PUBLIC Rockwell Automation TechED 2017 @ROKTechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved.

1
 Stora Enso
Modular Sequencing Helps Reduce Alarms to Improve Uptime

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Rockwell Automation TechED 2017 @ROKTechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 2
 ModularSequencingHelpsStora Enso
ReduceAlarmstoImproveUptime

Presentedby:
MattHanchey NabilSalman
ProcessControlEngineer SystemsIntegrationEngineer/ProjectManagerIntegration
Stora Enso CrossCompany(IntegratedSystemsGroup)
 Agenda
Overview

BriefProfilesCompany

B2XProject

Sequencer&AlarmManagement

LessonsLearned Sharing
 WhoisStora Enso?

KeyFacts

Sales - EUR 9.8 Billion

EBIT - EUR 884 Million
25,000 Employees
35 Countries
HQs - Helsinki and Stockholm
Company records back as far as 1288
Pulp, Paper, and Wood Products
 CrossCompany

Cross Company's Integrated Systems Group provides control

system design, system integration, programming services
and product fulfillment to industry and municipalities.
Extensive experience with legacy distributed control systems
migration and programmable logic controller migration, we
serve chemical, life sciences, alternative energy etc.
 Overview

Stora Enso Demonstration Plant

Location - Raceland, LA
Feedstock - waste biomass from neighboring
sugar cane mill, sugar cane bagasse
Process conversion of biomass into C5 sugars,
xylose
PlantProcessOverview
 Network&
HardwareArchitecture
 Integrated&Scalable

Server Hardware
Management of Code

Reuse of Code

Virtualization
Connection to any third party Equipment

Thin Clients
Expansion of current facility and new greenfield facilities
 WhatisthePlantPAx Sequencer?
The Rockwell Automation Sequencer Object (P_Seq) provides a flexible controller-
based step sequencing solution that reduces engineering time by automating
common operator procedures.
The step-by-step configuration makes it easy to adjust procedures directly from
the HMI displays without having to create or modify custom code in the controller.

Features:
Up to 32 discrete (BOOL) outputs for controlling or commanding devices
Up to 32 discrete (BOOL) inputs for monitoring device feedback
Up to 32 floating-point number (REAL) outputs for set-points or parameter values
A maximum of 500 steps
Rich and intuitive human-machine interface (HMI) screens for operation, monitoring, and
configuration
State model consistent with higher-level procedural control, with states for Idle, Running,
Complete, Held, Paused, and Stopped
 Sequencing&
AlarmManagement
Considerations for choosing this methodology
PlantPAx Sequencer - Utilize standards built on the International
Society of Automation Technical Report ISA-TR106.00.01-2013 for
Continuous Process Operations
Less attention needed from operators
State Based Transitions and Actions
Less time for Startup and Shutdowns BatchControlISA88
Automation of Continuous Steps
System Level Control vs Operator
Improve Uptime by reducing intervention from Operator

Batch Control ISA-88 not required

 Sequencing&
AlarmManagement
About 80 different sequences in this facility
Sequence Scope:
Between 3 and 12 states in each sequence
1 to 20 actions (motor starts, valve actuations, set-point
assignments, communications, etc.)
0 to 3 transition requirements with timers in each state

Alarms are enable/disabled according to sequence states

Sequence interlocks to shutdown sequence activity
Sequence to sequence communication and permissives
All sequences are individually started at this point, no sequencing of sequences, yet
 Sequencing&
AlarmManagement
Alarm & IO assignments
Utilized Structured text for IO and Alarm Set-points
Spare IO can be seen at a quick glance
Alarm Set-points are hardcoded to prevent changes by operator
Sequence Code
Ladder Logic vs Function Block
Acquire all devices/loops to Program Mode during start of sequence,
then release for manual control if needed
Custom AOI for Interlocks and Alarms
Sequences were made to remain in Running State
Custom AOI for Delayed Safe Shutdown Interlocks
Auto Reset Sequence when stopped
 LessonsLearned
Sequencebugs(needtoassertstart&stopafterpoweroutage)

PlantPAxobjectsconsumedscreenrealestate

Sequencecontrolsimplifiednewplantstartup

Sequence/statebasedcontrolreducednuisancealarms easytomakealarmsmatter

ASIBUSDeviceStationSetup

HMIDesignforMobileDevices(displayresolution,usability)

ProjectManagementCollaboration
 Onemorething
Virtualization
RockwellTemplates

StratusRedundantServer

ACPThinManager
FutureforRelevance

iPadMobility

DLRDiagnostics

FactoryTalkVantagePointReports

FactoryTalkHistorianSE
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PUBLIC Rockwell Automation TechED 2017 @ROKTechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 17
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