AP06 - Mobile Visibility and Control Key to W/WW Predictive Maintenance and Operator Efficacy
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Transcript of AP06 - Mobile Visibility and Control Key to W/WW Predictive Maintenance and Operator Efficacy
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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
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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
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Presenter Introduction
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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
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Safety Moment
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Exit Plan? Fall Restraint?
Picture from www.BrainJet.com
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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
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PASS Overview
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PASS Sizing
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Controller Verification
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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
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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
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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.
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AssetCentre
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File Organization / Archiving
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AssetCentre Process Device Configuration
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Via Profibus
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AssetCentre Process Device Configuration
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Online Values
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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.
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Modified Gray Scale Technology
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Gray Scale Technology
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Gray Scale Technology
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Situational Awareness
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Gray Scale Technology
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Situational Awareness
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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
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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.
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ISA 18.2 – Quick Drill Down
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Drilling Down to Problems
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ISA 18.2 Alarm Features
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Ability to Shelve Alarms
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ISA 18.2 Alarm Features
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Breadcrumbs – Alarm Priorities
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ISA 18.2 Alarm Features
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ISA 18.2 Alarm Management
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Single Alarm – Multiple Causes
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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
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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
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ISA 18.2 Alarming KPI Reports
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Top Alarms – Time to Acknowledge
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ISA 18.2 Alarming KPIs
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Alarms – Hourly Alarm Counts
24 Alarms/Hour
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ISA 18.2 Alarming KPI Reports
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Drill Down into 24 Alarms/Hour
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Tools to Help Improve Integration Effort
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“Smart” P&IDs
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Tools to Help Improve Integration Effort
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P&IDs Linked to Database
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Tools to Help Improve Integration Effort
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Database creates CSV Tag file for RSLogix5000
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Tools to Help Improve Integration Effort
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Same information used for HMI
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Tools to Help Improve Integration Effort
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PlantPAx_OnlineConfigTool_xxx.XLS
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Tools to Help Improve Integration Effort
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PAX_AlarmsBuilder_Vxxxx
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Tools to Help Improve Integration Effort
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PAX_AlarmsBuilder_Vxxxx
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Tools to Help Improve Integration Effort
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PAX_AlarmsBuilder_Vxxxx
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Tools to Help Improve Integration Effort
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PAX_AlarmsBuilder_Vxxxx
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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
Thank you!