NAFTA a.s. replaces multi-vendor solution with fully integrated control architecture from Rockwell Automation
25/09/2017 Rockwell Automation
Leading Slovak natural gas storage company deploys company-wide Allen-Bradley control infrastructure and sees flexibility and ease of use increaseBased in Bratislava in the Slovak Republic, NAFTA a.s. has extensive experience in natural gas storage and underground-facility development and is the Slovak leader in the exploration and production of hydrocarbons.
Favourable geological conditions and the location of its storage facilities create ideal conditions for the development of one of the key hubs of the European gas network. Storing natural gas in underground storage facilities is the core business of NAFTA - representing roughly 70 % of all its activities - with the storage capacity of natural gas underground facilities operated by NAFTA currently standing at 2.4 bcm (billion cubic metres).
NAFTA has been developing this area for 40 years, working intensively to increase its storage capacity. During development and reconstruction, it applies state-of-the-art technology that is environmentally friendly and special impetus is placed on high operational safety.
It was during a recent upgrade of its control solutions that NAFTA made the decision to drop its multi-vendor control solution and instead opt for an advanced integrated control solution and monitoring solutions comprising Allen-Bradley® products and systems from Rockwell Automation.
The primary challenge faced by the engineers at NAFTA was the migration of the hardware and software for the control architecture from multiple systems into one new unified solution, which also included new systems for visualisation and data management.
"We have a special department overseeing the control systems," explains Miroslav Simko, Head of MaR Engineering at NAFTA. "We are responsible for the design of each control system used within the NAFTA company infrastructure. As well as designing the systems, we also programme and maintain them, offering 24-hour support for each system.
"We are not a typical system integrator (SI)," he continues, "as we are also the end user, but in many ways we are similar to a typical SI because we design, programme, test and install control systems, but in this case it happens to be for our own company."
Geographic dispersal was also an issue, especially in relation to communication and maintenance. "The actual automation is not really an issue," Simko continues, "there are not many cycles or control loops - we mainly use PID control loops for pressure, flow and the temperature of gas in pipeline; and we simply control the valves (open/close) as well as a variety of digital IO. However, we do have multiple storage solutions in a complex network that must all be accessed as effectively as possible. It is this combination of multiple field stations and the subsequent connections to distribution lines and Trans-Europe pipeline that puts the real demands on the control and monitoring systems."
"We chose Rockwell Automation because we wanted to stick to a standard," Simko elaborates. "As well as training and operational aspects, we wanted to keep our spares inventory as lean as possible, and this can only truly be achieved with a single automation vendor. Rockwell Automation offered us the best overall package of hardware and software systems."
The migration project actually took place in several steps over a few years, and involved multiple field stations and technology platforms, all eventually interconnected through fibre optic lines and using EtherNet/IP™ for communication.
From a hardware perspective the upgrade comprised the installation of over 100 programmable automation controller (PAC) systems and 70 SCADA systems. The PACs included Allen-Bradley ControlLogix®, Allen-Bradley CompactLogix™ and Allen-Bradley GuardLogix® units for various safety valves and systems. Local operator interaction is achieved via numerous Allen-Bradley PanelView™ Plus HMIs.
"The Logix-based PACs offer a very flexible solution and for us they are incredibly valuable as they offer online access," Simko explains. "Our technology has to operate 24 hours a day all year, we have to make sure that shutdowns are minimal and that when they do occur they only occur for the shortest possible time. By accessing the PACs remotely we can save incredible amounts of engineering effort, travel and time."
The migration also included the implementation of various Rockwell Automation software solutions, starting with visualisation based on FactoryTalk®View SE, including FactoryTalk Historian for data collection and collation, FactoryTalk VantagePoint® for data reporting and dissemination and FactoryTalk ViewPoint for remote access via web browsers. Finally, the company also took advantage of a TechConnect-„ contract with Rockwell Automation, which provides software maintenance, real-time phone support and comprehensive online support for everyday support needs. "The vast majority of our knowledge is internal," Simko explains, "but we can also call upon Rockwell Automation, as we recognise that some special problems may well need Rockwell Automation help."
The primary result for NAFTA is that it now has a companywide standard for control solutions running on a single communication protocol over super-fast fibre optic lines. As well as all of the inherent advantages of a single supplier, NAFTA is also enjoying numerous technological benefits including remote access and single-platform programming.
"We do not document advantages or specific performance results when it comes to comparing the old and new control systems; however, our experience and knowledge of the new system means that we can say that it is a lot more flexible than that from our previous automation supplier. The PACs are also much easier to programme and use than those from our previous supplier, whose control solution was very strict and far less flexible.
"We are very close to the local Rockwell Automation team," Simko concludes, "because we have been working with them across many systems for nearly 20 years. They are always friendly and incredibly helpful and we already have them in mind for a number of new projects we have in the pipeline, which will also benefit from the use of Rockwell Automation solutions."
For more information, please contact:
Rockwell Automation Ltd
UK Marketing Communications Specialist
Pitfield
Kiln Farm
Milton Keynes K11 3DR
Tel: 0870 242 5004
Fax: 01908 839696
Email: ukmarketing@ra.rockwell.com
Web: www.rockwellautomation.co.uk
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