solution
 The process was broken down by unit operation:
 Milk receiving, Pasteurization, Ultrafiltration, Evaporation, etc.
 For each area:
 All-new PLC/HMI code was written
 New code was installed alongside existing code, but not activated
immediately
 At end of a daily Production/CIP run, new code was activated for a given
area

New Program Commissioning
Solution
 This method allowed a system with nearly 1000 I/O points and several
different unit operations to be upgraded and re-commissioned in a
systematic way
 Benefits:
 Smaller commissioning team required
 After initial <48-hr shutdown for hardware replacement, essentially no
further interruption to operations
 Operators have time to adjust to new process screens and other
operational changes
 One unit operation upgraded every 2-4 weeks until complete

Clean-in-Place (CIP) System
Problem
 Previous CIP programs:
 Documentation not up-to-date
 Many changes over the years
 Dead code
 Very difficult to edit
 No reporting - circular charts only

Recipe Based CIP System
Solution!
 Process and CIP operation controlled through
downloadable sequence charts
 CIP Steps easy to view/edit by sanitation
manager
 CIP Reports
showing real-time plus event-based data

Electronic CIP Reporting
Solution!
Web page for report selection, enter time and date range

Solution!
View summary of all CIPs, then select which CIP report to view

Solution!
 Trends of
temperature, flow,
conductivity
 Each CIP step
time-stamped
 Alarms, events
and operator
comments
summarized

Production and Energy Visibility
Benefits
Shift Reports

Agenda
Next steps
Benefits
Business Challenges
Path to Success

 System was previously not serviceable
 Now, code is documented
 Code now uses current standards
 Hardware was obsolete/unsupported
 Now, hardware is serviceable
 System is easily expandable
 HMI response time much improved
 Less time to diagnose and repair issues
System Serviceability
Operational Benefits

Visibility and Data Analysis
Business Benefits
 View of operations by management,
maintenance, operators
 Reports available to corporate users
 Remote support by Cybertrol
 Process troubleshooting, optimization
 E-mailed warnings and alerts provide
notification before problems become
more serious

 Real-time information for real-time decisions
 Reduction in automation system maintenance cost
 Automation system no longer preventing process
modifications and optimization
Plant Savings
Benefits

Agenda
Next steps
Benefits
Business Challenges
Path to Success

Troubleshooting using FactoryTalk® VantagePoint® – process or other
troubleshooting by making an ad-hoc trend
Continued Growth in Visibility
Next Steps

 Energy analysis – collection and reporting on
energy usage will allow for future plant savings
 Wastewater treatment - expansion of our
wastewater treatment facility will require
detailed reporting
Next Steps

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 34Rockwell Automation TechED 2017 @ROKTechED #ROKTechED
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Land O’Lakes Modernizes with Complete Code Rewrite, Minimal Downtime

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