ED16 - Maintain Data Continuity When Networks Fail with FactoryTalk Historian Machine Edition

Transcription

1 ED16 - Maintain Data Continuity When Networks Fail with FactoryTalk Historian Machine Edition Timothy J McCain Information Software Regional Manager November 2012

2 ED16 FactoryTalk Historian Machine Edition Session Agenda FactoryTalk Historian Strategy FactoryTalk Historian Machine Edition Use-Case Scenarios FactoryTalk Historian Reference Resources Summary and Q&A 2

3 Different types of Data Collection? Transactional vs. Time-Series Data Transactional Data Set of data in a data-processing area in which the incidence of the data is essentially random and unpredictable; hours worked, quantities shipped, and amounts invoiced are examples from, respectively, the areas of payroll, accounts receivable, and accounts payable. Source - Answers.com Time-Series Data Quantities that represent or trace the values taken by a variable over a period such as a month, quarter, or year. Time series data occurs wherever the same measurements are recorded on a regular basis. Source BusinessDictionary.com 3

4 FactoryTalk Historian: Why does this technology exist? Market drivers for Historian Software: Changing customer demands, market/economic pressures, and the need to continuously improve manufacturing/industrial operation Demand for the capture and storage of high-speed, time-series production data Relation Database Management Systems (RDBMS) are not easily adapted (and difficult to maintain) when acquiring, storing, and reporting large volumes of time-series data over extended periods of time Historians are utilized across many industries and applications: Consumer Products, Food and Beverage, Automotive, Life Sciences Continuous Process, Packaging, Material Routing, etc. 4

5 FactoryTalk Historian: Why do we need it? How is it used? Do you need to collect time-series data for the purpose of.. Optimizing Production Process Monitor and improve asset utilization Increase yield / decrease downtime / improve actual availability Improving Product Quality Determine root causes for variability Decrease scrap and rework Centralized Data Collection & Storage for Compliance Regulatory entities (EPA, DEP, FDA, etc.) Satisfying customer requirements and limiting liabilities Process Historians Provide IT Infrastructure for Data Collection & Storage to Address these Critical Business Issues! Monitoring, Optimizing, & Reducing Energy Consumption 5

6 Historian Strategy & Product Intro: Automation Fair 2006 Announcement 6

7 Historian Strategy & Product Intro: A New Twist Distributed Strategy Pervasive Information Across Enterprise, Site, Machine/Device 7

8 FactoryTalk Historian Strategy: Positioning Statements FactoryTalk Historian Enterprise Edition (EE) Aggregates and stores large volumes of time-series data from multiple sites FactoryTalk Historian Site Edition (SE) Site (Plant) or Historian dedicated to a Process Control System Hosted on Windows-based operating systems Data collection rates to *250mS (Ethernet Comms. to Rockwell Controllers) FactoryTalk Historian Machine Edition (ME) Hosted in ControlLogix chassis (1756 form-factor) Web-based user interface for configuration and data retrieval Integration with FactoryTalk Historian Site Edition Data collection rates to 10mS across ControlLogix backplane 8

9 FactoryTalk Historian Site Edition (SE): Software Architecture FactoryTalk Historian SE Clients FactoryTalk Historian SE Server Utilizes OSI PI Enterprise Pro Technology Compresses and stores data in a time-series archive based on point definition Other Information Systems -ERP - Maintenance - LIMS - RDBMS -SQC FactoryTalk Historian SE Server Interface Node Touch point to the control system communicates with underlying devices Performs data capture ( snapshot ) based on individual point configuration Interface node FactoryTalk Historian Client Tools Various tools for specific purposes Data Source (DCS, PLC) 9

10 FactoryTalk Historian Site Edition: Optimized Storage Exception & Compression FactoryTalk Historian Server After Compression Interface node After Exception Data Source (DCS, PLC, etc.) Raw Data Notes: Exception and Compression provide two-levels of filtering The same concepts apply for Machine Edition and Enterprise Edition 10

11 FactoryTalk Historian Machine Edition: Product Overview Commercial Details: 1756-HIST1G 1GB & 1756-HIST2G 2GB Add-on profile to Logix5000 that can provide basic control Integration with client tools FactoryTalk VantagePoint, DataLink, ProcessBook Key Technical Specs: 2500 Events/Sec, Max 2500 points 10mS Max Scan Rate (or 25 datapoints) 11

12 Data Transfer transfers archive data directly from the ME module to Plant Historian Where traditional data collection is done through interfaces and data servers 12

13 FactoryTalk Historian Machine Edition: Product Overview 13

14 ED16 FactoryTalk Historian Machine Edition Session Agenda FactoryTalk Historian Strategy FactoryTalk Historian Machine Edition Use-Case Scenarios FactoryTalk Historian Reference Resources Summary and Q&A 14

15 FactoryTalk Historian Machine Edition: Oil & Gas Infrastructure Application U.S. liquids pipeline system Pump stations spread across 9 states Remote control via WAN/SCADA system Challenges: Local data accessibility Chart Recorder, Alarms, PI Server WAN connectivity Tag scan-rates, Service Disruptions 15

16 When connection is down, the module will store data and forward the data once the connection is back up. 16

17 FactoryTalk Historian Machine Edition: Oil & Gas Infrastructure Application Station-Level Technical Benefits: Collect data in real-time at its birthplace Store and forward to server without loss of history due to outages or scan rate Simple configuration up in < 1 hour Solid state, no OS, patches Enterprise Technical Benefits: FactoryTalk Historian SE server for central access and long-term storage FactoryTalk Historian ME data pushed to the SE server periodically FactoryTalk VantagePoint provides unified access to station-level data Business Benefits: Better visibility into operating conditions Historical station-level data is now easily accessible Evaluated 3000HP pump-motor run temps, determined rebuild was not required

18 FactoryTalk Historian Machine Edition: Complex OEM Application Sewage Sludge Incineration Water is removed from sludge Remaining solid material is incinerated Emissions Include: Particulate, Metal, Toxic Organic Compounds Carbon Monoxide (CO) Nitrogen Oxides (NOx) Sulfur Dioxide (SO) Furnace Applications Single & Multiple Hearth, Electric Infrared, Fluidize Bed, and others Cross Section of a Multiple Hearth Furnace Source: US Environmental Protection Agency Emissions Factors & AP 42, Compilation of Air Pollutant Emission Factors Chapter 2: Solid Waste Disposal 18

19 FactoryTalk Historian Machine Edition: Complex OEM Application Sewage Sludge Incineration Improper operation of a furnace can cause costly damage Harsh Environment not suitable for server-based infrastructure Historian ME provides a rolling window of process variables and setpoints locally OEM can access Historian ME remotely for troubleshooting VPN 19

20 FactoryTalk Historian Machine Edition: Diversified User Application Continuous Process 1. Melting & Refining Ingredients are batched Multiple stages of heating 2. Finishing Product standardization Removal of impurities 3. Coating 4. Cut-to-Length 5. Packaging High unit margins Costly to start/stop process Inspection at each step Impact on finished goods: Raw materials Heating variability Draw speed/tension FactoryTalk Historian ME: High speed collection Feeds site OSI PI Enables incident investigation Supports Process Engineering 20

21 FactoryTalk Historian Machine Edition: Food & Beverage Application Baking Customer Low Unit Margins Need High Frequency & High Volumes Variable Input Costs Raw Materials Money is in the Metal Initial spend on automation was limited No integration between OEM equipment Limited network connectivity Now we need access to real-time and historical production data! Raw Materials Purchased in bulk Stored in silos Replenished infrequently FactoryTalk Historian ME: Stand-alone Persistent storage not required Reports built in Excel Reports accessed by Purchasing Data accessed directly from Historian ME 21

22 FactoryTalk Historian Machine Edition: Infrastructure Application Transit Operator Tunnel Monitoring Airflow & Fan Status Air Quality Equipment Runtime Noise & Vibration Large investment in instrumentation and PLCs Limited network infrastructure Harsh environment Need the ability to investigate incidents FactoryTalk Historian ME: Stand-alone Persistent storage not required Accessed as needed by Engineering 22

23 FactoryTalk Historian Machine Edition: Diversified User Application Batch Process 1. Mixing (Slurry) 2. Extrusion (Forming) Cut-to-Length (Rough) 3. Drying Discrete 1. Cut-to-Length 2. Multiple Finish/Inspect Steps 3. Drying 4. Finishing Kiln 5. Packaging * Inspections occur in multiple locations Finishing kiln requires monitoring (regulation) Lack of emissions data results in heavy fines Existing OSI PI Infrastructure PC-based Interface Node Challenges Network connectivity Limited scan rates Costly annual IT burden Difficult to add modify tags 23

24 ED16 FactoryTalk Historian Machine Edition Session Agenda FactoryTalk Historian Strategy FactoryTalk Historian Machine Edition Use-Case Scenarios FactoryTalk Historian Reference Resources Summary and Q&A 24

25 FactoryTalk Historian Machine Edition: Additional Reference Resources FactoryTalk Historian LinkedIn Group Users Conference Enbridge Presentation 25

26 ED16 FactoryTalk Historian Machine Edition Session Agenda FactoryTalk Historian Strategy FactoryTalk Historian Machine Edition Use-Case Scenarios FactoryTalk Historian Reference Resources Summary and Q&A 26

27 FactoryTalk Historian Machine Edition: Session Summary Closing Thoughts Part of 3-tier Process Historian Strategy Used in a variety of applications and industries Supports standalone and highly integrated applications Self-contained configuration and data access Integration with PC-based client tools FactoryTalk VantagePoint, DataLink, ProcessBook 27

28 Questions Timothy J McCain Information Software Regional Manager November 2012