T51 - Maximizing the Efficiency of OEM Skid Equipment in The Connected Enterprise

Transcription

1 CO900H T51 - Maximizing the Efficiency of OEM Skid Equipment in The Connected Enterprise PUBLIC

2 Agenda What is Smart Manufacturing Integration Challenges / Solution Program Modularity Modularity Above the Skid Why this is important

3 3 Smart Manufacturing Smart Manufacturing is a highly connected, knowledge-enabled industrial enterprise where all business and operating actions are optimized to achieve substantially enhanced productivity, sustainability and economic performance Rockwell Automation is a founding member of the Smart Manufacturing Leadership Coalition (partial list of members) Smart Manufacturing is delivered through The Connected Enterprise

4 BUSINESS VALUE Improved Asset Utilization Faster Time to Market END USER OEM Flexibility Integration & Standardization Performance/OEE Enterprise Risk Management Lower Total Cost of Ownership Productivity & Efficiency Goals Innovation to Drive Differentiation After Market Service & Support Total Cost to Design, Develop & Deliver SMART MANUFACTURING SMART MACHINES & EQUIPMENT PUBLIC Copyright 2015 Rockwell Automation, Inc. 4 All Rights Reserved.

5 Smart Machines & Equipment PUBLIC 5 Smart machines & skid equipment can more easily gather, transfer and analyze data by leveraging a single control and information platform. Smart Machines & Equipment Maximize Efficiency of Production Processes

6 Agenda What is Smart Manufacturing Integration Challenges / Solution Program Modularity Modularity Above the Skid Why this is important

7 Extracting Data can be complicated Traditional DCS Solution PUBLIC Considerations with traditional DCS: OEM Skid #1 OEM Skid #2 OEM Skid #3 HMI Graphics Duplication Skid < > DCS Tag & Alarm Mapping/Duplication Disparate Security Models Documentation - Maintenance Multiple Communication Networks/Protocols Data Aggregation Comms Protocol Gateway OPC Server Engineering Workstation Plant DCS Operator Workstation Maintenance Workstation App. Servers Device Integration Integration with Safety Not Scalable high cost to add or expand / licensing costs Distributed I/O Distributed I/O Communication Network Redundant Controllers Linking Device/ Gateway HART Instruments Foundation Fieldbus Instruments Profibus Instruments

8 8 Typical Skid Interface Checklist Network Interfacing Data Mapping Command, Status, Tag Naming Convention etc. Alarming HOW, WHAT, and WHEN to alarm, also WHAT NOT to alarm. HMI Standardization/Duplication Visualization, Object Naming, Security.

9 Simplified OEM Skid Integration Modern Plant-Wide Control Solution PUBLIC Benefits with Modern DCS: Common HMI Objects Plant and Skid OEM Skid #1 OEM Skid #2 OEM Skid #3 No Data Remapping Common Security Model Documentation: Common Terms and Definitions EtherNet/IP Communication Network = Standard Ethernet Skid Application Logic Untouched Simplified Device Integration Integrated Safety Easily Expandable System

10 Skid Interface Checklist PlantPAx Common Network Protocol CIP over Ethernet (EtherNet/IP). Alarming HOW is taken care of. Standardized HMI Security and Visualization. Class-based SKID Interface: DCS to/from Skid. Alarming WHAT, and WHEN to alarm, also WHAT NOT to alarm. Standardized HMI Object Naming. PUBLIC PlantPAx Allows You to Focus on the Process not the programming! 10

11 Agenda What is Smart Manufacturing Integration Challenges / Solution Program Modularity Modularity Above the Skid Why this is important

12 12 What Is Modularity? Object-based Programming Philosophy allows simplified management of process functions. Primary Concepts from ISA-88 s Physical Model. State-based Object (Usually EM), Contains CMs. No Direct Communication Between Peers Parent Layer Coordinates Child Objects. Single Interface Tag for Each Object ALL Data Needed by Child and Parent. Portable Container Program Folder in Logix

13 13 Quick Programming Summary Control Modules / Process Object Libraries NO Controller Scoped Tag References Equipment Module Commands and Sequences Many Program Scoped Tags One, and only one, tag exposed to the outside world Key Point

14 Quick Programming Summary Small number of tags in the controller scoped area. EMs have 1 ALIAS to one controller scoped tag the Module Interface Tag All command and status for each EM reside in its Module Interface Tag But, modular programming need not end inside the controller Procedures/Operations issue commands to the EMs through their Interface Tags The controller can also have a Public Interface for receiving commands and indicating status, just like any other piece of equipment. 14

15 Agenda What is Smart Manufacturing Integration Challenges / Solution Program Modularity Modularity Above the Skid Why this is important

16 Example Architecture Engineering Station(s) Server(s) Operator Interface(s) Identical Commands from the Public SKID Interfaces for the same Interface Equipment Class, even though the compressors are different styles. Status from the Public Interface Compressor Cmd - SP - Start Compressor Sts - Stop -psi -capacity -On/Off -Temp -Faults I/O Compressor Cmd - SP Compressor Sts - Start - psi - Stop - capacity - On/Off - Temp - Faults PUBLIC Machine HMI 16

17 17 Tag Structure This Controller scoped tag should be defined based on skid Class. Commands can be easily issued via an HMI, or a supervisory controller. The Cmd substructure receives data from the Parent. Elements should match the skid Class s requirements. The Sts substructure sends status data back to the Parent. Elements should reflect the skid Class s capabilities.

18 18 SKID Interface Interface Program in Child (Skid) Read MSG to Get Commands Write MSG to Send Status Map SKID Commands to Internal Logic Map Internal Values and Data to to PUBLIC SKID Status

19 Agenda What is Smart Manufacturing Integration Challenges / Solution Program Modularity Modularity Above the Skid Why this is important

20 20 Skid Integration on PlantPAx System Skids use same underlying Integrated Architecture as PlantPAx ControlLogix or CompactLogix Controllers FTView SE or FTView ME for HMI Skid Controllers can be added to an existing PlantPAx system Provide local Skid Control Fully integrated into the PlantPAx system Rockwell Automation works with equipment builders to achieve consistent user experience including integrated alarming using the pre-built libraries

21 21 Benefits for Engineering Ease of Implementation Identical Interface for Similar Equipment Standardized Logic and Graphic Objects Can Add Skids to a Running System Substantial Reduction in Commissioning Time

22 22 Benefits for Engineering Ease of Management Consistent Documentation Consistent Building Block Approach Code Module Objects Graphic Objects and Faceplates Portable Focus on Process Control NOT Code

23 23 Benefits for Maintenance Common Concept All Skids Use Same Interface Design Consistent Programming Approach Easier to Troubleshoot Interface Can Support Expandability Incorporate Spares to Allow Data Modifications

24 24 Benefits for Operations Consistent Interface Skids Use Same Graphic Objects as Greater System Consistent Programming Approach Easier to Operate Reduced Training Overhead Training Material Similar for Different Skids SOPs Easier to Update

25 Value Proposition Proof Points PUBLIC 60% 30% Of manufacturers lack the necessary equipment connectivity to capture the data Have NO integration at all Source: 2013 Industry Week Study With more than 11 machines required for our production process, we needed an integrated control architecture Mike Williams, Director of Engineering, King s Hawaiian Skid integration typically consumes ~50% to 70% of our project budget. We reduced this by 25% (plus a schedule savings of 3 weeks) by requiring PlantPAx templates on the OEM bid packages. The incremental costs for International OEM compliance was offset by the integration savings.

26 Integrated Control and Information INFRASTRUCTURE With more than 11 machines required for our production process, we need an integrated control architecture Mike Williams, Director of Engineering, King s Hawaiian Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

27 Takeaways Skids use same underlying Integrated Architecture as PlantPAx Skid Controllers can be added to an existing PlantPAx system Rockwell Automation works with equipment builders to achieve consistent user experience including integrated alarming using the pre-built libraries

28 Thank you. PUBLIC