Siemens Industry Oil and Gas Conference

March 30th, 2016

John Sullivan
Decreased Cost, Increased Performance
of a LACT Skid using the S7-1200
  Introduction

 Parts of LACT Skid

 Case Study Presentation

 Hardware Overview
Agenda  Communication
 Challenges

 Questions
Presenter Info
John Sullivan
Project Director

• Siemens Certified Professional

• Control Systems PE

• B.S. in Mechanical Engineering – Rose Hulman Institute

of Technology

• With DMC since 2009

• Relocated to Denver in August of 2014 with 3 other
engineers.
 DMC Company Profile

Established in 1996, offices in Chicago, Boston, Denver,

Houston, New York & customers throughout the world
85+
employees & growing

Industries Served:

Automotive Material Handling

Chemical and Food Metal Converting
Processing Packaging
Electronics/Semiconductor Pharmaceutical
Hydraulics Printing & Textiles
Laboratory Testing Oil & Gas
Machine Tool
Areas of Expertise
 PLC Programming

Motion Control
Engineering &
Servo Systems

HMI & SCADA

Expertise

Vision Inspection
Expertise

Intelligent Data
& Web Based
Systems

Robotics

MANUFACTURING
AUTOMATION & INTELLIGENCE
 LabVIEW
Development

NI FPGA

Machine Vision

NI Real-Time

Test Stand Design

Data Analysis &

Reporting

TEST & MEASUREMENT AUTOMATION

 Product
Development

Embedded
Design &
Programming

SDK, API
& Driver
Development

PC Application
Development

Web Application,
iOS, Android &
App Development

Database Systems

CUSTOM SOFTWARE
& HARDWARE DEVELOPMENT
 INDIVIDUAL
CERTIFICATIONS

10

10

5
MICROSOFT CONSULTING SERVICES
Manufacturing & Automation Certifications

DMC has the highest number of

S7 certified engineers in the US.
LACT Skid Introduction
What is a LACT Unit?
Lease Automatic Custody Transfer Unit
What is a LACT Unit

Image from FMC Technologies

What Is Important?
DMC Core Values

1. Accuracy (Flow Meter)

 1. Need flow measurements to
be very accurate

Accuracy 2. Variety of Flow Meters based

on conditions
(Flow Meter)
3. Different Flow Meters have
different interfaces to Controls
Key Features

2. Remote Connectivity
 1. Data is always collected by
central station

Remote 2. Data connection is not always

reliable
Connectivity
3. Need multiple interfaces to
provide for different customer
standards
DMC Core Values

3. Cost
 1. Transfers money, but can’t cost
much of it

Cost 2. Competition drives down cost

3. Lowest Cost usually makes the

decision
Key Features

4. Controls
 1. Reliability!

2. Need items that are quick and

Controls easy to configure

3. Need items with a range of

communication options

4. Remote connectivity is hugely

desired
Case Study
Project Requirements
 Configurable for Multiple Flow Meters

 Variety of Communication Options

 Local Control for Operator

 Remote Monitoring

 Availability for Expansion for Remote

Connectivity

 Low Hardware Costs

 Customer ownership for future

changes
Motivation for Change
 Current Solution
 AB MicroLogix PLC
 Panel View Component HMI
 Different Versions of Code for
Different Flow Meters

 Solution
 S7-1200
 Comfort Panel
 Common Code Base for a Variety of
Flow Meters.
 Single PLC for variety of different
customer connections.
Which PLC?
The S7-1200
 Communication/Remote Connection
 Profinet, Modbus TCP, Ethernet,
Ethernet/IP on board
 Expansion for Modbus RTU, Profibus,
AS-Interface, and others
 Cost
 Lower cost than most competitor
products
 Onboard IO helped drop overall cost
 Common Code Base
 Able to develop code to meet a
variety of different meters and
sensors.
The S7-1200
 Web Server
 Web Server with data tables to
provide remote troubleshooting
 SMTP
 Option to add in emails based on
events
 PLC Data Logging
 Built in Logging Functionality on
the PLC (accessible via webserver)
 Not implemented, but an option
for growth.
Which HMI?
Comfort Panel
 Configurable Analog Scaling
 Pop-up to change scaling of
analog inputs.
 Back-up Local Data
 Needed local data logging in case
connection went down.
 Wanted to trend non financial
values as well.
 Password Protection & User Admin
 Needed custom password
protection for different screens
 1. Far more functionality for a
lower cost

2. Less work for OEM when

Results building different skids

3. Better looking HMI

4. Lots of room for expansion to

future features
 1. LACT Units are vital for business
1. Good Flow Meter
2. Smart Controls

Recap
3. Good Communication

2. Siemens Solution
1. S7-1200 is low cost high feature
processor
2. Improved capability and room
for expansion
Questions?
John Sullivan John.Sullivan@dmcinfo.com
303.927.0191 www.dmcinfo.com