Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

AP06 - Mobile Visibility and Control Key to W/WW Predictive Maintenance and Operator Efficiency

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D. John Costello 2015

D. John Costello

• Over 41 years of Control System Design and Integration Experience

• With CH2M (Hill) for over 22 years

• CH2M Water Market West Regional Technology Leader – Automation Systems

• Rockwell Automation PlantPAx® System Integrator

• Certified Profibus DP & PA Network Engineer

donald.costello@ch2m.com

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Presenter Introduction

CH2M Hill

26,000 employees on six continents

Provides water industry planning, engineering, construction, and operations services

Provides Intelligent Water Solutions Services

Facility Automation

Smart Grid

Water Information Management

Integrated Security and Emergency Preparedness

Rockwell Automation® Recognized Control System Integrator

Rockwell Automation Recognized Process System Integrator

Rockwell Automation Recognized Information System Integrator

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Company Introduction

Safety Moment

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Exit Plan? Fall Restraint?

Picture from www.BrainJet.com

Project Overview

Client: Metro Wastewater Reclamation District

Project: Northern Treatment Plant – Brighton, CO

• 28.8 MGD Wastewater Treatment Plant

• Future Expansion to 75 MGD

• 1.0 Mile Long by 0.25 Mile Wide

Design-Build Contractor: CH2M HILL / Garney Construction

Cost: $250 Million

Delivery Method - Fast Track Progressive Design-Build

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Site Overview

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PlantPAx Integrated Architecture

FIELD DEVICE LEVEL • Profibus, DeviceNet, BACNet, DNP3

PROCESS CONTROL LEVEL • CompactLogix™ Hardware Platform

OPERATIONS LEVEL • FactoryTalk® View SE / ME HMI software

• Site Edition (SE): Uses FactoryTalk® Alarms and Events for alarming • Machine Edition (ME): Designed for use on PanelView™

• SUPERVISORY / MAINTENANCE CONTROL LEVEL • FactoryTalk® Historian / FactoryTalk® VantagePoint® Vantage Point Software

• Microsoft Excel reporting from FactoryTalk Historian and FactoryTalk Alarms and Events • FactoryTalk® AssetCentre Software

• Document Control / Disaster Recovery • Process device configuration • Calibration management

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Northern Treatment Plant - Special Features

• Rockwell Automation PlantPAx based

• HMI graphics developed to support ISA Standard 18.2 and a modified grey scale

• State-of-the-art video wall in the plant control room

• Wireless mobility using iPads

• Virtualized control system using high availability redundant SAN

• Virtual environment with zero clients

• Replica process simulation software

• Redundant Network(s)

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Control Room Video Wall

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Video Wall

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PASS Virtualized Servers

Process Network:

DMZ:

• Domain Controller – Primary

• Domain Controller – Secondary

• FactoryTalk Historian (5000 Tags)

• FactoryTalk VantagePoint

• Operator Workstations (Six Total + Video Wall)

Total of 18 Virtual Servers

• FactoryTalk® Directory

• FactoryTalk View SE [Unlimited Graphics] Primary Server

• FactoryTalk View SE [Unlimited Graphics] Secondary Server

• Engineering Server

• Engineering Workstation

• WIN911

• Windows Update Server

PASS Overview

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PASS Sizing

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Controller Verification

Control System Overview

Six Redundant Controllers & Four Non-Redundant Controllers

• 41 Hard-wired Analog Inputs

• 13 Hard-wired Analog Outputs

• 390 Hard-wired Digital Inputs

• 129 Hard-wired Digital Outputs

• 561 Profibus DP Devices

• 425 Profibus PA Devices

• 375 DeviceNet Devices

Thirteen Vendor supplied Controllers – Redundant & Non-Redundant Configurations

(ControlLogix® & CompactLogix™ + 1 non-Rockwell Automation solution)

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PASS Architecture

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Network / Processor Redundancy

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Simplified Diagram

Fieldbus Implementation

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Plant Control System (PCS) I/O Communicate via Fieldbus

Field Instruments Communicate via Profibus DP/PA

• Prosoft DP Module

• DP – Control Valves, Metering Pumps, Flowmeters and Analytical Instruments

• PA – Level, Pressure, Temperature, Weight

MCCs Communicate via DeviceNet

• MCC Bucket Control

• VFD Control

Most Packaged Systems Communicate via EtherNet/IP

Rockwell Automation’s AssetCentre Software

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Provides Automatic Program Version Control.

Provides ability to configure and troubleshoot field instrumentation over HART or

Profibus communications technology.

Provides ability to schedule, manage, track, and report on field instrumentation

calibration activities.

AssetCentre

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File Organization / Archiving

AssetCentre Process Device Configuration

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Via Profibus

AssetCentre Process Device Configuration

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Online Values

REPLICA SIMULATION SOFTWARE

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Use of Replica Process Simulation Software

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Influent Pump Station and the Tertiary Pump Station

modeled using Replica

Replica software blocks replicated in RSLogix™ 5000

(LogixDesigner) software.

Pump block resides in an Add-On-Instruction (AOI)

Incorporates pump curves to find most efficient

operating point.

Modified Gray Scale Technology

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Gray Scale Technology

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Gray Scale Technology

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Situational Awareness

Gray Scale Technology

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Situational Awareness

Liquids Flow Model

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Solids Flow Model

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ISA Standard 18.2 - Workflow

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Construction Phase

Operations Phase

Programming Phase

ISA Standard 18.2 - Philosophy

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Alarm definition

Roles and requirements

Rationalization requirements

Alarm class definitions, design, requirements

Alarm priorities, definitions, etc.

Alarm shelving / suppression rules

Alarm system monitoring requirements

Management of change

Training

Requires a committee of stakeholders

• Senior Management • Operators • Maintenance • SCADA Design Team

Draft, review, edit, repeat as necessary

Once approved, review the alarm philosophy periodically for any necessary changes

• Document should contain the minimum review period.

ISA 18.2 – Quick Drill Down

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Drilling Down to Problems

ISA 18.2 Alarm Features

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Ability to Shelve Alarms

ISA 18.2 Alarm Features

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Breadcrumbs – Alarm Priorities

ISA 18.2 Alarm Features

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ISA 18.2 Alarm Management

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Single Alarm – Multiple Causes

ISA 18.2 - Monitoring

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Alarms per Day: ~150/Day Target ~300/Day Maximum

Alarms per Hour: ~6 Average ~12 Maximum

Alarms per 10 Min: ~1 Average ~2 Average

Hours containing >30 Alarms: ~<1%

Priority Distribution:

•P1 (Urgent) ~5%

• P2 (High) ~15%

• P3 (Medium) ~80%

• P4 (Low / Maintenance Required) Event

ISA 18.2 Monitoring

FactoryTalk VantagePoint reporting installed to provide Alarming Key Performance Indicator Monitoring

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ISA 18.2 Alarming KPI Reports

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Alarms Grouped by Class

ISA 18.2 Alarming KPI Reports

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Top Alarms – Time to Acknowledge

ISA 18.2 Alarming KPIs

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Alarms – Hourly Alarm Counts

24 Alarms/Hour

ISA 18.2 Alarming KPI Reports

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Drill Down into 24 Alarms/Hour

Tools to Help Improve Integration Effort

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“Smart” P&IDs

Tools to Help Improve Integration Effort

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P&IDs Linked to Database

Tools to Help Improve Integration Effort

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Database creates CSV Tag file for RSLogix5000

Tools to Help Improve Integration Effort

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Same information used for HMI

Tools to Help Improve Integration Effort

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PlantPAx_OnlineConfigTool_xxx.XLS

Tools to Help Improve Integration Effort

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PAX_AlarmsBuilder_Vxxxx

Tools to Help Improve Integration Effort

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PAX_AlarmsBuilder_Vxxxx

Tools to Help Improve Integration Effort

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PAX_AlarmsBuilder_Vxxxx

Tools to Help Improve Integration Effort

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PAX_AlarmsBuilder_Vxxxx

Summary

Modeled the Process Using Replica

Used Fieldbus Technology

Used existing AOI (P_Alarm), knowing it would be upgraded at a later time to support S18.2

Alarm Management.

• This allowed development to start before the desired functionality was actually available without impacting

the project schedule.

Linked Directly to the AOIs

• Eliminated the HMI Tag Database

– Reduced Development Time.

– Reduces Processor Memory Usage roughly 50% over using UDTs

Implemented Rockwell Devices

• Rockwell Automation PowerMonitor™

– Imported the Add-On Profile and Configured the Device – Reduced Development Time.

Implemented FactoryTalk AssetCentre PDC

• Configure and Verify Instrument Operation – Reduce Start-Up Time

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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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