plantpax: the modern dcs

PUBLIC

Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 1

PlantPAx: The Modern DCSEnabling the Connected Enterprise

Presented by: Nicholas Bouchard, Channel Process Competency Lead

Kendall Electric Technology Summit

August 1, 2017

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 2

Connectivity is a hidden value amplifier.

Unlock profit potential with real-time decision power.

Supply

Chain

Headquarters

Distribution

Center

Smart Grid

Customers

THE CONNECTED ENTERPRISE


Manufacturing 27%

Retail Trade

Information Services

Finance & Insurance

Other Industries

11%

9%

9%

44%

$5.1 Trillion

INDUSTRIALInternet of Things

$19T VALUE AT STAKE


Today’sProduction

Facility

Design Operate Maintain Secure


Easily adopted

engineering tools

Easily integrate

multiple applications

DesignEasily move

information into your

business system


Alignment of

raw material to

production

OperateVisibility into

supply chain risks

Historical and

real-time data to

maximize yield


Integration of

power with

process control

Operate

Critical knowledge

from retiring

personnel

DCS operator

visibility into

safety system


Secure

Leverage new

technologies

securely

Enable IT and OT

collaboration


Maintain

Locally available

system support &

training

Robust disaster

recovery options

Spare parts

availability

Remote system

monitoring


PLANT-WIDEControl and Optimization

SCALABLEand Modular

SECUREOpen and Information-enabled

FLEXIBLEDelivery and Support


Control I/O Process

Safety

Engineering &

Configuration

Asset

Management

Advanced

Process ControlBatch

Management

Operator

EffectivenessOperator

Productivity


$Faster Time to Market

Improved Asset

Utilization

Enterprise Risk

Management

Lower Total Cost of

Ownership

Industrial Customer Value Drivers


Sizing:

• CPU

• Memory

• Comms

Design Rules:

• Task Structure

• Performance

Monitoring

• Organization

• No Minor FaultsCO

NT

RO

LLE

R

Sizing:

• CPU

• Memory

• Comms

Design Rules:

• OS Setup

• Software Selection

• Application Setup

• Display Design

• No Bad Tags

• Diagnostics

SE

RV

ER

S

Sizing:

• VM Sizing

Design Rules:

• Network Topology

• Domain Setup

• Switch selection

and configuration

• Security settings

• NIC card settings

• VM ConfigurationINF

RA

ST

RU

CT

UR

E

How Do We Ensure Performance?Critical to Quality Attributes


How Do We Ensure 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

Varying system sizes from

OEM/skid-based to distributed

server architectures.


Easy integration

into main control

Localized control

historian and batch

No data

remapping

SKID INTEGRATIONFaster Time to Market


Integrated development tools

Defined system architectures

Comprehensive library of process

objects

AUTOMATION PRODUCTIVITYFaster Time to Market


Comprehensive Deployment Guides

USER MANUALS

Infrastructure and Application

Configuration

SIMPLE OVERVIEWS

Flowchart summary

for each chapter

DETAILED STEPS

Click-by-click instructions

for each task

TOOLS INCLUDED

Configurations embedded in

Manuals along with verification

guidance


New Library Objects

I/O MODULE STATUS

Monitors the connection status of

I/O modules for Process Strategies

LEAD-LAG-STANDBY

Control parallel groups of pumps, fans,

and motors

DEADBAND CONTROL

On-Off control of an analog

process value


Library of Process Strategies

Pre-configured function block diagrams to

perform basic process control

• Developed and delivered with the Library

of Process Objects 3.5

• Simple routine import, w/ I/O mapping

performed using program parameters

• Template categories include: I/O

Processing, Regulatory and Procedural

Control, Motors, and Valves

Ensures characterized performance with

known control strategy configurations

Greatly reduces implementation time

Promotes consistent applications and

user experience

OVERVIEW

BENEFITS


System Checklist and Verification Tools

What is it?

Documented checklists and tools to verify

Critical to Quality Attributes of a new or

existing PlantPAx System against

characterized limits

Available from the Rockwell Automation Knowledgebase:

AID 771236 – PlantPAx Checklist and Verification Tools

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

http://rockwellautomation.custhelp.com/app/answers/detail/a_id/771236


Pre-built systems

images

Hardware

independence

Reduced

administrative efforts

VIRTUALIZED SYSTEMFaster Time to Market


Common

platforms

Seamless

information flow

Easy to manage

PLANTWIDE CONTROL & OPTIMIZATIONLower Total Cost of Ownership


DELIVERY & SUPPORT FLEXIBILITYLower Total Cost of Ownership

Remote support

System integrators

Local experts

Lifecycle support


Visibility into

plant operations

Monitor and diagnose

asset health

Flexibility and

regulatory compliance

INTEGRATED CONTROL AND INFORMATIONImproved Asset Utilization


REDUCED ENERGY CONSUMPTIONImproved Asset Utilization

Real time energy

management

Correlating energy

usage to production

Improved reporting

and analytics


Increased production in CPG

Decreased energy consumption

in CMM

Reduced variability in chemical and

oil & gas

PROCESS OPTIMIZATIONImproved Asset Utilization

Increased capacity in bio-fuels


PlantPAx® MPC

Fully functional MPC on a dedicated module:

• Develop and implement MPC up to 10 CV’s,

10 MV’s, and 10 DV’s

• Executed up-to five independent MPC

applications on one MPC module

• Information from the model can be easily

shared in the control layer

Model Predictive Control in the controller

chassis, no supervisory server required,

simple to use

Opens new opportunities to reduce

variability in high-speed applications

OVERVIEW

BENEFITS


ETHERNET/IP IT-OT CONVERGENCEEnterprise Risk Management

Common & robust network infrastructure

Unparalleled device compatibility

Off-the-shelf servers, workstations and switches

Strategic alliance with technology leaders


UNAUTHORIZEDA c c e s s D e n i e d

Reference architectures for network security

Layered security for defense in depth

Adherence to security

standardsAUTHORIZ

EDP e r m i s s i o n G r a n t e d

INDUSTRIAL SECURITYEnterprise Risk Management


Integrated or

independent

Shared variables

including diagnostics

Configurable SIS

packaged solution

INTEGRATED SAFETY & CRITICAL CONTROLEnterprise Risk Management


TRADITIONAL

DCS

LEGACY SYSTEM MIGRATIONSEnterprise Risk Management

Database conversion, scanners, cabling, wiring harnesses

Phased or rip and replace

Lifecycle protection


PLANT-WIDEControl and Optimization

SCALABLEand Modular

SECUREOpen and Information-enabled

FLEXIBLEDelivery and Support


Where to Find More Information?

PlantPAx System Selection Guide

(proces-sg001)

PlantPAx System Reference Manual

(proces-rm001)

PlantPAx Characterization Video

(YouTube)

Modern DCS White Paper

(proces-wp010)

PlantPAx System Infrastructure User

Manual (proces-um001)

PlantPAx System Application User

Manual (proces-um003)

Rockwell Automation Library of

Process Objects (proces-rm002)

http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/proces-sg001_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/proces-rm001_-en-p.pdf

http://www.youtube.com/watch?v=mukYOGVokIY

http://literature.rockwellautomation.com/idc/groups/literature/documents/wp/proces-wp010_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/proces-um001_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/proces-um003_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/proces-rm002_-en-e.pdf

plantpax: the modern dcs

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