PotashCorp New Brunswick division relies on Plantweb to save money and deliver faster start-ups. Mobile Worker

Transcription

1 PotashCorp New Brunswick division relies on Plantweb to save money and deliver faster start-ups Mobile Worker

2 Presenters Mike Sharp Bob Emery Shane Bast

3 PotashCorp PotashCorp was originally a Saskatchewan Crown Corporation Issued IPO in 1989, on NYSE and TSX (POT) Low cost and strong profitability provided the basis for growth and diversification PotashCorp is the largest global fertilizer producer in the world It is the #1 producer of Potash, #3 producer of Phosphate and #4 producer of Nitrogen PotashCorp has 5,400 employees in five countries Potash Division employs approximately 1,450 employees in Saskatchewan and 500 in New Brunswick

4 New Brunswick Division PCS- Producer of fertilizer products (potash, nitrogen and phosphate) 7 Sites produce 8.8 million tonnes of KCI (Potash) per year Increasing to 15M tonnes by % of world capacity 5400 employees in 5 countries NB site 0.8M tonnes Potash (2M tonnes by 2014) and 0.5M tonnes of Salt 500 employees You Are Here? Underground mining at depth of between 400 and 700 meters and above ground mill Recognized as one of the safest mines in Canada by the Canadian Institute of Mining, Metallurgy and Petroleum

5 Picadilly Potash Project Mine Brine Disposal Pipeline

6 Picadilly Potash Project Economic Impact $1.8 billion capital investment Over 2,500 person years of employment during construction Over 140 new, permanent jobs with above average wages and benefits Increased economic activity in Sussex and area Increased demand for supplies and services within New Brunswick

7 Introduction This major project provides a golden opportunity to put in place processes and tools to increase commissioning, startup and maintenance effectiveness Challenge is to rethink the way we do things today to take advantage of technology In the past we have presented the results and challenges of our experience. Today we will focus on commissioning and mobile worker

8 Compaction Plant Commissioning

9 Some Project Goals (Needs) Optimize commissioning work and time. Centralize system and process information. Enhance maintenance system architecture. Ensure effective operation and system tools. SAVE ON COMMISSIONING COSTS Establish a predictive maintenance process for after the project

10 Solution Make the most of System technologies System selection System Topologies Security Maintenance strategy

11 Technologies at PotashCorp DeltaV AMS Hart Foundation FieldBus Wireless HART Mobile Worker OPC interface Remote access servers Predictive Diagnostic (PD) Charms

12 Extending the Control Room to the Field Access process control, instrument, maintenance and operations data in real time

13 Remote access to AMS Deployed Wi-Fi network to enable remote access to AMS Device Manager and DeltaV control system Field workers access AMS in real-time for equipment calibration and diagnostics when in the field Reduced calibration time and increased calibration accuracy for flow transmitters

14 Had to make the case to Management to add the wireless access points and purchase Tablet PCs es h M e ss l e r Wi ork w t Ne a ge r e Co v

15 Mobile Operators Accessing Control Data in the Field Utilize operator control displays on mobile devices Access operational data and reports in the field Receive process alarms outside the central control room View historical trends while anywhere in the plant

16 Mobile Maintenance - Access Asset Management Data in the Field Configure, calibrate, diagnose, and document device activities Identify, troubleshoot and resolve device issues in the field Provisioning of field mounted WirelessHART devices

17 Mobile Commissioning Access to Real-time Data In the Field Equipment Calibration Electronic Access to Maintenance Documentation Electronic Access to Loop Narratives Access to Operator Displays Can Commission twice as much equipment with the same mount of people

18 Before Mobile Worker

19 With Mobile Worker

20 Access to Operator, engineering and Instrument databases AMS Operator Screen Control Studio DeltaV Configuration Plant Documentation

21 PotashCorp PlantWeb Topologies Maintenance Wireless Network Virual IO Module PLC Wireless PI Enterprise Gateway OPC Documentation Gateway DMZ Instruments DeltaV DeltaV AMS

22 Maintenance Terminal services Instrument supervisor has access to operator display, process alarms, AMS device alarms and diagnostics from his office or HOME via the plant network. DeltaV Terminal Server ProPlus - DeltaV - AMS Client Intranet Instrument Supervisor - Auditing system - Planning maintenance

23 Narratives access - DeltaV Operate Techs and Operator have access to complete narratives from anywhere in the plant

24 Loop Sheet access AMS or DeltaV Techs have access to Loop Sheets from anywhere in the plant

25 Instrument user manual - AMS Techs have access to complete Manuals from anywhere in the plant

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27 DeltaV via Terminal Server DeltaV DeltaV Terminal Server Wireless NW Mgmt System Access DeltaV via Microsoft Remote Desktop connection to a DeltaV Terminal Server Session DeltaV is not installed on the client device. DeltaV is running on the Terminal Server Any PC can be used.

28 Terminal Server Terminal Server Client Application Server Licensing Use Case Wireless Network Client Radio Range Microsoft Remote Desktop Microsoft Terminal Server Each session is licensed as the local work-stations Occasional operation Or Maintenance Wireless Mesh Network n Wi-Fi coverage area Use any kind of Microsoft PC Other applications can be run on the PC DeltaV runs on the Terminal Server in the control room The mobile PC runs Microsoft Remote Desktop (RDP) which connects to the Terminal Server The PC screen, mouse and keyboard data are passed between the RDP session and the Terminal Server

29 Applications Accessed By Mobile Workers DeltaV Asset Management System Microsoft Office Applications Potash Business Applications

30 Mobile Worker Solution Benefits Improves Productivity Improves Equipment Maintenance Accessing maintenance histories, instructions, and other diagnostic information on the spot helps workers troubleshoot problems Commissioning Rich real-time information from control and assetmanagement systems helps field workers resolve operational problems quickly and effectively One operator performs multiple jobs in a single operator round Can do more with less Avoid mistakes when Identifying equipment Operations Maintenance no longer have to Bother control room operators when doing maintenance tasks to field devices

31 Savings More work can be done with less people No lost time searching for documentation Documentation is kept current immediately Dry run commissioning by bringing the control room into the field.

32 Business Results Achieved Mike Sharp (commissioning technical lead) estimates that 1000 hours were saved using Mobile worker and AMS for the Compaction Plant commissioning. The same process will be used to commission the much larger Wetmill phase, with an estimated savings of 3000 to 3500 hours.

33 Summary Save money during commissioning with Mobile Worker and mobile access to tools and documentation Can do twice as much commissioning in the same time or faster Questions???

34 Where To Get More Information Give us a call