process system cuts hardware cost by 25% - polytron · 2019-11-26 · process system cuts hardware...

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ControlLogix 7 Remote I/O 7-3 Remote I/O 7-1 Remote I/O 7-2

ControlLogix 1 Remote I/O 1-1

ControlNet

ControlNet with Rack I/O

ControlLogix 2 Remote I/O 2-1 Remote I/O 2-2 Remote I/O 2-3

ControlLogix 3 Remote I/O 3-1 Remote I/O 3-2

ControlLogix 4 Remote I/O 4-1 Remote I/O 4-2

ControlLogix 5 Remote I/O 5-1 Remote I/O 5-2

ControlLogix 6 Remote I/O 6-3 Remote I/O 6-4 Remote I/O 6-1 Remote I/O 6-2

ControlLogix 8 Remote I/O 8-1 Remote I/O 8-2 Remote I/O 8-3

Figure 1. The control system originally planned for the food manufacturer consisted of connecting eight Allen-Bradley ControlLogix PACs to Remote I/O racks via ControlNet. The systems integrator analyzed the design and customer requirements using the Rockwell Automation Integrated Architecture Builder (IAB) software and EtherNet/IP Capacity Tool.

ControlNet with Rack I/O

Process System Cuts Hardware Cost by 25%A food manufacturer discovers that the right I/O hardware solution for its controls system can create significant cost savings.

SolutionProviderPartner

SolutionsEtherNet System with Allen-Bradley® Flex™ IO• Thenewprocesssystemincludedroughly 6,000I/Opointscomprisedofdigital, analogandDeviceNetI/O• Theprojectteamchangedthedesign fromControlNetwithrackI/Otoan EtherNetsystemwithAllen-Bradley FlexI/O

Solution Connects Flex/IO to Ethernet• Thenewdesignprovideda25%controls hardwarecostsavingscomparedtothe olddesign• Thenewdesignreducedthenetwork typesintheplant,decreasingtraining requirementsandsparepartsneeds• Thenewdesignallowedforadditional costsavingsduringinstallationdue tolower-costEthernetmediarun

ResultsSignificant Contribution• Thecollaborationbetween RockwellAutomationandPolytron,Inc., helpeddeliversignificantcostsavings

Results as anticipated• Abletosavemoneywhileimproving controlsystemperformance

• SuccessfulcollaborationbetweenPolytron andthefoodmanufactureridentifiedthe prosandconsofalloptionsandhelped ensurethattheproject’srequirements weremet

Reducingcostisalwaysoneofthetopprioritiesforeveryautomationintegrationproject.Combinethiswiththeeconomicdownturnlimitingcapitalinvestments,anditbecomesevenmorecrucialforsystemintegratorstodeliverthepromisedprojectresultsatthelowestpossiblecost.However,howcanyouachievecostreductionwithoutsacrificingtheproject’srequirements?Let’sexamineoneprojectandlearnhowafoodmanufacturerteamedwithPolytron,Inc.,aRockwellAutomationqualifiedProcessSolutionProvider,tosavemoneywhileimprovingcontrolsystemperformance.

Thenewprocesssystemforthemanufacturer’sstate-of-the-artgreenfieldfacilityincludedroughly6,000I/Opointscomprisedofdigital,analogandDeviceNetI/O.Polytronprovidedcontrolsautomationandmanufacturingexecutionsystem(MES)designservicesformultipleprocessandpackaginglines.

Polytronanalyzedthemanufacturer’splannedI/Ohardwaredesigntoensureitprovidedthebestvaluefortheproject.Thisanalysisofthenewdesign,resultedinanapproximate25%costsavingsforthecontrolshardware.

Asthesystem’smechanicaldesignevolved,additionalI/Ohadtobeaddedtosupporttheincreasedprocessingcapabilitiesrequestedbythemanufacturer.ThisincreasedtheI/Obymorethan20%,from6,000I/Opointstomorethan7,000.Thisincreaseofscopetypicallycreatesbudgetissuesforaproject.

However,thenewdesignallowedtheadditionalscopetobedeliveredata10%costsavingsoftheoriginalcontrolshardwarebudget.

The Technical ApproachTheoriginallyplannedcontrolsystemconsistedofconnectingeightAllen-Bradley®ControlLogix®programmableautomationcontrollers(PAC)fromRockwellAutomationtoRemoteI/OracksviaControlNet(seeFigure 1).Atthestartofthedetaileddesignphase,theplanneddesignandcustomerrequirementswereanalyzed.ThisanalysisincludeduseoftheRockwellAutomationIntegratedArchitectureBuilder(IAB)software(www.rockwellautomation.com/go/iab)andEtherNet/IPCapacityTool.

TheIABprovidedaBillofMaterialbasedondesigninformationenteredintotheIABsoftware,suchasI/Otype,numberofnodes,I/Opointsconnectedtoeachnodeandnetworktype.This,inturn,allowedpricingtobeobtainedforeachdesignoption.“Whatif”scenarioswerethendevelopedtodeterminethecostforeachconfigurationoption.

TheEtherNet/IPCapacityToolwasusedtodeterminethepredictedperformanceforeachEtherNet/IPnetworkoption.

Thetoolcalculatedthepredictednetworkbandwidth,numberofconnectionsusedandremainingconnectionsavailable,basedonthetypeandnumberofnodesonthenetwork.

Ethernet (Cu)Ethernet (F.O.)

ControlLogix 1

ControlLogix 2

ControlLogix 3

ControlLogix 4

ControlLogix 5

ControlLogix 6

ControlLogix 7

ControlLogix 8

Flex I/O 1-1 Flex I/O 2-1 Flex I/O 2-2 Flex I/O 2-3

Ethernet Switch

Ethernet Switch Ethernet Switch

Ethernet SwitchFlex I/O 3-1 Flex I/O 3-2 Flex I/O 4-1 Flex I/O 4-2

Flex I/O 5-1 Flex I/O 5-2 Flex I/O 6-1 Flex I/O 6-2

Flex /IO 6-3 Flex I/O 6-4 Flex /IO 7-1 Flex I/O 7-2

Flex /IO 7-3 Flex I/O 8-1 Flex /IO 8-2 Flex I/O 8-3

Ethernet with Flex I/O

Figure 2. The project team changed the design to an Ethernet with Allen-Bradley Flex I/O. As a result, the manufacturer saved 25% on controls hardware, reduced network types in the plant and achieved smaller panel footprints.

ThisinformationallowedPolytrontodeterminethenetworklayoutandconnectionmedia(fiber,copper)mostsuitablefortheproject.Inaddition,itconfirmedthattheEtherNet/IPnetworkringhadenoughbandwidthavailabletoprovidetherequiredcommunicationsifoneofthepathsbecameaccidentallydisconnected.

TheIABandEtherNet/IPCapacityToolsoftwaretoolshelpedoptimizetheI/Oandnetworkdesign.However,thesetoolsalonecan’tdeterminewhichdesignprovidesthebestoverallvaluewhilestillmeetingtheproject’srequirements.Todothis,Polytronworkedwiththefoodmanufacturertoevaluateeachoption’sbenefitsandlimitations.

The Solution Connects Flex/IO to EthernetTheprojectteamdecidedtochangethedesignfromControlNetwithrackI/OtoanEthernetsystemwithAllen-BradleyFlexTMI/OfromRockwellAutomation(seeFigure2).Thedecidingfactorsforthenewdesignwereasfollows:

•Thenewdesignprovideda25%controlshardwarecostsavingscomparedtotheolddesign.

•Thenewdesignreducedthenetworktypesintheplant,thusdecreasingtrainingrequirementsandsparepartsneeds.

•ThenewdesignallowedforadditionalcostsavingsduringinstallationbecauseoflessexpensiveEthernetmediaruncomparedtoControlNet.

Everydesignoptiontypicallyhasdrawbacksthattheprojectteamneedstoacceptorfindanalternatesolution.Inthisproject,thesystemincludedsafetyandothernonsafetyI/OconnectedviaDeviceNet.Thenewdesignrequiredthattherack-mountedAllen-Bradley1756-DNBcards,usedforconnectingtothesafetyI/O,bereplacedwithstand-aloneAllen-Bradley1788-EN2DNmodulesbecausethefieldracksweretobeeliminated.

ThiswasagoodsolutionforthenonsafetyI/O.However,the1788-EN2DNmodulesaren’tratedtoconnecttosafetyI/O.

Tosolvethisproblem,aCLXrackwitha1756-DNBcardwasaddedineachAllen-BradleyCENTERLINE®MotorControlCenter(MCC)withIntelliCENTER®forconnectingtheMCC’sdrivesandstartersbacktotheAllen-BradleyGuardLogix®safetycontroller.

Make the Most of a ProjectForanyautomationintegrationproject,initialdesignassumptionsmadeduringtheearlyphasesshouldberevisitedduringstartofdetaileddesigntoensurethat

thehighest-valuesolutionisimplemented.SuccessfulcollaborationbetweenPolytronandthecustomertoidentifytheprosandconsofalloptionshelpedensurethattheproject’srequirementsweremet.

Solution ProvidersAselectgroupofRockwellAutomationsystemintegratorshasachievedSolutionProviderpartnershipstatus.ThisisaheightenedandexclusivebusinessrelationshipwithRockwellAutomation.SolutionProviderpartnersareproven,trustedandestablishedorganizationsthatofferextensiveexperienceinthedesign,implementation,projectmanagementandmaintenanceofcustomers’industrialcontrolsystems.

Discipline: ToearnSolutionProvider(SP)partnerstatus,integratorsmustpossesshighcorporatestandards,financialstability,provenmethodologiesandcompetencyusingRockwellAutomationtechnologies.

Credibility:SPsarewell-establishedorganizationsthatofferextensiveexperienceinadvancedautomationsolutions.Theyhavebeentrustedadvisersfortheircustomersfrominitialdesignandconsultation,systemdevelopment,throughthecommissioningofcomprehensiveRockwellAutomationsolutions.

Expertise: Whetheryourneedisindesign,projectmanagement,implementationormanufacturingsystemsmaintenance,SPspossesstheindustryknowledge,domainexpertise,resourcesandskillstodeliverworld-classsolutions.

RockwellAutomationrecentlyexpandeditsProcessSystemsIntegratorProgramin2009with45newmembers.Withexpertiseinthemetals,powergenerationandotherprocessindustries,thenewprogrammemberswillsupporttheRockwellAutomationPlantPAxTMProcessAutomationSystem,bringingplant-widecontrolonasingleplatformtomanufacturerslookingtomigratetheiragingDCSsystems.Newprogrammembersalsoinclude18LatinAmericanSolutionProviderpartners.

Theseprocesssystemintegratorsarereviewedfordomainexpertise,engineeringexcellenceandgeographicreach,amongothercriteria.

They’reselectedfortheirabilitiestohelpRockwellAutomationdelivervaluethroughthedesign,developmentanddeliveryphasesofcustomers’projects.

FormoreinformationontheRockwellAutomationProcessSystemIntegratorProgramandSolutionProviderProgram,visitwww.rockwellautomation.com/go/sitj.

Rockwell Automation Solution Provider Polytron, Inc., Duluth, Ga., is a system integrator that provides project management, electrical engineering, automation, manufacturing execution systems and training services for the food, beverage, consumer products and pharmaceutical industries.

PublicationFOOVP-AP006A-EN-P–January2011 Copyright©2011RockwellAutomation,Inc.AllRightsReserved.PrintedinUSA.

RockwellAutomation,Allen-Bradley,DeviceNet,ControlLogix,IntegratedArchitecture,EtherNet/IP,FlexI/O,CENTERLINE,IntelliCENTER,GuardLogixandPartnerNetworkaretrademarksofRockwellAutomation,Inc.TrademarksnotbelongingtoRockwellAutomationarepropertyoftheirrespectivecompanies.

3300 Breckinridge Blvd, Suite 100Duluth, GA 30096-8983USAPhone: 678-328-2999Fax: 770-447-9537http://www.polytron.com/

Polytron helps customers engineer and operate with manufacturing excellence. Since their founding in 1983, Polytron applied project management and engineering expertise in hundreds of engagements with many of the world’s largest Food, Beverage, Pharmaceutical, and Consumer Products companies, as well as in the Water and Wastewater Treatment industries. Their areas of expertise include: Process Systems, Power, Automation & Information, Manufacturing Intelligence, Technology Transfer & Training, Machine Automation, and Water & Wastewater Treatment. All Polytron project managers are Project Management Professionals, certified through PMI.

RockwellAutomationandPartnerNetworkcompaniescollaboratetohelpyoudevelopanongoingapproachtoplant-wideoptimization,improveyourmachineperformanceandachieveyoursustainabilityobjectives.