What s New with the PlantPAx Distributed Control System

Transcription

1 What s New with the PlantPAx Distributed Control System Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 1

2 PLANT-WIDE Control and Optimization SCALABLE and Modular SECURE Open and Information-enabled FLEXIBLE Delivery and Support Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 2

3 4.0 RELEASE MARCH 2016 AUTOMATION PRODUCTIVITY ENABLING TECHNOLOGY Decrease time to market Adopt new system capabilities ENHANCED CONTROL Help to meet productivity goals Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 3 3

4 More Flexibility in System Design Updated PlantPAx System Estimator Inside IAB EXPANDED sizing model for multi-disciplined control with new Plant-wide controller types TIGHT INTEGRATION of motor control centers with new MCC I/O Location type COMPLETE system coverage with new SQL server and domain controllers HIGH GRANULARITY sizing option with new advanced sizing worksheet Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 4

5 PlantPAx Virtual Image Templates Batch Management Asset Management Engineering Workstation Operator Workstation Process Automation System Servers Information Server Information Server Information Server REDUCE engineering time and validation costs EXTEND system lifecycle ENHANCED availability options through virtualization EASE lifecycle management Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 5 5

6 Updated Design Environment Studio 5000 Architect SHARE DATA Start from other design artifacts Incorporate existing control and visualization projects Reduce configuration time by leveraging automation system project templates and content LAYOUT & CONFIGURE Layout your control, visualization, and communications network Configure devices from central location Build automation projects Central place to configure and manage your system MANAGE & VIEW Centrally manage your automation system Launch your control and visualization projects Quickly search across your automation system Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 6

7 Comprehensive Deployment Guides USER MANUALS SIMPLE OVERVIEWS DETAILED STEPS TOOLS INCLUDED Infrastructure and Application Configuration Flow chart summary for each chapter Click-by-click instructions for each task Configurations and templates attached inside manual Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 7

8 PlantPAx System Network Why is it important: Ensures characterized performance Ensures functionality can be achieved such as disaster recovery and field device integration Ensures secure and maintainable environment What is provided: IT/OT integration with Stratix family of switches PlantPAx standard configurations More flexibility offered with CPwE Consulting services offered when needed Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 8

9 Library of Process Strategies OVERVIEW Pre-configured function block diagrams to perform basic process control Developed and delivered with the Library of Process Objects 3.5 Simple routine import, w/ I/O mapping performed using program parameters Template categories include: I/O Processing, Regulatory and Procedural Control, Motors, and Valves BENEFITS Ensures characterized performance with known control strategy configurations Greatly reduces implementation time Promotes consistent applications and user experience Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 9

10 Process Library Localization OVERVIEW Language switching of RA Library of Process Objects 3.5 faceplates: Static (Non-controller) text on library faceplates will be language switchable with translations provided Uses native FactoryTalk View language switching capability at each OWS Includes: Portuguese Spanish French Simplified Chinese Korean BENEFITS Support global operations and multi-lingual operators with a consistent interface Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 10

11 New Library Objects DEADBAND CONTROL On-Off control of an analog process value LEAD-LAG-STANDBY Control parallel groups of pumps, fans, and motors I/O MODULE STATUS Monitors the connection status of I/O modules for Process Strategies Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 11

12 PlantESP: Operational Insight & Optimization PlantPAx Loop Analytics enhances production efficiency and throughput with plant-wide control loop diagnostics. Monitor Identify Isolate OVERVIEW New process diagnostic and optimization capability integrated within PlantPAx Proactively identifies issues and facilitates isolation of associated root-causes Recommends corrective action using advanced heuristics Automatically generates alerts and customized reports Recommend Report BENEFITS Improves awareness of issues that affect operational efficiency (i.e. mechanical, process architecture, loop tuning) Targets unique information needs of engineering, operations and maintenance Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 12

13 PlantPAx System SILAlarm Master Alarm Database Integration Master Alarm Database Operator Response Data Process Library Alarm Builder Process Objects FactoryTalk Alarms Master Alarm Database FactoryTalk VantagePoint OVERVIEW SILAlarm facilitates and documents the results of alarm rationalization in a master alarm database Use PlantPAx Alarm Builder to exchange alarm design between PlantPAx System and SILAlarm Access alarm rationalization information during operations from the HMI screen BENEFITS Helps apply the ISA 18.2 standard: Management of Alarm Systems for the Process Industries Makes alarm design information available to assist operations, compliance, and troubleshooting Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 13

14 Expanded System Training Capabilities Controller emulation integration with Operator Training Systems Emulated Controllers OVERVIEW Emulate your system without the expense of hardware or impact to production Provides dynamic, real time responses like the actual plant Use your own or third party simulation tools to interact with emulated controllers with the OTS option to create scenarios and simulate the plant responses Simulation Software BENEFITS Provides dynamic, real-time responses like the actual plant Train operators in specific scenarios in a risk free environment on what appears a fully functioning system using the actual displays from operations. Develop and test new control strategies or plant optimizations in a lab environment Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 14

15 System Checklist and Verification Tools What is it? Documented checklists and tools to verify Critical to Quality Attributes of a new or existing PlantPAx System against characterized limits What problems does it solve? Verifies PlantPAx System implementations: ensures proper design before commissioning, helps customers verify quality of delivery, provides method to identify root cause of system performance issues Available from the Rockwell Automation Knowledgebase: AID PlantPAx Checklist and Verification Tools Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 15

16 Why is a the System Checklist a good idea The PlantPAx solution has a highly flexible delivery model. We provide you with solutions to achieve consistency and performance: PlantPAx System Estimator Virtual Image Templates Documentation Example: PlantPAx Selection Guide Use the PlantPAx Checklist, a tool to check that your installation conforms to our guidelines. 16 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 16

17 Section 1 The PASS (Process Automation System Server) A PASS is a required system element that can host: Displays Alarms Data connection to controllers Key topics: Alarm Display settings Expressions Global Objects Tag counts 17 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 17

18 Section 2 <Controller> Checklist The controller is the brains of the operation. Proper configuration is key to successful deployment. In this section, we will be checking controller configuration and loading. Key topics: CPU usage Memory usage Connection counts Tasking model 18 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 18

19 Section 3 <Server & Workstation> Our servers are: Pre-configured Pre-engineered Contains all of the hardware needed to run multiple OS s and applications off of virtualized servers. Key topics: Computer settings CPU usage Hard disk health Memory usage 19 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 19

20 Section 4 System Network Checklist Check your infrastructure Key topics: Bandwidth Hardware health Network diagnostics 20 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 20

21 Section 5 System Architecture System architecture checklist covers: FactoryTalk View Application Design FactoryTalk View HMI Servers FactoryTalk Alarm and Event Servers FactoryTalk Live Data Servers FactoryTalk AssetCentre Server FactoryTalk Historian SE Server 21 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 21

22 Overview What's in KB The Checklist Spreadsheet (.xlsx) The Instructions Document (.pdf) Graphic Audit Tool (and other tools to assist audit) FTViewSE files (help show RSLinx and Controller data) 22 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 22

23 Checklist Results Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 23

24 PlantPAx MPC OVERVIEW Fully functional MPC on a dedicated module: Develop and implement MPC up to 10 CV s, 10 MV s, and 10 DV s Executed up-to five independent MPC applications on one MPC module Information from the model can be easily shared in the control layer BENEFITS Model Predictive Control in the controller chassis, no supervisory server required, simple to use Reduce Scrap - Opens new opportunities to reduce variability in product quality Improve Output Run your processes faster by allowing more aggressive set points Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 24

25 Scalable Model Predictive Control (MPC) ControlLogix Module in the Chassis Small to Medium Sized Linear Processes (or adaptive systems) Fast Process Applications Server-based Solutions; Any DCS Medium to Large Sized Linear Nonlinear Processes Complex Process Applications Scalable Products from Integrated to Comprehensive Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 25

26 Typical MPC Benefits Increase capacity for food processing lines by 6% Decrease water main breaks by 21% Reduce utility energy consumptions by 10% Reduce catalyst usage by 26% and increase yield by 50% Increase recovery by 5% and reduced energy by 5% Ensure compliance with modeling and sensor validation Reduce Polymer transitions by 50% and off-spec by 40% Solution Payback less than12 Months Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 26

27 PlantPAx System 4.0 Release: March 2016 Automation Productivity Enabling Technology Decrease the time to market required to deploy and maintain systems Leverage Studio 5000 enhancements, including Studio 5000 Architect Expanded design tools and documentation New pre-built Process Control Strategies Infrastructure improvements to deliver a robust and reliable experience Standard Network Configurations including the new Stratix 5400 and Stratix 5410 Mobility enhancements to provide access to contextual information whenever and wherever you need it Complete portfolio of Virtual Image Templates Application Code Manager Enhanced Control Enhance the user experience while increasing operational productivity PlantPAx MPC in the chassis reduces waste and variability Leverage Visualization and Control enhancements: New Control Objects: Deadband Controller, Pump/Lead/Lag Spare Batch Application Toolkit to assist with development of Batch Solutions MPC Simplify the system to help delivery teams on capital projects in our traditional markets. Increase global adoption with language support and process control strategies Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 27

28 PlantPAx System Release 4.0 Combined HMI & controller environment (partial credit) Easier project deployment and backup/restore Develop a set of standard (sample) control strategies Basic alarm grouping for tag based alarms Channel isolated HART I/O Batch recipe change management and version control Implement model predictive control (MPC) in Logix Batch recipe security and versioning Simplified MPC platform available to end users, SI/SP s and distributes Easier integration of I/O diagnostics into process objects Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 28

29 Where to find more information? PlantPAx System Selection Guide (proces-sg001) PlantPAx System Infrastructure User Manual (proces-um001) PlantPAx System Reference Manual (proces-rm001) PlantPAx System Application User Manual (proces-um003) Modern DCS White Paper (proces-wp010) PlantPAx Characterization Video (YouTube) PlantPAx System Verification and Troubleshooting (proces-um004) Rockwell Automation Library of Process Objects (proces-rm002) Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 29

30 OVERVIEW Safely and securely deliver your CONTENT to any combination of DEVICE, USER and LOCATION Get unparalleled flexibility for your computer networks by centrally managing every device from one powerful software platform BENEFITS Increases Productivity (centrally manage users and devices in an easy-to-use interface) Increases Visualization (customize multiple monitors and virtual screens) Increases Security (no locally stored data, content delivered based on role and/or location) Provides Location-Based Mobility (exclusive mobile security) Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 30

31 Visualization Enhanced Trending Leverages the VantagePoint trend control which provides market leading capabilities: Stacked Y-axis Logarithmic trends Easy runtime configuration Real time and historical data on one trend. Ad-hoc trending Data sources for first release Next: Live Data, Data Logs, Historian Alarms connector, Operator events connector Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 31

32 Thank You! Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 32