T75 - Process Skid Integration Solutions Reducing Design and Commissioning Time and Risk

Transcription

1 T75 - Process Skid Integration Solutions Reducing Design and Commissioning Time and Risk PUBLIC PUBLIC CO900G Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

2 PUBLIC Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 2 Agenda PlantPAx and Skids Modularity Inside The Controller / Skid Modularity Above the Skid Alarming OEM Skid Graphics / Libraries Documentation Load

3 MB05 Process Skid Equipment: Companies face challenges in today s competitive, global, business environment. One particular challenge is minimizing site integration costs that are associated with OEM equipment skids. Increase Productivity and Reduce Integration Costs with the PlantPAx System. The scalability of the PlantPAx system allows it to control your entire plant floor and/or your process skid equipment. This provides plant operations with increased visibility to both process and skid information. By using a common control platform, you achieve lower skid integration costs, simplified equipment maintenance and troubleshooting, and benefit from modular skid programming methodology for process skid equipment. We ll discuss the advantages for both OEMs and end users.

4 4 Current Skid Integration is Time Consuming, Complicated, and Costly Issues compound when left unmanaged Communication Protocol Media Naming conventions HMI graphics Alarming Equipment interfaces Remap all tag data Safety interlocks Common security System documentation OPC

5 5 Project Design Challenges to Address Challenges Communication Protocol Media Naming conventions HMI graphics Alarming Equipment interfaces Remap all tag data Safety interlocks Common security System documentation Why do these issues exist? Few established specification standards to address skid integration Since no standards exist End- Users, SI s, EPCs and OEMs create their own proprietary standard application

6 6 Check List to Help You Create Standards Common Network and Protocol Common Public Interface from Skid Controller to DCS Alarming Define what to alarm Define when and when not to alarm Graphical Objects Naming Conventions agreed on by operator s perspective Documentation Standards

7 7 PlantPAx Simplifies Process Skid Integration Communication Ethernet? Modbus? EtherNet/IP Protocol? backbone HMI No graphics data remapping Alarming Common security Equipment Single HMI interfaces object for Re-map local skid all and tag data main Safety control room HMI Common security System documentation EtherNet/IP OPC

8 8 Agenda PlantPAx and Skids Modularity Inside The Controller / Skid Modularity Above the Skid Alarming OEM Skid Graphics / Libraries Documentation Load

9 9 Quick Programming Summary (bottom up) Control Modules / PlantPAx Process Libraries NO Controller Scoped Tag References Equipment Module Commands and sequences Many Program Scoped Tags One, and only one, ALIAS to a controller scoped tag Key Point

10 10 Quick Programming Summary (bottom up) Small number of tags in the controller scoped area. EM s have 1 ALIAS to one controller scoped tag All command and status for that EM resides in this UDT But, modular programming need not end inside the controller Procedures/Operations issue commands to the equipment through this UDT The controller should have a Public Interface for receiving commands and indicating status, just like any other piece of equipment.

11 11 Agenda PlantPAx and Skids Modularity Inside The Controller / Skid Modularity Above the Skid Alarming OEM Skid Graphics / Libraries Documentation Load

12 12 Quick Programming Summary (bottom up) This Controller scoped tag should be defined based on skid Class or type. In this fashion, commands can be easily issued by the operator at an HMI, or via a supervisory controller. In this example, there are two controller scoped tags for the Public Interface. One to receive commands, and the other for status indication.

13 13 Sample Public Interface Cmds HB HeartBeat An always changing number coming from the parent controller. Sts While this value is changing, the parent controller is communicating and Set_TotalFlow HB in run mode The HB value copied from the Cmds. As long as this value DINTis The total flow in the changing, entire system. this controller is communicating and in run mode DINT Running Includes the entire ON=skid system flow, is running not just this skid REAL BOOL Set_Ing1 FlowMixerOut Ingredient 1 Setpoint gpm in total Percent flow from the mixing skid REAL REAL Set_Ing2 Ing1_Rate Ingredient 2 Setpoint Current in Percent gpm flow for ingredient 1 REAL REAL Set_Ing3 Ing2_Rate Ingredient 3 Setpoint Current in Percent gpm flow for ingredient 2 REAL REAL Start Ing3_Rate Start command Current gpm flow for ingredient 3 BOOL REAL Reset NumofIngredients Fault and Interlock Configured Reset command number of ingredients in this skid BOOL DINT Fault On=skid is faulted BOOL Fault_D1 on=mixing skid's 1st daughter skid is faulted BOOL Fault_D2 on=mixing skid's 2nd daughter skid is faulted BOOL CommLoss on=loss of comms to the mixer or daughter BOOL CommLossD1 on=1st daughter skid has lost comms BOOL CommLossD2 on=2nd daughter skid has lost comms BOOL Interlocked on=the mixer is reporting an interlock violation BOOL Interlocked_D1 on=1st daughter skid has violated an interlock BOOL Interlocked_D2 on=2nd daughter skid has violated an interlock BOOL Names A string array, length 3, that contains the names of the ingredients STRING20[3] FaultName String containing the name of the current fault reported by the mixer STRING

14 14 Typical Small Plant Architecture Engineering Station(s) Server(s) Operator Interface(s) Commands from the Public Interface Identical Public Interfaces for the same equipment type, even though the compressors are different Status from the Public Interface Compressor CMDs -SP -SU -SD Compressor STAT -psi -capacity -On/Off -Temp -Faults Machine HMI I/O Compressor CMDs -SP -SU -SD Compressor STAT -psi -capacity -On/Off -Temp -Faults

15 15 Getting Access to the Skid Data OI Server(s) Data can be gathered by the DCS controller Using PlantPAx / When using ControlLogix, any ControlLogix then or simple MSG instructions CompactLogix or controller from small to large: Produced/Consumed Same Tags. Programming Same Tools Same Interfaces EWS

16 16 Getting Access to the Skid Data OI PlantPAx PAx FactoryTalk ViewSE Data can be gathered by the PlantPAx SCADA Using PlantPAx/ FactoryTalk View SE, then add a controller shortcut into FactoryTalk View SE EWS

17 17 Agenda PlantPAx and Skids Modularity Inside The Controller/Skid Modularity Above the Skid Alarming OEM Skid Graphics / Libraries Documentation Load

18 18 Alarming Alarming with PlantPAx / FactoryTalk View SE OEMs can use the FactoryTalk Alarm and Event instructions. When using this feature with FactoryTalk View SE, skid alarms are automatically detected and monitored. OEMs can provide an Alarm import file compatible with FactoryTalk View SE.

19 19 Alarming Skids MUST disable alarms when the skid is OFF. The first step in proper alarm management is to eliminate or disable alarms during various evolutions, such as maintenance. The control room might not wish to see a skid Tank low level Alarm, when the skid is Out of Service and maintenance personnel are draining the tank. Some skid alarms can be active when the skid is Ready, while others might only be active when the skid is currently running.

20 20 Agenda PlantPAx and Skids Modularity Inside The Controller / Skid Modularity Above the Skid Alarming OEM Skid Graphics / Libraries Documentation Load

21 21 Integrating Graphics and Displays HMI/Visualization Symbol Linked to the Status Public Interface class the we defined. HMI/Visualization Symbol and Tag Mapping. [shortcut]public.status /areaname::[shortcut]public.status #1Public.Status

22 Design Productivity: Reusable Process Library Rockwell Automation Standard Library Out of the box Suite of Control & HMI objects to accelerate project engineering Built-in troubleshooting features Fully documented & supported by RA Tech Support

23 Efficient Graphical Interface Aids Skid Integration & Operation Effective Displays Library of contextual display objects to drive productivity Procedural Control PlantPAx Sequencer automates procedures to free operator to focus on process Standards-based Alarming effectively direct the operator s attention with alarms to improve the productivity, safety, and environment of your plant Common look and feel in both skid and plant-wide

24 Equipment Interface Implementation (Public Interface) Equipment Interface AOI Toolkit Implementation guide for new installation (steps summarized) Import AOI into equipment program Map Commands and Status data to equipment controller tags Create code to process line control commands if necessary. Use ViewME verification tool to test the interface. When complete / verified Export the interface (rung/routine) to save the mappings for future use. Mapping examples provided with Equipment Interface Toolkit Equipment Commands Equipment Status

25 26 What is RAPID? Solution: RAPID Line Integration System Supervisory HMI Performance Management Line Configuration Screens Equipment Configuration Screens Fault & Event Definition Tools Equipment Interface Tools Supervisory PAC Pre-Configured Work Cells Dynamic Event Configuration Line Level Root Cause Reporting EMI Software Connection Equipment RAPID Interface OEM CODE : Custom Code Program by OEM A Equipment Interface OEM CODE : End User Std Program by OEM B Equipment Interface OEM CODE : S88/PackMLv2 Program by OEM C Equipment #1 Equipment #2 Equipment #3 Equipment Interface OEM CODE : S88/PackMLv3 Program by OEM C Equipment #4

26 27 Agenda PlantPAx and Skids Modularity Inside The Controller / Skid Modularity Above the Skid Alarming OEM Skid Graphics / Libraries Documentation Load

27 28 Documentation Load In addition to the normal set of documents provided to an OEM, consider.. Requiring the OEM to include time for commissioning This speeds integration time by requiring a machine-specific expertise onsite. Define how the HB (heartbeat) functions. This makes it easy for both controllers to be aware of each other s status. Plant Controller Commands with HB Skid HB Status with same HB HB

28 Documentation Load Cmds Sts Public Interface definition, by equipment/skid class. All compressors have the same public interface regardless HeartBeat of number of stages etc. HB HB The HB value copied from the Cmds. As long as this value is An changing, always this changing controller number is communicating coming from the and parent in run controller. mode DINT Running While this value is changing, the parent controller is communicating and Standard ON=skid in run items is running mode in all Public Interfaces BOOL DINT FlowMixerOut gpm total flow from the mixing skid REAL Set_TotalFlow Ing1_Rate The total flow in the entire system. Current gpm flow for ingredient 1 REAL Equip Includes Ready the entire Boolean system flow, not just this skid REAL Ing2_Rate Current gpm flow for ingredient 2 REAL Set_Ing1 Ingredient 1 Setpoint in Percent REAL Ing3_Rate Current gpm flow for ingredient 3 REAL Set_Ing2 Maintenance Ingredient 2 Setpoint in Percent REAL NumofIngredients Configured number of ingredients in this skid DINT Set_Ing3 Ingredient 3 Setpoint in Percent REAL Fault On=skid is faulted BOOL Start HeartBeat Start command BOOL Fault_D1 on=mixing skid's 1st daughter skid is faulted BOOL Reset Fault and Interlock Reset command BOOL Fault_D2 on=mixing skid's 2nd daughter skid is faulted BOOL CommLoss on=loss of comms to the mixer or daughter BOOL CommLossD1 on=1st daughter skid has lost comms BOOL How to handle Alarming. CommLossD2 Glossary of Terms on=2nd daughter and skid has Definitions. lost comms People have BOOL different Interlocked on=the mixer is reporting an interlock violation BOOL Interlocked_D1 interpretations. on=1st daughter skid has violated an interlock BOOL Interlocked_D2 on=2nd daughter skid has violated an interlock BOOL Names A string array, length 3, that contains the names of the ingredients STRING20[3] FaultName String containing the name of the current fault reported by the mixer STRING Auto/Manual. Is this a loop, or HMI vs PLC control? Local/Remote/RTU? Does local mean, local on the machine or local in the control room? Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 29

29 30 Your Check List is a Living Document Common Network and Protocol Common Public Interface from skid controller to DCS Alarming Define what to alarm Define when and when not to alarm Graphical Objects Compressor CMDs -SP -SU Compressor STAT -SD -psi -capacity -On/Off -Temp -Faults Naming Conventions agreed upon from the operators perspective Documentation Standards HMI/Visualization Symbol and Tag Mapping. [shortcut]public.status Glossary and Definitions (another living document) /areaname::[shortcut]public.status #1Public.Status

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