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Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
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Rockwell Automation Process Solutions User Group (PSUG)November 14-15, 2011Chicago, IL – McCormick Place West
PlantPAx System Overview
Jason P. WrightProduct Marketing ManagerPlantPAx System Core
PlantPAx System Overview Introduction
This session is an introduction to the PlantPAx Process Automation System:
– Review of PlantPAx System capabilities– Examples of PlantPAx System applications– Summary of PlantPAx System benefits– Where to go for more information
2Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Manufacturing Challenges
Globalization, Sustainability, Productivity, Innovation
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Solution: Plant-Wide Optimization
New pressures are driving manufacturers across their enterprise on continuous improvementat all stages of the plant lifecycle.
Manufacturers today must leverage their automation investment to create an architecture for continuous optimization.
Maximize Return on Assets Flexible Operations Innovative engineering
• Risk Mitigation• Time To Market• Supply Chain Efficiency• Globalizing Footprint• Demand Forecasting
• Asset Efficiency• Cost Management• Production Intelligence• Utilization• Quality, Yield, Productivity
• Decision Support• Advanced Process Control • Design Productivity• Total Lifecycle cost• Global/ Local Standards
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
PlantPAx Process Automation System
Protection of plant personnel …production …and the environment
Scalable high availability throughout the architecture• Protect only what you need without over-investing• Focused not only on availability and uptime, but also
maintainability
Information-based solution for operations productivity• Decision support, production analysis, and optimization drive
profitability
Plant-wide control, performance tuned for process applications
• Standards-based architecture enables multi-disciplined control• Extends EtherNet/IP as control backbone
…equipment
PlantPAx: Plant-wide optimization solution for the process industries
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Control and I/O Portfolio
Modern infrastructure via the most cost effective design
Scalable Controller Portfolio… From ten loops to
hundreds per controller
Comprehensive Integration… The broadest range of traditional I/O
and intelligent devices
Robust Network Infrastructure… CISCO technology and EtherNet/IP
with redundancy options at every level
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Operator Efficiency
Operators should spend their time controlling the plant, not being distracted by the control system
Integrated Visualization … Intuitive displays, objects, and
faceplates with integrated diagnostics
Decision Support Tools… Dashboards help identify opportunities
for continuous improvement
Scalable Architecture… Solutions for on-process, mobile, and stand-alone applications up to
large distributed systems—deployed traditionally or virtualized
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Engineering and Configuration
Consolidated Deployment Tools… Comprehensive system configuration environment
and tools for library management and bulk system engineering
Modular Object Library… Predefined logic and HMI objects shorten
development and testing time
Shorten development time and minimize human error
Defined System Architectures… Minimizes risk of mid-sized
systems and ensures system performance
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Asset Management and System Maintenance
Ensure process uptime via asset performance management and predictive maintenance
Instrument Diagnostics
Instrument ManagementInstrument
Health
Inst
rum
enta
tion
Device Diagnostics
Device Management
Device HealthPow
er C
ontr
ol
Operator: “Is it OK?”
Maint: “How bad is it?”
Tech:“How do I fix it?”
Valves and Instrumentation… Comprehensive
management enabledby industry standards
Devices… Intelligent drives and MCCs as native system components
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Intelligent Motor Control
• Variable speed AC drives• Packaged & pre-engineered solutions• LV and MV motor control solutions • Asset management
Control | Communicate | Protect
Supporting capital investments long term
• Electronic overload protection relays• Soft starters• Condition monitoring
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Safety and Critical Control
Risk reduction by protecting only critical assets
SIL 0Process Control
SIL 1Fail Safe
SIL 2Fail Safe
SIL 2Fault
Tolerant
SIL 3Fail Safe
SIL 3Fault
Tolerant
High Availability Process Control… High availability solutions
from redundant I/O to redundant controllers, resilient networks to redundant HMI servers
Scalable Process Safety… Integrated BPCS and scalable
SIS solutions, including TMR for the highest availability
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Batch Management
Flexibility to respond to external pressures – regulatory compliance, yield optimization, production agility
Native ISA-88 Structure… Simplify change management
and regulatory compliance
Integrated Analysis Tools… Batch reports, material usage, genealogy,
and solutions to optimize batch production
Scalable Platform… From simple, single unit scale to highly complex, integrated batch solutions
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Operations Productivity
Actionable information in the hands of decision makers
Scalable Data Collection… Chassis-based, plant-wide or
enterprise-wide historian
Decision Support Portal… Track production KPIs to manage
cost, quality, resources
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Process Optimization
Proven economic gains – increase production, reduce costs, improve quality, reduce environmental risks
Broad Advanced Control Portfolio… From simple model-based control to fuzzy logic,
soft sensors to complex model predictive control
IMC_01
IMC ...
Internal Model Control0.0
PV0.0
SPProg0.0
SPCascade0.0
RatioProg0.0
CVProg0.0
HandFB0
ProgProgReq0
ProgOperReq0
ProgCasRatReq0
ProgAutoReq0
ProgManualReq0
ProgOverrideReq0
ProgHandReq
CVEU0.0
SP0.0
ProgOper0
CasRat0
Auto0
Manual0
Override0
Hand0
IMC_01
IMC ...
Internal Model Control0.0
PV0.0
SPProg0.0
SPCascade0.0
RatioProg0.0
CVProg0.0
HandFB0
ProgProgReq0
ProgOperReq0
ProgCasRatReq0
ProgAutoReq0
ProgManualReq0
ProgOverrideReq0
ProgHandReq
CVEU0.0
SP0.0
ProgOper0
CasRat0
Auto0
Manual0
Override0
Hand0
CC_01
CC ...
Coordinated Control0.0
PV0.0
SPProg0.0
CV1Prog0.0
CV2Prog0
CV3Prog0
ProgProgReq0
ProgOperReq0
ProgCV1AutoReq0
ProgCV2AutoReq0
ProgCV3AutoReq0
ProgCV1ManualReq0
ProgCV2ManualReq0
ProgCV3ManualReq0
ProgCV1OverrideReq0
ProgCV2OverrideReq0
ProgCV3OverrideReq
CV1EU0.0
CV2EU0.0
CV3EU0.0
SP0.0
ProgOper0
CV1Auto0
CV2Auto0
CV3Auto0
CV1Manual0
CV2Manual0
CV3Manual0
CV1Override0
CV2Override0
CV3Override0
CC_01
CC ...
Coordinated Control0.0
PV0.0
SPProg0.0
CV1Prog0.0
CV2Prog0
CV3Prog0
ProgProgReq0
ProgOperReq0
ProgCV1AutoReq0
ProgCV2AutoReq0
ProgCV3AutoReq0
ProgCV1ManualReq0
ProgCV2ManualReq0
ProgCV3ManualReq0
ProgCV1OverrideReq0
ProgCV2OverrideReq0
ProgCV3OverrideReq
CV1EU0.0
CV2EU0.0
CV3EU0.0
SP0.0
ProgOper0
CV1Auto0
CV2Auto0
CV3Auto0
CV1Manual0
CV2Manual0
CV3Manual0
CV1Override0
CV2Override0
CV3Override0
MMC_01
MMC ...
Modular Multivariable Control0.0
PV10.0
PV20.0
SP1Prog0.0
SP2Prog0.0
CV1Prog0.0
CV2Prog0
CV3Prog0
ProgProgReq0
ProgOperReq0
ProgCV1AutoReq0
ProgCV2AutoReq0
ProgCV3AutoReq0
ProgCV1ManualReq0
ProgCV2ManualReq0
ProgCV3ManualReq0
ProgCV1OverrideReq0
ProgCV2OverrideReq0
ProgCV3OverrideReq
CV1EU0.0
CV2EU0.0
CV3EU0.0
SP10.0
SP20.0
ProgOper0
CV1Auto0
CV2Auto0
CV3Auto0
CV1Manual0
CV2Manual0
CV3Manual0
CV1Override0
CV2Override0
CV3Override0
MMC_01
MMC ...
Modular Multivariable Control0.0
PV10.0
PV20.0
SP1Prog0.0
SP2Prog0.0
CV1Prog0.0
CV2Prog0
CV3Prog0
ProgProgReq0
ProgOperReq0
ProgCV1AutoReq0
ProgCV2AutoReq0
ProgCV3AutoReq0
ProgCV1ManualReq0
ProgCV2ManualReq0
ProgCV3ManualReq0
ProgCV1OverrideReq0
ProgCV2OverrideReq0
ProgCV3OverrideReq
CV1EU0.0
CV2EU0.0
CV3EU0.0
SP10.0
SP20.0
ProgOper0
CV1Auto0
CV2Auto0
CV3Auto0
CV1Manual0
CV2Manual0
CV3Manual0
CV1Override0
CV2Override0
CV3Override0
Flexible Deployment… From loop and unit-level optimization in the controller
to plant-wide economic optimization at the supervisory layer
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Industrial Security
Reduce Risks to Safe and Reliable Operation…Control system architecture with layered security to
help maintain operational integrity under threat
Protect Assets & Information…Product and system features to help control access, tamper-proof and limit information exposure
Government and Standards Alignment …Responsible disclosure with control system solutions that follow global standards and help fulfill independent & regulatory security requirements
Address risk to helps protect people, assets andinformation from accidental and malicious threats.
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Lifecycle Support: Protect Your Investment
On-Site and Managed Service:
• Application Support
• Integrated Parts &
Labor Services
Continuous RemoteMonitoring and 24x7 Support:
• System-level Support
• Disaster Recovery
System Training:• Instructor-led
• On-site
• Assessments
Process Device Management:
• Device Calibration• Field Device Integration
& Asset Management• Spare Parts Management
Consulting Services:
• Safety & Energy• Network & Security• System Migration
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Consumer-Driven Industries
17
Total Cost of Ownership (TCO) savings and continuous process improvements
• Anheuser-Busch• Coca-Cola• Kellogg• Kraft/Nabisco• M&M Mars• Nestlé• PepsiCo/Frito-Lay• SABMiller
Food & Beverage
• 3M• Beiersdorf• Colgate-Palmolive• DuPont• Henkel• Kimberly-Clark• Procter & Gamble• Unilever
Household & Personal Care
• Abbott Laboratories• Johnson & Johnson• Merck• Pfizer• Sanofi• Wyeth-Ayerst
Life Sciences
True Plant-Wide Control… Drives total cost of
ownership savings
Continuous Improvement… Provides plant-wide
manufacturing intelligence
OEM Scalability… Cost effective in
skid integration
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Life SciencesNew Active Pharmaceutical Ingredient Plant
Application:• Primary (API) production plant
Solution:•Recipe-based operation & EBR
•Workflow automation
•Design, engineering, startup and operator training
Technology:• PlantPAx DCS• FactoryTalkPharmaSuite (MES)
Batch execution
Batch execution
Exception review
Exception review
Exception closing
Exception closing
Weigh and Dispense
Weigh and Dispense
PlantPAx batch control & MES integration for production flexibilityCopyright © 2011 Rockwell Automation, Inc. All rights reserved.
Resource-Driven Industries
19
Optimized approaches for engineering, operations and maintenance
• BP• Chevron• ConocoPhillips• Exxon Mobil• Shell
Oil & Gas
• Alcoa• BHP Billiton• CEMEX • Holcim• Lafarge• Rio Tinto• US Gypsum• Vulcan
Mining / Metals / Cement
• A & E Firms• Consultants• Design Engineer Firms• Design Institutes • Global Municipalities• Privatizers• Pump OEMs• System Integrators
Water / Wastewater
• Agilent• Applied Materials• ATS Automation• Axcelis• IDC / CH2M• KLA-Tencor• Novellus• Praxair• Seagate
Semiconductor
High Availability… Ensures uptime and
safe operation
Sustainability… Reduces cost associated
with W.A.G.E.S.
Operational Excellence… Provides critical asset
performance information
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Water:DCS migration for water authority
Application:• Complete upgrade of a water purification plant
Solution:•Controls for filter beds, fluoride and pumping
•Design, engineering, startup and operator training
Technology:• PlantPAx DCS• Smart instruments
Commissioned without interruption in city water supplyCopyright © 2011 Rockwell Automation, Inc. All rights reserved.
Pulp & Paper:DCS migration for paper mill
Application:• Stock prep• Paper machine control
Solution:•Process and power control
•Network design•Design, engineering, startup and operator training
Technology:• PlantPAx DCS• MV Drives, MCC
US$5 million CapEx reduction for plant reconfigurationCopyright © 2011 Rockwell Automation, Inc. All rights reserved.
Driving Differentiation
Plant-wide Control and Optimization… Process, Power, Information and Safety… Enables vendor rationalization (lowers total cost)
… Real-time information for continuous improvement
… Scalable across applications, operations and environments
Lower Total Cost of Ownership… Common plant platform - reduced downtime
… Lower IT integration costs
… Reduce operator error and training costs
… Lower licensing renewal costs
Unified IT Infrastructure… Easy plug-in to EtherNet/IP
… Information enable for decision support
… Cisco partnership and standards
… IT friendly (decision partner for large projects)
OEM Scalable… DCS-compliant, easy integration of skids to DCS
… Supports multi-vendor integration in projects
… Cost-effective in design, development and deployment
… Rapid field device integration
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
• Assist with system definition and procurement
• Ties in with PSE and Characterization• Defines how to procure a system for
optimal performance
Where to find more information
PlantPAx Selection Guide (Proces-SG001)
• Concentrates on the implementation recommendations that apply to all PlantPAx Systems
• Defines how to configure a system for optimal performance
PlantPax Reference Manual (Proces-RM001)
PlantPAx TOC on KnowledgeBase: 6236623Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Customer Voice – Thank you!!!
Archer Daniels Midland
Colorado Springs Utilities
Dupont
Gerrie Process Group
Industrial Furnace Company
JNE Automation
Kimberly-Clark
24
Kraft Foods
Pacific Gas and Electric
Pfizer
Premier Systems
Procter & Gamble
Others
Represents a broad base of customers and industries:
Process Customer Advisor Board (CAB) directs the success of the Process Solution User Group(PSUG)
Each year at PSUG, you help define PlantPAx system development direction and features
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.