T103 PlantPAx System Fundamentals

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1 T103 PlantPAx System Fundamentals PUBLIC INFORMATION Rev 5058-CO900E Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

2 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. What is a DCS? Distributed Control System (DCS)

3 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 3 Applications Manufacturing - continuous or batch Oil refining Petrochemicals Central station power generation Fertilizers Pharmaceuticals Food and beverage manufacturing Cement production Steelmaking Papermaking

4 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 4 THE CONNECTED ENTERPRISE Visibility, Supply Chain Integration Collaborative, Demand Driven Compliant & Sustainable Enterprise PRODUCTIVITY SECURITY SUSTAINABILITY Smart Grid AGILITY Customers Supply Chain Distribution Center Connectivity is a hidden value amplifier. Unlock profit potential with real-time decision power.

5 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Industrial Customer Value Drivers $ Faster Time to Market Lower Total Cost of Ownership Improved Asset Utilization Enterprise Risk Management

6 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 6 Agenda Rethink what to expect from your DCS PlantPAx System Architecture PlantPAx System Engineering PlantPAx System Operations Summary

7 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Rethink what you expect from your DCS Traditional Approach Desired Approach Value Faster Time to Market And Flexibility

8 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. PLANT-WIDE Control and Optimization SCALABLE and Modular SECURE Open and Information-enabled FLEXIBLE Delivery and Support

9 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 9 Expected Capabilities of a DCS PlantPAx offers all core functionality with additional value Control I/O Process Safety Engineering & Configuration Asset Management Advanced Process Control Batch Management Operator Effectiveness Operator Productivity

10 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 10 DCS performance PlantPAx System Characterization PlantPAx System Characterization Goals: Define PlantPAx System architectures that meet DCS expectations Provide guidance early in the sales cycle through project execution to drive repeatable PlantPAx System success Controller wall (50 + PACs) Distributed System (4 servers) Centralized System (1 server) Virtual System OEM (L2/L3)

11 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 11 Agenda Rethink what to expect from your DCS PlantPAx System Architecture PlantPAx System Engineering PlantPAx System Operations Summary

12 System Architecture Characterized Performance Minimizes risk of incorrectly sized systems using guidelines and tools proven by characterization High Availability High availability solutions from redundant I/O to redundant controllers, resilient networks to redundant HMI servers Scalable and Flexible Same platform for single station or large distributed architectures, easily connected to allow for skid integration PUBLIC INFORMATION Shorten development time and minimize human error Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 12

13 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 13 Sizing PlantPAx Systems Selection Guide PlantPAx Selection Guide (PROCES-SG001) provides high level guidelines to define and size your system

14 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 14 PlantPAx System Estimator System Definition Wizard Wizard within Integrated Architecture Builder (IAB) tool, free download Build your system architecture Leverage the knowledge of system characterization to verify architecture Leverage PlantPAx System scalability to buy only what you need Generate system bill-ofmaterials Detailed sizing model reduces design risk, enables what-if analysis

15 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 15 Virtualization Faster deployment Pre-built system images Process system server, engineering workstations and operator workstations + historian Hardware independence Develop automation strategy without hardware present Images can be transported between development teams improving lead times Reduced administrative efforts Centralized architecture facilitates updates, upgrades, security and license management while decreasing IT efforts

16 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Skid and Process Equipment Solutions Engaging skid builders to help end-users with changing business demands Partnerships with Process Skid Builders Drive consistency in automation designs despite the shift towards modular-design plants Reduce Integration Cost and Risk Ensure OEM automation scope is easily integrated into PlantPAx according to best practices and proven methodologies Overall System Performance Proven, tested architectures not only for DCS applications, but skid-sized solutions as well to ensure total system performance, no excuses

17 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 17 Agenda Rethink what to expect from your DCS PlantPAx System Architecture PlantPAx System Engineering PlantPAx System Operations Summary

18 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 18 PlantPAx System engineering Design, build and deploy quickly and consistently Application Templates Simplify initial project configuration by guiding initial project setup and providing preconfigured HMI and controller content templates Modular Object Library Predefined logic and HMI objects provide rich operator experience and shorten development time Engineering Tools Streamline workflows and facilitate efficient engineering

19 How to build a PlantPAx System Easy process to start building your solutions PROCES-RM001 PROCES-QS001 How to build - documented in PlantPAx Reference Manual Enabled by PlantPAx PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 19

20 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 20 PlantPAx What does it contain? Controller Project HMI Application HMI Template Diagnostics

21 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 21 PlantPAx What does it contain? Controller Project HMI Application HMI Template HMI Diagnostics

22 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 22 PlantPAx What does it contain? Controller Project HMI Application HMI Template Diagnostics

23 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 23 PlantPAx What does it contain? Controller Project HMI Application HMI Template HMI Diagnostics

24 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. PlantPAx What does it contain? Controller Project HMI Application HMI Template HMI Diagnostics

25 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. PlantPAx What does it contain? Controller Project HMI Application HMI Template HMI Diagnostics

26 Library of Process Objects Free to download, fully documented and supported Suite of control and HMI objects to accelerate project engineering and provide rich operator experience Role-based feature set for Operation Maintenance Engineering Download from the Rockwell Automation Software Download Site: PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 26

27 Migrations Solutions Free to download, fully documented and supported Still running a DCS System installed in the 80s or 90s? Concerned about : Lack of domain expertise? Rising support costs? Limited access to information? Hard to find spare parts? Rockwell Automation offers: Database conversion, scanners, cabling, wiring harnesses Phased or rip and replace Lifecycle protection (Bailey) Infi 90 (Bailey) Net 90 TDC 2000 TDC 3000 (Fisher) Provox (Moore) APACS TPS (Foxboro) I/A Series Strategy and experience to migrate your installed base PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 27

28 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 28 Agenda Rethink what to expect from your DCS PlantPAx System Architecture PlantPAx System Engineering PlantPAx System Operations Summary

29 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 29 Operations Enabling operators to effectively run your 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

30 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 30 Expanded toolkit for HMI design Turning data into information, effective displays drive productivity PlantPAx Library includes display element toolkit for effective displays Add context to the display of process values Graphically show relationships with other values Appropriate use of color to indicate alarms Consistent use of icons to identify abnormal conditions

31 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 31 Operations What Shut Us Down? Easily navigate from motor to interlock to cause Interlocks with first-out Access to logic for complex interlocks Quick troubleshooting for improved MTTR

32 Instrumentation Power Control PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Asset Management and Maintenance Exposing contextual data from smart devices to the operators Instrument Health Instrument Diagnostics Instrument Management Valves and Instrumentation Comprehensive management enabled by industry standards Tech: How do I fix it? Maint: How bad is it? Operator: Is it OK? Device Health Device Diagnostics Device Management Devices Intelligent drives and MCCs as native system components Ensure process uptime via asset performance management and predictive maintenance

33 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 33 Automated Sequencer Object Capturing operator experience and knowledge How can the PlantPAx Sequencer object help you? Easily configurable to capture critical sequences Rich visualization provided to the operator Built-in Exception Handling Automate procedures to free operator to focus on process

34 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 34 Standards-based alarming Increased accident prevention through effective alarm management ISA 18.2 State Model Alignment Adds Operator Shelve with Timeout Tracks operator, design, and maintenance actions separately Remote Commands Better integration of alarms with control strategies New shelve alarm capability per ISA 18.2 Enter shelve time duration and comments Better integration with PlantPAx Library

35 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 35 Standards-based alarming Built-in capabilities for alarm suppress-by-design Provides method for gating threshold alarms or indications Includes: Gate Input Gate Delay On-Delay Off-Delay

36 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 36 Agenda Rethink what to expect from your DCS PlantPAx System Architecture PlantPAx System Engineering PlantPAx System Operations Summary

37 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 37 PlantPAx System Modern DCS using Plant-Wide Technology The PlantPAx process automation system provides... all the capabilities of a traditional DCS multi-disciplinary Pant-wide control open, information-enabled and secure architecture scalability and flexibility to match YOUR requirements support by a global network of local experts

38 Differentiation: Technology Information Enabled Designed from the beginning to play a vital role in the operation of your business. IT friendly technologies ensure key production data gets to the right people at the right time. Scalable Solutions A system that can scale from 50 I/O to 50,000 I/O, which means your OEMs can use the same technology on their skids as you use for your plant-wide DCS. Multi-Disciplined Control with a Single Platform Process control coexists with discrete, safety, power, and motion control in the same system no gateways, bridges, interfaces, multiplexors, or translators. PUBLIC INFORMATION Innovative technology designed for today s business challenges Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

39 Differentiation: Support Ecosystem Massive Partner Network Strategic alliances with leaders in adjacent spaces and product and technology partners to solve any conceivable problem Sales and Solutions Partners Local sales, local inventory, local support, local solutions. Global experience and expertise Ability to help you standardize operations, globally. Lifecycle Management Programs Built to help you manage training, spare parts, and budget for support Unmatched ability to support the entire lifecycle of your system directly and through our partners PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

40 Differentiation: Customer Focus Listen. Think. Solve. Our commitment to understanding your needs, applying the best automation expertise, and solving your problems Sustainability, Productivity, Globalization, Innovation Solving today s business challenges, today while helping you prepare for tomorrow Rockwell Automation The world s largest company dedicated to industrial automation and information, makes our customers more productive and the world more sustainable PUBLIC INFORMATION Passionate People. Innovative Products. Unmatched Results. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

41 PUBLIC INFORMATION Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 41 Where to find more information? PlantPAx System Selection Guide (proces-sg001) PlantPAx System Reference Manual (proces-rm001) Modern DCS White Paper (proces-wp010) PlantPAx Characterization Video (YouTube)

42 Thank You!! PUBLIC INFORMATION Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. Rev 5058-CO900F Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

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