RA TechED 2019 - PR03 - Implementation of PlantPAx Systems
Phoenix Control Systems
1. PROJECT REVIEW Industrial
Automation
CAPSA (CHANGAN AUTOMOBILES and PSA) SHENZHEN CHINA – PAINT SHOP
Sales Value € 3,750,000
Control Media Allen Bradley 1756-L61
Control Gear Rockwell
Variable Speed Drives Powerflex
Networks Ethernet IP, DeviceNet
Project Duration Feb’12 – Mar’13
CUSTOMER
Changan PSA Automobiles Co Ltd (CAPSA) is a joint venture initiated by China Changan Automobile
Group and PSA Peugeot Citroën established in November 2011. It is the PSA Group's second joint
venture company in China. Production trials started in early 2013. With the initial annual
production capacity of 200,000 vehicles and engines, CAPSA will gradually expand the production
capacity according to the market demand. The joint venture will initially produce the Citroen DS.
REQUIREMENTS
To supply the electrical control panels and software (project manage, design, supply, program and
commission) for the following elements of the new Paint Shop at the new CAPSA facility in
Shenzhen, China:
• Complete Conveyor System
• Pretreatment
• E Coat
• E Coat, Sealer and Topcoat Ovens
• Topcoat Booth
• Paint Distribution
• Paint Shop Supervision
2. PROJECT REVIEW Industrial
Automation
OVERVIEW
Phoenix won the electrical controls for a PSA & Mitsubishi joint venture new 35uph Paint Shop
project for Taikisha Europe in Kaluga Russia. Design for this project started in Feb 2010 and an 18
month schedule concluded in late summer/early Autumn 2011.
For this project in Shenzhen China, Phoenix was approached again to provide the electrical controls
of the new CAPSA 60uph Paint Shop involving the Conveyor System, Process Plant, Paint Distribution
and Plant Supervision Systems. The project size was 50% greater than the Kaluga project. Phoenix
won the project but this time a more aggressive 12 month schedule had to be achieved.
The project commenced with design meetings with the CAPSA pilot and Phoenix at their
headquarters in China. From these initial design meetings a Functional Design Specification was
generated for each of the systems (14 in total) and agreed by all parties.
Following the finalisation of the Design specs with CAPSA the Electrical Design and Control Panel
Manufacture was undertaken. All the panels were manufactured in our premises at Speke and from
there shipped to China.
The complete conveyor from Paintshop entry to the exit comprises six systems each of which has
it’s own PLC and suite of panels. In addition Phoenix provided the electrical panels for the Pre-
Treatment and E Coat Systems, The Ovens for E Coat, Sealer and Topcoat. The Topcoat Booths, The
Paint Distribution and Central Supervision System.
Once installed all these systems were commissioned commencing by Phoenix engineers,
commencing in December 2012
All Control Panels were manufactured in our Liverpool premises.
3. PROJECT REVIEW Industrial
Automation
The contract for the Control Panels was won as a separate contract from the Project Management
& Design and we won the entire scope inclusive of shipment to Shenzhen China. Our competition
was Chinese and Japanese suppliers.
The scope covered the following:
• Rockwell CLX PLC (14x PLCs).
• 15x Ethernet Switch Enclosures for Paint Shop Ethernet Network
• 21x Conveyor Control Panel suites (51x 800mm Sections).
• 277x Conveyor Remote Motor Control Boxes
• 13x Remote HMI Stations
• 3x Pre-treatment Plant Control Panel suites (11x 800mm Sections
• 1x Electrocoat Plant Control Panel suites (6x 800mm Sections)
• 23x Oven Control Panel suites (50x 800mm Sections)
• 14x Spray Booth Control Panel suites (66x 800mm Sections)
• 1x Paint Mix Control Panel suite (10x 800mm Sections)
• 18,750 Panel Shop Hours of Build and Testing in a duration of 4.5 months
• All Panels Manufactured in the UK and shipped to Shenzhen China
• Complete Project Management
• Complete Electrical Design.
• Complete PLC Software Code & HMI Design
• Creation of Interfaces to PSA Hierarchical Computer Systems for Body Tracking, Process
Parameter Reporting and Fault Diagnostic Reporting
• Complete Documentation for the Project
• Commission and Production Support.
