Tradebe Implements PlantPAx to Control Barcelona Hydrocarbon Terminal

Solution

SURIS chose the PlantPAx® distributed control system from Rockwell Automation because it offered scalability, flexibility and easy integration of skids or third-party units. The solution was designed utilizing EtherNet/IP™ and included a complete and integrated information rich operator workstations (OWS) and engineering workstations (EWS) providing KPIs for better management decisions.

As a result, the system can easily integrate different terminal equipment, including the tank level measurement system, motor-driven valve network and starters, frequency converters, platform scales, energy monitors, load controllers in the truck loading stations, and other third-party systems.

An EtherNet/IP network was implemented, consisting of one Ethernet network at the physical level and several logic networks (VLAN) that provide the system with the best available level of accessibility, visibility and security, and helps ensure optimal communication performance through segmentation of the existing traffic. Stratix 8000™ modular managed ethernet switches were used and the network was segmented into three logic networks: one for I/O, a second one for TCP/IP communication and a third network to connect controllers and PASS visualization servers.

Safety elements were implemented to meet the SIL 2 requirements of the hazard and operability study (Hazop) report for the site. For this purpose an ESD (emergency shutdown) system was installed, in parallel with the process control system. The core element in the safety system is a GuardLogix® controller seamlessly integrated into the plant-wide PlantPAx solution; it can support up to SIL 2 safety applications.

For the terminal visualization and information, PlantPAx servers (Process Automation System Server, PASS) and OWS are used. Information exchange between the control system and the terminal management ERP system is aided by FactoryTalk® Transaction Manager which helps provide excellent information flow between the corporate system and the control system.

All the application servers have been implemented on a virtual infrastructure streamlining the number of physical servers and helping to increase the system lifecycle and availability. In addition, maintenance has been simplified.

Results

Since the completion of the new TRADEBE hydrocarbon terminal, “the Rockwell Automation PlantPAx distributed control system is working seamlessly” states the Services Manager of TRADEBE. “It’s a very rugged system and all devices integrate perfectly, thus easing the plant management and automation, resulting in cost savings and less complexity,” he adds.

“The combination of scalable and flexible solutions enabled TRADEBE to integrate the plant, both for control and safety. The open communication allowed us to easily integrate third-party equipment. Likewise, it streamlined data capture and allowed information to flow to our corporate systems.”

SURIS reiterated the advantages gained. ”We have been able to work with open tools and protocols, as well as the flexibility and modularity of all Rockwell Automation equipment. What’s more”, he continues, “scaling the solution according to our needs, anytime and anywhere, has made the implementation much easier.”