Under the Hood with PlantPAx CT426 PUBLIC
Today s challenges: Fragmented and/or Disparate Control Systems SYSTEMS: Facilities Building Management System Utilities PLC + HMI Volatile Storage Safety Shutdown System Electrical PLCs & MCCs Material Handling PLC w/ HMI Process Area Distributed Control System Packaging Packaged Systems Warehouse Environmental Monitoring System Disparate systems restrict flexibility & responsiveness NEEDS: Security-Network & Application(IP) Common Operating/Engineering Environments Alarm Management/Diagnostics Process Optimization (ROI) Training Data / Reporting Enterprise Integration Integrating Expansion & Changes Lifecycle Management Spare Parts
What is a DCS? Distributed Control System (DCS) Secure Control Network Scalable Architectures Common Control Strategies & I/O Common Operating & Engineering Environments Field Device Integration Asset Management Batch Integration & Management Process Safety Integration Model Predictive Control Information/Production Intelligence (Enterprise Integration)
PLANT-WIDE Control and Optimization SCALABLE and Modular SECURE Open and Information-enabled FLEXIBLE Delivery and Support 4
DCS Functionality PlantPAx System capabilities Control and I/O Process Safety Engineering & Configuration Asset Management Process Optimization Batch Management Secured Environments Operations Productivity
How is performance ensured? PlantPAx System Characterization PlantPAx System Characterization Goals: Define PlantPAx System architectures to provide optimal performance Provide guidance from project development through project execution to drive repeatable PlantPAx System success The Characterization Lab accommodates varied system sizes from OEM/skid-based to distributed server architectures. Controller wall (50 + racks) OEM Scale Large System (multiple PASS) Small Medium System (single PASS) Virtualized System 6
Where can one get this information? PlantPAx System Documentation Selection Guide: How do I define a system? http://literature.rockwellautomation.com Keyword PROCES-SG001 Reference Manual: How do I build a system? http://literature.rockwellautomation.com Keyword PROCES-RM001
PlantPAx System Design Considerations Critical attributes ensuring performance and functionality INFRASTRUCTURE Sizing: VM Sizing Design Rules: Network Topology Domain Setup Switch selection and configuration Security settings NIC card settings VM Configuration CONTROLLER Sizing: CPU Memory Comms Design Rules: Program Design & Organization Task Structure Performance & Monitoring SERVERS Sizing: CPU Memory Comms Design Rules: OS Setup Software Selection Application Setup Display Design No Bad Tags Diagnostics
Integrated Control & Information Our Core Platforms Enable The Connected Enterprise Integrated Architecture & Software Intelligent Motor Control Solutions & Services
PlantPAx System Network Why is it important: Foundational for system performance 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
Logical Framework Converged Plantwide Ethernet (CPwE) Wide Area Network (WAN) Data Center - Virtualized Servers ERP - Business Systems Email, Web Services Security Services - Active Directory (AD), Identity Services (AAA) Network Services DNS, DHCP Call Manager Identity Services Enterprise External DMZ/ Firewall Internet Enterprise Zone Levels 4-5 Information Technology Physical or Virtualized Servers Patch Management AV Server Application Mirror Remote Desktop Gateway Server Physical or Virtualized Servers FactoryTalk Application Servers and Services Platform Network & Security Services DNS, AD, DHCP, Identity Services (AAA) Storage Array Level 3 - Site Operations (Control Room) Wireless LAN Controller (WLC) Active Standby Identity Services Remote Access Server Core Switches Distribution Switch Stack Plant Firewalls Active/Standby Inter-zone traffic segmentation ACLs, IPS and IDS VPN Services Portal and Remote Desktop Services proxy Distribution Switch Stack Access Switches Cell/Area Zone Levels 0 2 Access Switches Cell/Area Zone Levels 0 2 Industrial Demilitarized Zone (IDMZ) Industrial Zone Levels 0 3 (Plant-wide Network) Industrial IT Camera WGB Phone Controller LWAP SSID 5 GHz WGB Controller LWAP Cell/Area Zone - Levels 0 2 Redundant Star Topology - Flex Links Resiliency Unified Wireless LAN (Lines, Machines, Skids, Equipment) LWAP SSID 2.4 GHz Drive Rockwell Automation Stratix 5000/8000 Layer 2 Access Switch Controller HMI Soft Starter Cell/Area Zone - Levels 0 2 Ring Topology - Resilient Ethernet Protocol (REP) Unified Wireless LAN (Lines, Machines, Skids, Equipment) I/O Instrumentation Servo Drive Safety Controller HMI Robot Safety I/O AP SSID 5 GHz Cell/Area Zone - Levels 0 2 Linear/Bus/Star Topology Autonomous Wireless LAN (Lines, Machines, Skids, Equipment) Safety I/O WGB Operational Technology 11
Logical Model Converged Plantwide Ethernet (CPwE) Level 5 Level 4 Email, Intranet, etc. Enterprise Network Site Business Planning and Logistics Network Enterprise Security Zone Remote Desktop Gateway Services Application Mirror Patch Management Web Services Operations AV Server Reverse Proxy Firewall Firewall Web Email CIP Industrial DMZ Level 3 Level 2 Level 1 FactoryTalk Application Server FactoryTalk Client Batch Control FactoryTalk Directory Operator Interface Discrete Control Engineering Workstation FactoryTalk Client Drive Control Remote Access Server Engineering Workstation Continuous Process Control Site Operations Area Supervisory Control Operator Interface Safety Control Basic Control Industrial Security Zone(s) Cell/Area Zones(s) Level 0 Sensors Drives Actuators Robots Process CPwE - Logical Model Converged Multi-discipline IACS CPwE - Plant/Site View Converged Multi-discipline IACS 12
Reference Architectures Converged Plantwide Ethernet (CPwE) Tested, validated and documented Reference Architectures Tested for performance, availability, repeatability, scalability and security Comprised of a collection of Cisco and Rockwell Automation Validated Designs Built on technology and industry standards Future-ready network design Content relevant to both OT and IT Engineers OT Operational Technology Industrial Control Systems Deliverables Tested and Validated Reference Architectures Deploy Firewalls Within a CPwE Architecture Dec. 31, 2016 Industrial Network and Security Whitepapers Deployment of Industrial Firewalls Dec. 30, 2016
System Attributes Characterized Performance Minimizes risk of incorrectly sized systems using guidelines and tools proven by characterization (PlantPAx sizing Tool shown) High Availability High availability solutions including redundant controllers, redundant I/O, resilient networks, and redundant HMI/Data servers Scalable and Flexible Same platform for single station or large distributed architectures, easily connected to allow for skid and/or OEM integrations Shorten development time and minimize human error
System Engineering Design, build and deploy quickly and consistently Application Controller Templates Simplify initial project configuration by guiding initial project setup and providing preconfigured HMI and controller content templates Modular HMI Object Library Predefined logic and HMI objects provide rich operator experience and shorten development time Engineering Tools Streamline workflows and facilitate efficient engineering
Operations Enabling operator effectiveness across the entire plant 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
Migrations Solutions Concerned about : Lack of domain expertise? Rising support costs? Still running a DCS System installed in the 80s or 90s? 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 TPS 2000 TDC 3000 (Fisher) Provox Strategy and experience to migrate your installed base (Moore) APACS (Foxboro) I/A Series 1970 1980 1990 2000
PlantPAx System Design Process PlantPAx System Estimator Studio 5000 with PlantPAx Libraries and Design Guides PlantPAx System Checklist and Verification Tools Size and Select Implement Verify Well defined and closed loop design process based on System Characterization
More Flexibility in System Design PlantPAx System Estimator Sizing model for multi-disciplined control with expanded plant-wide controller types Tight Integration of motor control centers with MCC I/O Location type Complete system coverage including SQL server and domain controllers High granularity sizing option with advanced sizing worksheet
SIMPLIFIED DEPLOYMENT Reduced Effort for Faster Time to Market Expanded Virtual Image Templates Comprehensive Deployment Guides Updated Design Environment Pre-built Process Strategies
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
Updated Design Environment Studio 5000 In1 Out1 In2 Process Strategies STUDIO 5000 ARCHITECT Single-place to deploy, view, and manage configuration of system LOGICAL ORGANIZER Simplify design with code organization that matches your plant PROGRAM PARAMETERS Simply map to I/O using program parameters.
Studio 5000 Architect System Templates
Studio 5000 Architect Simplified Setup and Configuration Graphical representation of the system Project Explorer helps organize and manage system application code from one place Hardware Library: Controllers, I/O, Switches, HMIs, and Computers Manage and configure communications between controllers and between controllers and servers Easily find and system code through search; open directly into editor User Libraries: Process Objects provided by default.
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 location 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
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
Operator Training Systems New Interface Provides Tight Integration with Operator Training Systems MYNAH
Application Code Manager DESIGN Library Designer is integrated into Logix Designer Flexible library authoring, structuring reusable content the way you want PUBLISH Combine control, visualization, historical and alarm management into one library object Centralized repository for easy access and version management Maximize reuse and quickly build projects BUILD Easily generate your standardized application code Bulk configure projects Leverage Rockwell Automation provided libraries (OEM building blocks)
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
System Checklist and Verification Tools What is it? Documented checklists and tools to verify Critical to Quality Attributes of a PlantPAx System (NEW or EXISTING) 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
System Checklist and Verification Tools How does it work? 1 Detailed instructions provided for each field on the check list 4 Once complete ensure each field on the checklist has been completed, that there are no failures, and all warnings have reviewed and annotated per the instructions. 2 5 For each design element enter the observed value as instructed Print and/or preserve the checklist to document baseline that could be used for later. 3 Icon Observe the results and take action as necessary. Possible results shown below. Description Failure outside recommendations Warning requires additional attention Passed aligns with system recommendations Not Applicable Not completed or does not apply Information only Documentation purposes only
System Checklist and Verification Tools Summary of Checklist Content System Area Description System Area Description System Architecture Checklist to verify the design and configuration of your system architecture including FactoryTalk View, FactoryTalk Historian, and FactoryTalk AssetCentre configuration <Server or WS> Checklist to verify the loading and configuration of each individual server or workstation. This worksheet should be copied and filled out for each server and workstation on your system. <PASS> Checklist to verify applications hosted by your PASS servers including FactoryTalk View SE graphics, alarm setup, and communications. This worksheet should be copied and filled out for each PASS on your system. System Network Checklist to verify your network switch configurations. <Controller> Checklist to verify applications and loading on your controllers. This worksheet should be copied and filled out for each controller on your system. System Servers and WS Checklist to verify design elements shared across all your system servers and workstations.
System Checklist and Verification Tools Where do I get it? Download the checklist from the Rockwell Automation Knowledgebase: AID 771236 PlantPAx Checklist and Verification Tools. CONTENTS Filename PlantPAx Checklist Instructions v4.0.pdf PlantPAx Checklist v4.0.xlsx PlantPAx Checklist GraphicAudit v1.11.zip PlantPAx Checklist FTView files v4.0.zip Description Instructions of how to complete and review the PlantPAx Checklist to verify your PlantPAx System design. The checklist: a Microsoft Excel workbook used to record and verify design information. Tool to document and verify your FactoryTalk View SE application design for completion of the checklist. FactoryTalk View SE display and supporting files to automate collection of controller and communications data for completion of the checklist.
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) Rockwell Automation Library of Process Objects (proces-rm002) PlantPAx Characterization Video (YouTube)
Thank you!! PUBLIC www.rockwellautomation.com