PlantPAx System Overview - ab.rockwellautomation.com · management enabled by industry standards...

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


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


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


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


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


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


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


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


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


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


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


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


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.


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


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


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


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


• 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



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Rockwell Automation Process Solutions User Group (PSUG)November 14-15, 2011Chicago, IL – McCormick Place West

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PlantPAx System Overview - ab.rockwellautomation.com · management enabled by industry standards...

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