Choosing PlantPAx vs DeltaV Benefits for end users and integrators

Transcription

1 Choosing PlantPAx vs DeltaV Benefits for end users and integrators Alan Stanfill Stone Technologies MES Project Manager November 2012 Copyright 2012 Rockwell Automation, Inc. All rights reserved.

2 2 Agenda Introductions Customer Information Situation / Goals Project Specifics Wrap Up / Q&A

3 3 Introductions Alan Stanfill MES Project Manager Stone Technologies Audience How Many End Users System Integrators Rockwell Automation Distributor Other Experience with PlantPAx Various DCS solutions

4 4 Customer Information Midwest plant (company name and other details withheld at their request) of a chemical manufacturing company needed to move production from an existing facility drive was to improve efficiency and reduce costs to produce product Make products for food, pharmaceutical, agriculture, and industrial applications Very competitive Tight profit margins Sound familiar? Mix various products, prepare for final product format (granulated or powder), and send to finished goods bin for packaging Had a GREAT functional specification as a starting point!

5 5 Goals Get the new production facility up and running quickly Run as efficiently as possible Have a unified control system Include mixing tanks and other process related items system stopped short of packaging in this case Mix various products, prepare for final product format (granulated or powder), and send to finished goods bin for packaging

6 6 Customer Focus Areas SYSTEM As an existing DeltaV user, the plant expected the new solution to function as a system just like a true DCS STANDARDS A conscious decision was made to follow the out of the box PlantPAx standards very closely SUPPORTABLE Both by Rockwell and a wide variety of system integrators SAVINGS Initial solution cost as well as ongoing support as always, cost was a significant concern

7 7 What is PlantPAx anyway? Utilizes standard Rockwell products ControlLogix FactoryTalk View SE Object and code libraries to create full solutions Tested and implemented as a SYSTEM Predictable and repeatable performance Allows an integrator and end user to work on the system rather than all of the individual components

8 8 Approach - boring or effective? Stick to standard objects as much as possible Customer s request Stone s preference Allows for greatest advantage from the objects as well as future proofing of the solution Hit the ground running Start with the customer s functional specification Two engineers working concurrently PLC HMI PlantPAx was a huge advantage when using this approach Required VERY little extra communications / status

9 9 Challenges Lack of historical trending on standard objects Real-time trending functioned well but historical based trends were required No real ad hoc trending functionality built in Unlike some DCS solutions, ViewSE was somewhat limited in the functionality for creating trends on the fly Small items needed on faceplates that did not exist Various small items that the customer wanted to see but weren t in the standard objects

10 10 Challenges PlantPAx alarms (priority 1-4) were not related to FT Alarm and Event alarms (1-1000) Needed a manual work around to maintain continuity between both lists No global color change settings for various uses Alarms Warnings Hold Still have to manage these across multiple global objects

11 11 Sample - Navigation

12 12 Add Ons Sequential Function Charts in ControlLogix were used for sequencing of multiple ladder based phases Needed a way to view / track the status from the HMI Built a view of the SFC in the HMI Used the PlantPAx permissive to drive these steps Made things easy for the operator or maintenance to track the process without leaving the HMI Historical and customizable trending

13 13 Sample SFC Monitoring

14 14 Results - SYSTEM The starting point for every functionality decision was the same: Here is what DeltaV does Need to mimic that for ease of operator use and minimal retraining The customer was very adaptable and wanted to be sure of long term functionality for the system Overall decisions were made based on features, functions, and also ease of implementation and support for future A considerable amount of weight was given to future upgrades and support when looking at additional features

15 15 Results - STANDARDS The customer s strong preference was to stick to standard objects over custom code or additions as much as possible This worked well as it is also Stone s standard operating procedure 12 primary PlantPAx objects were utilized to build the solution PLC code followed the standards as much as possible Make the standards fit if you can and only add on where required HMI screens used standard objects with very minimal customization around them for critical features SFC monitoring Historical trending

16 16 Results - SUPPORTABLE While the project was successfully implemented by Stone, it is critical to the customer that they not be reliant on Stone for future support With standard objects used almost exclusively, Rockwell has been able to help with some support issues Stone personnel (even ones new to the system) can support the standard objects Should the customer ever need it there are MANY other integrators who can support the standard PlantPAx implementation Not stuck with a single provider as they were with the DCS solution

17 17 Results - SAVINGS Initial purchase price was significantly lower than the DCS solution Ongoing support costs (DeltaV support vs TechConnect) are also lower Implementation costs for the integration were far less All adds up to a substantial TCO difference Customer can do their own adds / changes

18 18 Benefits of PlantPAx - Customer Support is easier if new people are introduced to the project Let Rockwell support the underlying objects and layout while the integrator focuses on the specific application TIME standard objects shorten implementation time frames significantly MONEY Out of the box cost Ongoing support Integration

19 19 Benefits of PlantPAx - Integrator Focus more on the customer and their process Less of the repetitive work to get PLC / HMI integration working Support is easier if new people are introduced to the project Ease of communications between PLC and HMI engineering resources TIME MONEY

20 20 Summary Goals Get new production up and running quickly and efficiently Keep the solution cost effective Approach Stick to standard objects as much as possible Integrate around those objects as needed for functionality Results SYSTEM the PlantPAx solution does operate as a system STANDARDS PlantPAx standard objects were used extensively SUPPORTABLE Rockwell and other integrators can support if ever needed SAVINGS the system ultimately costs less than the DCS to implement and maintain

21 21 Stone Technologies Information Founded in 1996 Of our top 20 clients since the inception of the company in 1996: Doing business with ALL of them today Average of 50 projects per client Average adding 2 3 new clients a year Focused on the F&B, Consumer Products Industry, Fine Chemical, Medical Device, Power Generation industries Technology Focus and experience 22 engineers focused on process and other controls systems 14 engineers focused on MES and information solutions 7 dedicated project managers The technical staff has an average of 22 years of technical experience Our least experienced employee has 12 years of industry experience

22 22 Stone Technologies Expertise

23 Questions Thank you for your time! Alan Stanfill Stone Technologies MES Project Manager November 2012 Copyright 2012 Rockwell Automation, Inc. All rights reserved.