Golden Triangle Energy Cooperative Selects PlantPAx Automation System

Summary

The video highlights how Golden Triangle Energy Cooperative, a major U.S. ethanol producer, modernized its plant to overcome frequent downtime caused by an obsolete control system. Processing 21,000 bushels of corn daily, the facility required a reliable, always-on automation solution. Bachelor Controls, a Rockwell Automation partner, replaced the aging DCS with the PlantPAx platform, integrating new infrastructure, redundant networks, and familiar operator interfaces. The upgrade improved reliability, scalability for future expansion, data visibility, and overall plant performance. The seamless implementation impressed the team, delivering a modern system that ‘just works’ with enhanced efficiency and lower support costs.

Takeaways

• 😀 Golden Triangle is a U.S. producer of high-quality ethanol, converting 21,000 bushels of corn a day into alcohol and high-quality spirits.
• 😀 The plant faced issues with an obsolete control system, resulting in increased downtime and unexpected shutdowns.
• 😀 The goal was to have a control system that acted as an asset to the plant, ensuring continuous operation without disruptions.
• 😀 The implementation of a new system started with emergency calls from the maintenance manager due to frequent system failures.
• 😀 Bachelor Controls, a Rockwell Automation solution provider, replaced the old DCS system with the PlantPAx process automation system.
• 😀 The new control system was designed with redundancy and robust communication infrastructure, using the CLX platform and ControlNet backbone.
• 😀 The plant's system was upgraded in two phases to avoid downtime during implementation and ensure smooth transitions between old and new equipment.
• 😀 The customized MMI (Man-Machine Interface) was designed to be familiar to operators, minimizing training requirements and easing the transition.
• 😀 Rockwell Automation's support and systematic approach were crucial in ensuring the success of the project, with professionalism and clear planning.
• 😀 The infrastructure was designed to accommodate future expansion, including a planned increase in distillation capacity.
• 😀 The new system provided extensive data tracking capabilities, including the ability to track every gallon of product and adjust for proof gallons.
• 😀 The implementation led to cost savings, as evidenced by a reduction in support costs compared to the previous system.

Q & A

What is Golden Triangle Energy Cooperative, and what do they produce?

Golden Triangle Energy Cooperative is a U.S.-based ethanol producer that uses approximately 21,000 bushels of corn daily. They convert the corn into ethanol and high-quality spirits.

What challenges was Golden Triangle facing with its previous control system?

Golden Triangle faced increased downtime and unexpected shutdowns due to their outdated and obsolete control system. This created operational disruptions and inefficiencies.

How did Golden Triangle plan to address the issues with their control system?

Golden Triangle partnered with Bachelor Controls, a Rockwell Automation solution provider, to upgrade their existing DCS to a more reliable and modern process automation system.

Which platform was chosen to replace Golden Triangle's old DCS system?

The PlantPAx process automation platform from Rockwell Automation was selected to replace Golden Triangle's existing DCS.

What are the key features of the new automation system implemented at Golden Triangle?

The new system included Rockwell’s CLX processors, PowerFlex drives, and a redundant control net backbone to improve system reliability, data communication, and operational efficiency.

Why was the implementation of the new system done in two phases?

The implementation was split into two phases to minimize plant downtime and ensure that new communications infrastructure and equipment could be integrated smoothly without disrupting operations.

How did the operators react to the new system after it was implemented?

The operators found the transition smooth because the new MMI (Man-Machine Interface) platform was customized to replicate the look and feel of the old system, making it easier for them to adapt to the new technology.

What role did Rockwell Automation play in Golden Triangle's system upgrade?

Rockwell Automation, through their solution provider Bachelor Controls, supplied the new system components, provided technical consultation, and offered ongoing support to ensure a successful upgrade.

How did the new system improve Golden Triangle's ability to manage and track production?

The new system allowed Golden Triangle to track every gallon of ethanol and spirits produced, adjusting them to proof gallons for better quality control. The system also offered extensive data insights and trend analysis to optimize operations.

What benefits did Golden Triangle see in terms of operational costs after the system upgrade?

After the system upgrade, Golden Triangle was able to reduce its support costs significantly. For example, the cost of spare parts and support was less than what they had been paying the previous year, contributing to operational cost savings.