P08 Plantpax DCS: Sistema de Controle para Aplicações Pequenas, Médias E Grandes

P08 PlantPAx DCS
Sistema de Controle para aplicações Pequenas, Médias e Grandes
Marcelo André Ferraz

Tendências Tecnológicas - Goiânia
04/04/2017
PUBLIC
Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 1

THE CONNECTED ENTERPRISE
Optimized for Rapid Value Creation
Production
Headquarters Customers
Smart Grid
Field-Based Assets
Distribution Center
Supply Chain

2
What is a DCS?
Rockwell Automation TechED 2016 @ROKTechED #ROKTechED Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. 3
DCS functionality
PlantPAx System capabilities
Characterized Process Safety Engineering & Asset
Control and I/O Configuration Management
Process Batch Secured Operations

Optimization Management Environments Productivity
Today’s challenges:
Fragmented Control Systems
SYSTEMS: NEEDS:
Facilities Material Handling Expansion /
Building Management System PLC + HMI Changes
Optimization
Utilities Process Area
PLC + HMI Distributed Control System Alarm Mgmt
Training
Volatile Storage Packaging
Data / Reports
Safety Shutdown System Packaged Systems
Security
Electrical Warehouse Lifecycle Mgmt
PLC + MCC Environmental Monitoring System
Spare Parts
Disparate systems restrict flexibility and responsiveness

Rethink what you expect from your DCS
Traditional Desired Value

Approach Approach
Faster
Time to
Market
And
Flexibility
How do we ensure performance?
Critical to Quality Attributes
INFRASTRUCTURE
Sizing: Sizing:
• VM Sizing • CPU
• Memory
SERVERS
Design Rules: • Comms
• Network Topology
Design Rules:
• Domain Setup
• OS Setup
• Switch selection
• Software Selection
and configuration
• Application Setup
• Security settings
• Display Design
• NIC card settings
• No Bad Tags
• VM Configuration Sizing: • Diagnostics
CONTROLLER
• CPU
• Memory
• Comms
Design Rules:
• Task Structure
• Performance
Monitoring
• Organization
• No Minor Faults
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.
Architectures for Demanding Applications
Functionality and Performance
Characterized Performance
Minimizes risk of incorrectly sized systems using
guidelines and tools proven by characterization
High Availability
High availability solutions from redundant I/O to
redundant controllers, resilient networks to redundant
HMI servers
Scalable and Flexible

Same platform for single station or
large distributed architectures, easily connected to
allow for skid integration
Shorten development time and minimize human error

Simplified Deployment
Design, build and deploy quickly and consistently
Application Templates
Simplify initial project configuration
by guiding initial project setup and
providing preconfigured HMI and
controller content templates
Modular Object Library

Predefined logic and HMI objects
provide rich operator experience
and shorten development time
Engineering Tools
Streamline workflows and facilitate
efficient engineering
Operational Value
Standards Based Approach to Effective Operations
Effective displays
Library of contextual display
objects to drive productivity
Procedural control
PlantPAx Sequencer automates
procedures to free operator to
focus on process
Standards-based alarming
Effectively direct the operator’s
attention with alarms to improve
the productivity, safety, and
environment of your plant
Operational Value
Plantwide Integration to Power and Field Devices
Integration to Instrumentation & Control

• Provide an immediate and measurable impact
on asset availability, operational efficiency, and
energy management.
• Reduced integration cost of disparate systems.
• Safe monitoring of energized devices on

operator screens.
Operational Value
Supporting Scalable Skid-based Solutions
Partnerships with Process Skid Builders

Drive consistency in automation designs despite
the shift towards modular-design plants
Reduce Integration Cost and Risk

Helps ensure OEM automation scope is easily integrated
into PlantPAx® according to best practices
and proven methodologies
Overall System Performance

Proven, tested architectures not only for DCS
applications, but skid-sized solutions as well
to helps ensure total system performance, no excuses
Migration Solutions
Still running a DCS System installed in the 80s or 90s?
Concerned about :
Lack of domain expertise? (Bailey) Infi 90
Rising support costs? (Bailey) Net 90
(Moore) APACS
Limited access to information?
Hard to find spare parts? TDC TPS
2000 TDC 3000
Rockwell Automation offers: (Fisher) Provox
Database conversion, scanners, cabling, (Foxboro) I/A Series
wiring harnesses
Phased or rip and replace 1970 1980 1990 2000
Lifecycle protection
Strategy and experience to migrate your installed base
PlantPAx System
What you must know
What makes a modern DCS?
Provides all the capabilities expected from a DCS
Meets system performance criteria of a DCS (Critical System Attributes)
+ Uses Plant-Wide automation technology
The PlantPAxTM 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
17
More Flexibility in System Design
PlantPAx System Estimator
EXPANDED sizing model for multi-disciplined

control with new Plant-wide controller types
TIGHT INTEGRATION of motor control centers

with new MCC I/O Location type
COMPLETE system coverage with new SQL

server and domain controllers
HIGH GRANULARITY sizing option with new

advanced sizing worksheet
SIMPLIFIED DEPLOYMENT
Reduced Effort for Faster Time to Market
Expanded Virtual
Image Templates
Comprehensive
Deployment Guides
Updated Design
Environment
Pre-built Process
Strategies
PlantPAx Virtual Image Templates
Consider
PR09
Batch Asset Engineering Operator Process Automation Information Information Information

Management Management Workstation Workstation System Servers Server Server Server
REDUCE engineering EXTEND ENHANCED availability EASE

time and validation costs system lifecycle options through virtualization lifecycle management
PlantPAx System Network
Why is it important:
Ensures characterized performance
Ensures functionality can be achieved
such as disaster recovery and field
device integration
Ensures secure and maintainable
environment
What is provided:
IT/OT integration with Stratix family of
switches
PlantPAx standard configurations
More flexibility offered with CPwE Consider
Consulting services offered when NS04
needed
Comprehensive Deployment Guides
Consider
PR02
USER MANUALS SIMPLE OVERVIEWS DETAILED STEPS TOOLS INCLUDED

Infrastructure and Application Flow chart summary Click-by-click instructions Configurations and templates
Configuration for each chapter for each task attached inside manual
Updated Design Environment
Studio 5000 Architect
SHARE DATA LAYOUT & CONFIGURE MANAGE & VIEW

• Start from other design artifacts • Layout your control, visualization, • Centrally manage your automation
• Incorporate existing control and and communications network system
visualization projects • Configure devices from central • Launch your control and visualization
• Reduce configuration time by location projects
leveraging automation system • Build automation projects • Quickly search across your
project templates and content automation system
Central place to configure and manage your system

System
Templates
Simplified Setup and Configuration
Graphical representation of the system
Hardware Library:
Project Explorer helps Controllers, I/O,
organize and manage Switches, HMIs, and
system application code Computers
from one place
Manage and configure

communications
between controllers User Libraries:
and between Process Objects
controllers and servers provided by default.
Consider
PR05
Easily find and system code through search; open
directly into editor
Application Code Manager
DESIGN PUBLISH BUILD

• Library Designer is integrated • Combine control, visualization, • Easily generate your
into Logix Designer historical and alarm management standardized application code
• Flexible library authoring, into one library object • Bulk configure projects
structuring reusable content the • Centralized repository for easy • Leverage Rockwell Automation
way you want access and version management provided libraries (OEM
Consider building blocks)
CL05/07/08
Maximize reuse and quickly build projects

Operator Training Systems
New Interface Provides Tight Integration with Operator Training Systems
MYNAH
Consider
PR27
New Library Objects
Consider
PR03
DEADBAND CONTROL LEAD-LAG-STANDBY I/O MODULE STATUS

On-Off control of an analog Control parallel groups of pumps, fans, Monitors the connection status of
process value and motors I/O modules for Process Strategies
Library of Process Strategies
OVERVIEW
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
BENEFITS
Ensures characterized performance with
known control strategy configurations
Consider Greatly reduces implementation time
PR05 Promotes consistent applications and
user experience
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
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
Consider
PR02 Available from the Rockwell Automation Knowledgebase:
AID 771236 – PlantPAx Checklist and Verification Tools
PlantPAx MPC
OVERVIEW
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
BENEFITS
Model Predictive Control in the controller
chassis, no supervisory server required,
simple to use
Opens new opportunities to reduce
Consider variability in high-speed applications
PR16
PlantPAx System
Summary: What’s New
Decrease the time to market required to deploy and maintain systems

Automation •Leverage Studio 5000 enhancements Application Code Manager
Productivity •Expanded design tools and documentation

•New pre-built Process Control Strategies
Infrastructure improvements to deliver a robust and reliable experience

Enabling •Standard Network Configurations
Technology •Mobility enhancements
•Complete portfolio of Virtual Image Templates
Enhance the user experience while increasing operational productivity

Enhanced •PlantPAx MPC in the chassis reduces waste and variability
Control •Leverage Visualization and Control enhancements:
MPC
•Batch Application Toolkits for easy adoption by delivery teams
Where to find more information?
PlantPAx System Selection Guide PlantPAx System Infrastructure
(proces-sg001) User Manual (proces-um001)
PlantPAx System Reference Manual PlantPAx System Application User

(proces-rm001) Manual (proces-um003)
Modern DCS White Paper Rockwell Automation Library of

(proces-wp010) Process Objects (proces-rm002)
PlantPAx Characterization Video

(YouTube)
PR01 - PlantPAx® System
What's New & What's Next
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P08 PlantPAx DCS

Sistema de Controle para aplicações Pequenas, Médias e Grandes

Marcelo André Ferraz

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

Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. 2

Process Batch Secured Operations

Disparate systems restrict flexibility and responsiveness

Traditional Desired Value

Varying system sizes from

Scalable and Flexible

Shorten development time and minimize human error

Modular Object Library

Integration to Instrumentation & Control

• Reduced integration cost of disparate systems.

• Safe monitoring of energized devices on

Partnerships with Process Skid Builders

Reduce Integration Cost and Risk

Overall System Performance

The PlantPAxTM System is the Rockwell Automation modern DCS:

EXPANDED sizing model for multi-disciplined

TIGHT INTEGRATION of motor control centers

COMPLETE system coverage with new SQL

HIGH GRANULARITY sizing option with new

Batch Asset Engineering Operator Process Automation Information Information Information

REDUCE engineering EXTEND ENHANCED availability EASE

USER MANUALS SIMPLE OVERVIEWS DETAILED STEPS TOOLS INCLUDED

SHARE DATA LAYOUT & CONFIGURE MANAGE & VIEW

Central place to configure and manage your system

Manage and configure

DESIGN PUBLISH BUILD

Maximize reuse and quickly build projects

DEADBAND CONTROL LEAD-LAG-STANDBY I/O MODULE STATUS

What problems does it solve?

Decrease the time to market required to deploy and maintain systems

Productivity •Expanded design tools and documentation

Infrastructure improvements to deliver a robust and reliable experience

Enhance the user experience while increasing operational productivity

PlantPAx System Reference Manual PlantPAx System Application User

Modern DCS White Paper Rockwell Automation Library of

PlantPAx Characterization Video

Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. 37

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