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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION PlantPAx® System Fundamentals

PlantPAx System Fundamentals

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This session will discuss and demo how to use the plant-wide control capabilities of Integrated Architecture to implement traditional DCS applications. This introductory course will discuss the advantages of the PlantPAx system and how the system concepts and tools can help improve any system application.

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Page 1: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

PlantPAx® System Fundamentals

Page 2: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2

Agenda

PlantPAx System Operations

PlantPAx System Engineering

PlantPAx System Architecture

What is PlantPAx?

PlantPAx – A Modern DCS

Page 3: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Today’s challenge:Fragmented control systems

3

Process Area

Distributed Control System

Volatile Storage

Safety Shutdown System

Material Handling

PLC + HMI

Packaging

Packaged Systems

Warehouse

Environmental Monitoring

System

Facilities

Building Management

System

Utilities

PLC + HMI

Electrical

PLC + MCC

Needs:

� Expansion /

Changes

� Optimization

� Alarm Mgmt

� Training

� Data / Reports

� Security

� Lifecycle Mgmt

� Spare Parts

Systems:

Disparate systems restrict flexibility and responsiveness

Page 4: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

DCS vs. PLC: an old story

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Page 5: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Rethink what you expect from your DCS

“….Nobody wants to buy or manage Disparate Control Systems…”

“I want……Plant-wide Automation

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Page 6: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx SystemModern DCS vision

6

Redefine the DCS by offering a Process Automation System with:

* all the capabilities of a world-class DCS

* multi-disciplinary Plant-wide Control

* a modern, standards-based architecture

* scalability and flexibility to match YOUR requirements

Page 7: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 7

Agenda

PlantPAx System Operations

PlantPAx System Engineering

PlantPAx System Architecture

What is PlantPAx?

PlantPAx – A Modern DCS

Page 8: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx SystemWhat you must know

What makes a modern DCS?

�Uses Plant-wide automation technology

�Provides all the capabilities expected from a DCS

�Meets system performance criteria (Critical System Attributes)

The PlantPAx® Process Automation System is the Rockwell

Automation modern DCS:

� Built on Integrated Architecture

� Follows PlantPAx Selection Guide for system sizing

� Follows PlantPAx Reference Manual for architecture rules

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Page 9: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

DCS performancePlantPAx System characterization

Goals of PlantPAx System characterization:

� 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)

CentralizedSystem(1 server)

OEM (L2/L3)

Virtual System

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Page 10: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

DCS capabilitiesLibrary of Process Objects

� Suite of control and HMI objects to accelerate project engineering and provide rich operator experience

� Role-based feature set for

� Operation

� Maintenance

� Engineering

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PlantPAx Standard Library – “Out of the Box”

Page 11: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

2009 V1.0

• Characterized

Performance

• Library

• Batch Reports

2011 V2.0

• High Availability

• Device Integrity

• Design Prod

2013 V3.0

• Virtualization

• Engineering eff.

• Operator eff.

2014 Updates

• New Virtual

Templates

• Library Additions

• Smaller LBSM

• Alarming

• Recipe Versioning

2015 V4.0

ComingSoon!

DCS capabilitiesPlantPAx System releases

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Page 12: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

DCS capabilitiesPlantPAx System summary

Operations

SystemArchitecture

Services &

Support

Engineering

Maintenance

PlantPAx Process Automation System:Modern DCS based on Plant-wide control technologies

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Page 13: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 13

Agenda

PlantPAx System Operations

PlantPAx System Engineering

PlantPAx System Architecture

What is PlantPAx?

PlantPAx – A Modern DCS

Page 14: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

System Architecture

Scalable and FlexibleSame platform for single station or

large distributed architectures, easily connected to

allow for skid integration

Shorten development time and minimize human error

Characterized PerformanceMinimizes risk of incorrectly sized systems using

guidelines and tools proven by characterization

High AvailabilityHigh availability solutions from redundant I/O to

redundant controllers, resilient networks to redundant

HMI servers

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Page 15: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Sizing PlantPAx SystemsSelection Guide

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PlantPAx Selection Guide (PROCES-SG001) provides high level guidelines to define and size system

Page 16: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx System Estimator

� 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

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Detailed sizing model reduces design risk, enables “what-if” analysis

Page 17: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx System EstimatorBuilding your system tree

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Page 18: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

App

Process ControlEtherNet/IP

Asset Management

OperatorWorkstations

EngineeringWorkstations

Process AutomationSystem Server and

Application Servers – HMI

BatchManagement

InfoManagement

ProcessControllers

Variable Speed Drives

Local, Distributed, and Intelligent I/O

Valves andInstrumentation

IntegratedProcess Skids

• # of Tags on Scan

• # of OWS

• # of Alarms

• CPU %

• Memory %

• # of Tags on Scan

• # of I/O

• Control Strategies

• Controller types

• # of OWS

PlantPAx System EstimatorModeling performance

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Page 19: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx System EstimatorEntering I/O and Control Strategy Info

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Page 20: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx System EstimatorHow does PSE show sizing problems?

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Page 21: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 21

Virtualization for faster deployment

• Rockwell

Automation Virtual

Infrastructure

• Templates for easy

deployment of

servers and

workstations

• Sizing and

architecture rules

Extend lifecycle of system install

Page 22: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 22

Agenda

PlantPAx System Operations

PlantPAx System Engineering

PlantPAx System Architecture

What is PlantPAx?

PlantPAx – A Modern DCS

Page 23: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx System engineering

Modular Object Library… Predefined logic and HMI objects

provide rich operator experience and

shorten development time

Application Templates… Simplifies initial project configuration

by guiding initial project setup and

providing preconfigured HMI and

Controller content templates

Engineering Tools…Streamline workflows and facilitate

efficient engineering

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Page 24: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

How to build a PlantPAx System

“How to build” - documented in PlantPAx Reference ManualEnabled by PlantPax QuickStart

PROCES-RM001 PROCES-QS001

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Page 25: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

What does the PlantPAx QuickStart contain?

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QuickStart

Controller Project

Setup

QuickStart

HMI Application

Setup

QuickStart

HMI Template

Setup

QuickStart

Diagnostics

Setup

Page 26: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 26

What does the PlantPAx QuickStart contain?

QuickStart

Controller Project

Setup

QuickStart

HMI Application

Setup

QuickStart

HMI Template

Setup

QuickStart

Diagnostics

Setup

Page 27: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

What is the PlantPAx Library of Process Objects?

The PlantPAx Library of Process Objects is a predefined library of

controller code (Add-On Instructions), display elements (global objects), and

faceplates that let you quickly assemble large applications with proven

strategies, rich functionality, and known performance.

Step 2: Create andconfigure AOI

Step 3: Create global display and assign to AOI

Step 4: Access faceplate forruntime control and maintenance

Step 1: Import the PlantPAx Library into Project

Download from the Rockwell Automation Software Download Site:

http://download.rockwellautomation.com/webupdates/enter.aspx27

Page 28: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 28

Agenda

PlantPAx System Operations

PlantPAx System Engineering

PlantPAx System Architecture

What is PlantPAx?

PlantPAx – A Modern DCS

Page 29: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Operations

Operators should spend their time controlling the plant, not being distracted by the control system

Effective DisplaysLibrary of contextual display

objects to drive productivity

Procedural ControlPlantPAx Sequencer automates procedures

to free operator to focus on process

Standards-based AlarmingEffectively direct the operator’s attention with alarms to improve the productivity,

safety, and environment of your plant

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Page 30: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Standards-based alarming

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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

More effective management of alarms to prevent incidents

Page 31: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Standards-based alarming

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� Provides method for gating

threshold alarms or indications

� Includes:

� Gate Input

� Gate Delay

� On-Delay

� Off-Delay

Built-in capabilities for alarm suppress-by-design logic

Page 32: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Capturing operator knowledge through automated sequencer

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New PlantPAx Library sequencer object:

� Easily configurable to capture critical sequences

� Rich visualization provided to the operator

� Built-in Exception Handling

Automates procedures to free operator to focus on process

Page 33: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Expanded toolkit for HMI design

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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

Turning data into information: effective displays drive productivity

Page 34: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

New library navigation features

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Library Object-to-Object Navigation

� Easily navigate from motor to interlock to cause

� Allows for quick troubleshooting

Quick troubleshooting for improved MTTR

Page 35: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

And finally….

Page 36: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx 2014 System updatesV

irtu

al

Tem

pla

tes

Historian and

AppServ-OWS

Images Release

Pro

cess

Ob

ject

Lib

rary

Ala

rmin

g36

Reduce Risk Simplify

Improve Core

New objects for Power

Product Integration

Dynamic Severity and

Alarm Horns by Priority

Page 37: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 37

Advancing PlantPAx with a strong foundation of differentiation

Design & Operator Efficiency Connected Enterprise

Global Solutions & Services

DistributedBatch Control

Page 38: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Where to find more information?

� PlantPAx Process Automation System

Selection Guide (proces-sg001)

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� PlantPAx Process Automation System

Reference Manual (proces-rm001)

� PlantPAx Characterization Video

(YouTube)

Page 39: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Questions / Demo

Page 40: PlantPAx System Fundamentals

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

We care what you think!

� On the mobile app:

1. Locate session using

Schedule or Agenda Builder

2. Click on the thumbs up icon on

the lower right corner of the

session detail

3. Complete survey

4. Click the Submit Form button

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Please take a couple minutes to complete a quick session survey to tell us how we’re doing.

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Page 41: PlantPAx System Fundamentals

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