Train iT - Plant Liqu iT - System Overview

Overview of the Plant iT process control system

Version 9
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Train iT, 9
Train iT - Plant Liqu iT - System Overview – Overview of the Plant iT process
control system
R01, Edition: 4. July 2014

01_TrLit_V900_SYS.doc

No responsibility can be assumed for the details contained in this manual;

changes can be made at any time. The software described in this document is
subject to the license conditions.
Designations for hardware and software mentioned in this manual are registered
trademarks of hardware and software products.

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 Table of contents

Table of contents

1 Introduction ..............................................................................................................5

2 Modules of the Plant iT process control system ..................................................6

2.1 Plant iT – the system platform ...................................................................................7
2.2 Plant Acquis iT - production data management .........................................................8
2.3 Plant Direct iT – the basic automation .......................................................................9
2.4 Plant Liqu iT – the technology-oriented recipe control .............................................10
2.5 Plant Batch iT – the batch system according to ISA 88 ...........................................10
2.6 Plant iT Material – the process-oriented material management ..............................11
2.7 Plant iT integrate – the cross-area integration .........................................................11
2.8 Plant iT Connect – the parameterizable communication interface ..........................11

3 Differences between process control systems and conventional automation

solutions .................................................................................................................12
3.1 Advantages of process control systems ..................................................................12
3.2 Advantages of conventional automation solutions ...................................................12
3.3 What does Plant iT offer? ........................................................................................13

4 The basic functionality of Plant iT .......................................................................14

4.1 Process control system ............................................................................................14
4.2 Production data management ..................................................................................14
4.3 Multi-language capability as a basis for worldwide use ...........................................14
4.4 International standards and guidelines are also fulfilled ..........................................14
4.5 Video mode ..............................................................................................................14
4.6 Add ons ....................................................................................................................15
4.6.1 Messenger ..................................................................................................15
4.6.2 Proleit Active X Data Engine (PAX DE) ......................................................15
4.6.3 Acquis iT pack .............................................................................................15
4.6.4 Acquis iT OEE .............................................................................................15
4.6.5 Acquis iT energy .........................................................................................15
4.7 High integration within the entire system platform ...................................................15

5 The development of the Plant iT process control system .................................16

6 Scalability of Plant iT .............................................................................................17

6.1 Single-user system ..................................................................................................17
6.1.1 Components ................................................................................................17
6.1.2 Available for Plant iT Version 90 .................................................................17
6.1.3 Supported operating systems .....................................................................17
6.2 Client/server system (single-server) ........................................................................18
6.2.1 Components ................................................................................................18
6.3 Multi-server system ..................................................................................................18
6.3.1 Components ................................................................................................18

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 Table of contents

7 Distribution of functions: Client – Server – PLC ................................................19

8 The technical basis of Plant iT .............................................................................20

9 Technical key data .................................................................................................21

9.1 Quantity framework ..................................................................................................21
9.1.1 Servers, workstations, and PLCs ................................................................21
9.1.2 Data capacity ..............................................................................................21
9.2 IT hardware ..............................................................................................................21
9.3 Communication interface .........................................................................................22
9.3.1 Ethernet.......................................................................................................22

10 Summary.................................................................................................................23
10.1 Highlights .................................................................................................................23
10.1.1 Visu-Recorder (optional add-on) .................................................................23
10.1.2 Process management with material reference ...........................................23
10.1.3 Integrated production data management ....................................................23
10.2 Main characteristics of Plant iT ................................................................................23

11 Exercises ................................................................................................................25

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 Introduction

1 Introduction

Plant iT is an open, PLC-based, object-oriented, freely parameterizable, modular

client/server process control system with real-time database.
Plant iT consistently relies on established standards, like Microsoft Windows,
SQL Server, Office, and C#.
Plant iT has an extensive library with basic technical classes (e.g. valves, drives)
and technological classes, such as the phase controller and OCM (Object Con-
trol Matrix).
These technological classes make procedural process controls parameterizable.

Objective
Name the process control system components
Name the prerequisites for the use of the process control system
Describe the tasks of the individual process control system components
Understand the principle interaction between the process control system
components

More advanced manuals

"Plant iT Installation – Setup"

"Plant iT – System Description"

"Plant iT - Release Notes"

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 Modules of the Plant iT process control system
Plant iT – the system platform

2 Modules of the Plant iT process control system

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 Modules of the Plant iT process control system
Plant iT – the system platform

2.1 Plant iT – the system platform

Basic functions and tools for all the following modules.

The Plant iT system platform provides uniform configuration and backup tools
for all other Plant iT modules. These in turn contain the possibility for using addi-
tional system-wide functions, like multi-language capability, user management,
project backup, and file distribution.

Tasks:
Consistent configuration tool
Consistent user interface
Excel add-ins for parameterization
Central backup function
User management
Multi-language capability
Archiving
Time synchronization
Time zoning
Licensing

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 Modules of the Plant iT process control system
Plant Acquis iT - production data management

2.2 Plant Acquis iT - production data management

Module for acquiring and evaluating plant, process, machine, and energy
data.
It is used together with Plant Direct iT or autonomously (without the Plant
iT-based process automation).
Its application is mainly in process engineering, including related areas of
discrete manufacturing (e.g. plant data acquisition in filling plants).
Plant Acquis iT makes the integration of heterogeneous control levels poss-
ible.

Process, production, plant, and machine data can be acquired continuously via
event control or manual input using Plant Acquis iT. With this module, com-
plete plant data acquisition projects can be realized or only parts used for plant
automation, such as message and measured value acquisition. The module al-
so includes the possibility of a process screen visualization of the plants and
machine states, as well as tools for data searches.

Note
The Plant Acquis iT module can be used independently as a process control system
component.

Tasks:
Data acquisition, for example:
Curve recording
User messages
Counter value acquisition
Servicing

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 Modules of the Plant iT process control system
Plant Direct iT – the basic automation

2.3 Plant Direct iT – the basic automation

The Plant Direct iT module is used for monitoring, operating, and observing a
plant.
Plant Direct iT is a PLC-based process control system available on the modular
platforms of the market leaders.
Rockwell ControlLogix
Siemens SIMATIC S7
Note
Until now, the full scope of functions have been available only for Siemens SIMATIC
S7 controllers. The scope of functions for Rockwell controllers, however, is being ex-
panded continuously.

Tasks:
Process visualization
Visualization recorder for recording the process visualization and searches
Basic automation classes, such as valves, motors, analog inputs, control-
lers
Object control matrixes
Phase control

Note
Together with Plant Acquis iT, the Plant Direct iT module can be used as an inde-
pendent process control system component.

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 Modules of the Plant iT process control system
Plant Liqu iT – the technology-oriented recipe control

2.4 Plant Liqu iT – the technology-oriented recipe control

Plant Liqu iT is used for the control and monitoring of processes oriented toward
the complex handling of liquids.
Plant Liqu iT enables the creation of parameterizable, sequence-based process
controls with dynamically selectable parameter sets.
Plant Liqu iT has path control, tank farm administration, a job list, and recipe
control.

Tasks:
Sequence processes
Recipe system
Process parameters
Task planner for automatic order starts
Tank farm administration for the connection of pipes with source-
destination preselections
Interface for equipment modules, the technological classes

Note
The Plant Liqu iT module can be used only together with the Plant Direct iT and
Plant Acquis iT modules.
The Brewmaxx process control system consists of just these three modules.

2.5 Plant Batch iT – the batch system according to ISA 88

Plant Batch iT is designed for ISA 88-compliant plant and process modeling.
Plant Batch iT supports order-related, selectable recipe models, including bill of
materials-based production.
Plant Batch iT has order and recipe management with version management,
electronic batch recording, and seamlessly integrated material management.

Tasks:
Order management and processing
Recipe generator
Automatic recipe creation using bill of materials
Batch visualization
Material management

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 Modules of the Plant iT process control system
Plant iT Material – the process-oriented material management

2.6 Plant iT Material – the process-oriented material management

Plant iT material has master data management.
Plant iT material is designed for stock management and evaluations with regard
to material or storage location, especially in the batch tracking.
Plant iT material can be flexibly combined with all other system components.

Tasks:
Management and editing of orders
Batch tracking
Booking of material movements
Management of inventories

2.7 Plant iT integrate – the cross-area integration

Plant iT integrate combines, consolidates, and pre-compresses information for
management reporting.
Plant iT integrate is a data warehouse with a Web-based, freely configurable re-
porting system.

Tasks:
Cross-area reporting
Connection of partial systems to the overall system (e.g. cross-site)

2.8 Plant iT Connect – the parameterizable communication interface

Plant iT Connect is a flexibly usable communication interface for the communi-
cation with external systems like LIMS, the ERP system, intelligent testing de-
vices (e.g. inspectors), etc.
Plant iT Connect enables a centralized engineering of all communication con-
nections.
Plant iT Connect provides a uniform, transaction-exact online diagnosis for all
connections.

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 Differences between process control systems and conventional automation solutions
Advantages of process control systems

3 Differences between process control systems and

conventional automation solutions

A process control system offers a consistent, homogeneous system from the

actuators/sensors to the control level.
Engineering according to standardized methods (parameterization and/or graph-
ic configuration)

3.1 Advantages of process control systems

Process control systems offer better software quality due to lower error rates,
which leads to shorter commissioning times.
They have low risk in the expansion, adaptation or step-by-step realization of
plants since the limits of process control systems are permanently defined from
the beginning.
A (re-)qualification is considerably simplified or, indeed, made possible at all.
This is because the configuration is standardized and thus comprehensible due
to the use of qualified standard modules.
Process control systems therefore offer you better investment protection.

3.2 Advantages of conventional automation solutions

Conventional automation solutions mean lower investment costs for licenses
and hardware at the beginning.
The availability of technical personnel with adequate system knowledge is
greater.
The openness of the system simplifies the integration of existing infrastructure.
Because they do not have to follow the rules of a process control system, con-
ventional automation solutions provide more flexibility with regard to adaptations
and expansions.

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 Differences between process control systems and conventional automation solutions
What does Plant iT offer?

3.3 What does Plant iT offer?

Plant iT combines the advantages of classical process control systems with
those of conventional automation solutions.
Plant iT is an open system despite true process control system functionality
(flexible integration of external controllers).
Engineering, process, and movement data are stored in a central database.
The compiler-free system architecture of Plant iT permits maximum flexibility
when making changes during operation.
The Plant iT platform offers integrated functionality "with a view upwards" (MES
functionality).
The Plant iT platform fulfils the requirements of current standards.

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 The basic functionality of Plant iT
Process control system

4 The basic functionality of Plant iT

Plant iT is an open, PLC-based process control system.

Plant iT is an object-oriented, freely parameterizable client/server system with a
real-time database.
Plant iT consistently relies on established standards, like Microsoft Windows,
SQL Server, Office, and C#.

4.1 Process control system

An extensive library with basic classes is already included in the standard pack-
age, for example, technical classes (e.g. valves, drives) and technological
classes, such as the phase controller and OCM (Object Control Matrix).
These technological classes make procedural process control parameterizable.

4.2 Production data management

Plant iT contains production data acquisition, including standard evaluations,
curve representation, import and export, and archiving.

4.3 Multi-language capability as a basis for worldwide use

The standard version of the basic system is available in German and English.
The configuration of the multilingual content of the user interface takes place di-
rect via the central engineering environment.
The import/export of all translation-relevant content to Excel is supported and
system texts can thus also be translated by external service providers.
The language is switched over online through user log-on to the operating sta-
tion.
The system is completely Unicode-compatible so that Cyrillic and Chinese cha-
racters can also be shown.

4.4 International standards and guidelines are also fulfilled

The system supports GMP-compliant working according to CFR21 Part 11.
The audit trail and electronic signature are integral parts of Plant iT.
Plant iT supports batch tracking according to EU Directives 0178/2000 and
1935/2002.

4.5 Video mode

With the video mode, processes from the past can be played back by the nor-
mal visualization system, similar to a video.

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 The basic functionality of Plant iT
Add ons

The period and the playback speed can also be selected and changed.

4.6 Add ons

4.6.1 Messenger

The Plant iT Messenger can be used to send messages to a mobile telephone

or per SMS. It also allows messages to be output as audio.

4.6.2 Proleit Active X Data Engine (PAX DE)

The Proleit Active X Data Engine can be used to compress operating data from
the database in an Excel template.

4.6.3 Acquis iT pack

Offers in filling systems, troubleshooting, status analysis (Pareto chart), stan-

dard reports (shift report, filling report) and order management with shift plan-
ning.

4.6.4 Acquis iT OEE

Offers a weak-point analysis

4.6.5 Acquis iT energy

This module can be used to acquire energy consumptions throughout the plant,
visualize as curves, create energy reports, form limit values and shutdown spe-
cific process units.

4.7 High integration within the entire system platform

Plant iT has a central database.
Plant iT has central user management.
Plant iT has central event logging.
Plant iT offers seamless integration, even of complex functions.

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 The development of the Plant iT process control system
High integration within the entire system platform

5 The development of the Plant iT process control sys-

tem

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 Scalability of Plant iT
Single-user system

6 Scalability of Plant iT

Plant iT is scalable and thus suited for use in both small and large plants.

6.1 Single-user system

6.1.1 Components

1 server with
1 integrated client
1 controller (if necessary, also soft PLCs)

6.1.2 Available for Plant iT Version 90

Direct iT
Liqu iT or brewmaxx

Note
Only for "XS" dimensioning
max. 100 automation points
max. 1,150 data points

Note
Single-user solutions under Windows7 cannot be extended
Not available for Batch iT

6.1.3 Supported operating systems

Note
The supported operating systems are described in the current "Release Notes" for the
associated process control system version

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 Scalability of Plant iT
Client/server system (single-server)

6.2 Client/server system (single-server)

Note
This is the most commonly used configuration and the one that we recommend.

6.2.1 Components

1 dedicated server
1 or more clients
1 or more controllers (if necessary, also soft PLCs)

6.3 Multi-server system

A multi-server system is the corporate solution.

A multi-server system consists of several area servers and a central database
server for integration in higher-level IT systems.

6.3.1 Components

1 database server
2 or more area servers
Several clients, and
Several controllers

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 Distribution of functions: Client – Server – PLC
Multi-server system

7 Distribution of functions: Client – Server – PLC

Plant iT is a PLC-based process control system that uses the Microsoft platform
to implement its client-server architecture. This architecture and the central, da-
tabase-supported configuration form the basis for the almost unrestricted scala-
bility from the single-user system through to the multi-server system.
The most important application for the parameterization, operation, and monitor-
ing are assigned to the stations here.

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 The technical basis of Plant iT
Multi-server system

8 The technical basis of Plant iT

Plant iT has a comprehensive client/server architecture.

Plant iT requires MS Windows as the operating system for the servers and
clients.
Plant iT uses MS SQL Server as its system database.
MS Excel is used as the analysis, reporting, and engineering tool (system and
application parameterization).
C# is the development environment for system components.

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 Technical key data
Quantity framework

9 Technical key data

Note
The current technical key data and system requirements can be found in the current
"Release Notes".

9.1 Quantity framework

9.1.1 Servers, workstations, and PLCs

At least 1 server and 1 workstation

Number of workstations not technically limited
Controllers (PLCs)
Number of PLCs not technically limited
The communication method can be selected

9.1.2 Data capacity

Number of data points practically unlimited

Recording rate > 1/s

9.2 IT hardware

Note
The current technical key data and system requirements can be found in the current
"Release Notes".

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 Technical key data
Communication interface

9.3 Communication interface

9.3.1 Ethernet

ISO over TCP IP (RFC1006)

OPC Server
PROFINET

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 Summary
Highlights

10 Summary

10.1 Highlights

10.1.1 Visu-Recorder (optional add-on)

Processes from the past can be played back by the normal visualization
system, similar to a video.
High transparency and good diagnostic capabilities for complex processes.
The period and the playback speed can be selected flexibly.

10.1.2 Process management with material reference

Plant iT material
Parameterization of storage structures
Master data administration for materials and storage locations
Stock management

10.1.3 Integrated production data management

Production data acquisition including

Standard reports
Curve representation
Data import/export and
Archiving

can be deployed for

Industrial applications and
Associated areas of the discrete manufacturing
Coverage of hybrid processes with a consistent system

10.2 Main characteristics of Plant iT

Client/server system
-> scalable

Object-oriented
-> modern software architecture

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 Summary
Main characteristics of Plant iT

One central real-time database

-> simplification for updating, extending and creating the reports

Compiler-less software architecture

-> extensions can be performed during running operation without needing to
stop the plant

Complete logic in the PLC

-> plant and process continue to run without server connection

Open system
-> customer-specific extensions can be realized without problem

Multiplatform
-> PLCs from Siemens and Rockwell can be deployed under one server and
one plant configuration

Visualization with vector graphics

-> graphics can be zoomed Central operation using the Operation Manager
-> touch operation supported

Central operation from the Operation Manager

-> no switch between different applications required
-> clear alarming

Process screen designer integrated in the system

-> no dependency on third-party software
-> simple process screen creation using drag-and-drop functionality
-> central storage of the process graphics in the database

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 Exercises
Main characteristics of Plant iT

11 Exercises

1. Which components belong to the Plant iT process control system?

2. Which tasks do the individual process control system components have?

3. What are the main characteristics of the Plant iT process control system?

4. Which requirements must be fulfilled so that the Plant iT process control system can be used?

5. Which add-ons are available for Plant iT?

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 Exercises
Main characteristics of Plant iT

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