Achieving Process

Automation Excellence

-System & Solutions Overview

- March 2009

EXTERNAL, CUSTOMER VERSION:PROCES-SP027A-EN-E

Copyright © 2008 Rockwell Automation, Inc. All rights reserved.

Delivering process solutions with leading customers

Oil
Oil&&Gas
Gas Food
Food&&Beverage
Beverage Household
Household&&Personal
PersonalCare
Care Life
LifeSciences
Sciences

React Satisfy
Satisfyconsumer Meet
Meetregulatory Reduce
Reducecosts
costswhile
Reacttotochanging
changing consumer regulatory while
production demand,
demand,while challenges
challenges&&improve meeting
meetingthethedemands
productionconditions
conditions reducing
while
costs, quality,
improve
consistency,
demands
ofofever-changing
while maintaining
while maintaining reducing costs, quality, consistency, ever-changing
minimizing
minimizingwaste
waste&& flexibility
flexibility&& regulations.
regulations.
operations
operationsatatpeak
peak improving
improvingasset
asset time-to-market.
time-to-market.
efficiency. • •Abbott
efficiency. performance.
performance. AbbottLaboratories
Laboratories
• •ConocoPhillips • •3M
3M • •EliEliLilly
ConocoPhillips • •Anheuser-Busch Lilly
Anheuser-Busch • •Beiersdorf • •Johnson
• •Exxon/Mobil
Exxon/Mobil • •Coca-Cola
Coca-Cola
Beiersdorf Johnson&&Johnson
Johnson
• •CNOOC • •Colgate-Palmolive
Colgate-Palmolive • •Merck
CNOOC • •Kellogg
Kellogg Merck
• •CNPC • •DuPont
DuPont • •Pfizer
CNPC • •Kraft/Nabisco
Kraft/Nabisco Pfizer
• •Shell • •Henkel
Henkel
• •M&M • •Sanofi
Shell
• •PDVSA M&MMars
Mars • •Kimberly-Clark Sanofi
PDVSA • •Nestlé Kimberly-Clark • •Wyeth-Ayerst
Nestlé • •L’Oréal Wyeth-Ayerst
• •Chevron
Chevron • •PepsiCo/Frito-Lay L’Oréal
PepsiCo/Frito-Lay • •Procter
• •BP
BP • •SABMiller Procter&&Gamble
Gamble
SABMiller • •Unilever
•Sinopec
•Sinopec Unilever
•Petronos
•Petronos
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Use Only)
2008 CopyrightAutomation,
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Inc. Automation, Inc. All rights reserved.
All rights reserved. 4
Delivering process solutions with leading customers

Water
Water/ /Wastewater
Wastewater Mining
Mining/ /Metals
Metals/ /Cement
Cement Pulp
Pulp&&Paper
Paper

Achieve
Achievelow Execute Increase
Increaseproduction
productionand
low Executereal-time
real-time and
long
long‑termcost
‑ term cost&& control & maintain quality while reducing
quality while reducing
on-demand control & maintain
on-demandengineering
engineering critical
criticalprocess
process
risk
risk&&total
totalcost
costofof
expertise
expertise withscalable
with scalable ownership
ownershipbybyusing
usingaa
parameters
parameterstotorespond
respond
solutions.
solutions. single automation
single automation
totocustomer demands.
customer demands. control
• •AA&&EEFirms control&&information
information
Firms • •Alcoa infrastructure.
infrastructure.
• •Consultants
Consultants Alcoa
• •Design • •BHP
BHPBilliton
DesignEngineer
EngineerFirms
Firms • •CEMEX
Billiton • •Kimberly
KimberlyClark
Clark
• •Design Institutes (Asia) CEMEX • •International
InternationalPaper
Paper
Design Institutes (Asia) • •Holcim
• •Global • •Abitibi Bowater
GlobalMunicipalities
Municipalities Holcim
• •Lafarge
Abitibi Bowater
• •Procter
• •Privatizers
Privatizers(Europe)
(Europe) Lafarge Procter&&Gamble
Gamble
• •Rio • •Weyerhaeuser
• •Pump OEMs
Pump OEMs RioTinto
Tinto Weyerhaeuser
• •US Gypsum • •Georgia
GeorgiaPacific
Pacific
• •System
SystemIntegrators
Integrators US Gypsum
• •Vulcan • •Domtar
Domtar
Vulcan

We
Wehave
haveexpertise
expertiseininyour
yourindustry
industry&&your
yourapplication!
application!
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Inc. Automation, Inc. All rights reserved.
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 The Essentials

PlantPAx represents:
1. A scalable portfolio unifying the Rockwell Automation
investments that enhanced process technologies, solutions and
services
2. A Process Control core based on the widely adopted Rockwell
Automation Integrated Architecture technologies for plant-wide
control
3. A core system with defined performance, i.e. a “characterized”
system
4. Accompanying tools and utilities that accelerate the
implementation of a process automation system
5. And, a healthy road map of planned new features, enhancements
and expansion of system capacities

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 9

 Automation for the Process Industry

System Core
Field Device Process
Information
Integration & Asset
Management

Critical Control &

Batch Management Safety
& Control

System Tools Strategic Partners

& Utilities

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 10

 Centralized Engineering

• Simplified Configuration Effort

• Single Starting Point
• Synchronization w/ Running System
• Modularity & Reuse
• Library for Managing Reusable Logic
• Copy/Paste; Drag/Drop;
XML-based Import/Export
• Complete Toolset
• System View, Logic Editor, HMI
Designer, Batch Configuration,
Process Networks, etc…

Library Extension Configuration Mgmt Engineering Efficiency

Coming
• Manage HMI objects • Unified Search & • Synchronize with
Soon
• Revision Mgmt Deploy multiple design tools

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 13

 Rich Visualization

• Operator Effectiveness
• Right information, right time
• Alarm management solutions
• Pervasive Access to Information
• Displays, Alarms, Historical Trends,
Batch Status, etc. via Thick, Thin, or
Web-based Clients
• Scalable, Extensible Architecture
• From stand-alone, single unit,
industrially hardened
• To large, distributed multi-server
multi-client plant wide solutions

Alarm Management System-wide Focus

Coming • Simple Alarm Reports • Additional Supported Topologies
Soon • Sub-system guidelines based on • Continued Integration Focus
industry standards

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 14

 Powerful Process Control
Supervisory
• Production Optimization Model-based
Control
• Portfolio of Process Optimization
Capabilities
Fuzzy Logic
• Open & Closed Loop Auto-tuning
• Advanced Regulatory and Unbounded
Fuzzy Logic Supervisory Control
• Linear & Nonlinear Multivariable Logix APC &
Loop Tune
Model-Predictive Control, Real-time
Economic Optimization
• Broad Control Platform
• Choice of controller & I/O offerings –
mix & match – choose the right
solution
• Multiple Control Disciplines Ongoing focus…
• Continuous, Batch, Discrete, Motion, • Configuration Enhancements for
Safety, Drive Control – One Platform improved modularity & reuse
• Function Block, Sequential Function • Additional platforms – put more in a
Chart, Structured Text, Ladder Logic single controller, or pick smaller
controllers & distribute your system

Copyright
Copyright ©© 2008Rockwell
2008 Rockwell Automation,
Automation, Inc. AllAll
Inc. rights reserved.
rights reserved. 15
 Process Visualization Bundles

Current
CurrentFocus
Focus PlantPAx EWS
Engineering Workstation
PlantPAx PASS PlantPAx OWS
Process System Server Operator Station

• Typically Required
Engineering Software

• Visualization Server • Visualization • Workstation Computer

Software Client Software Hardware

• Server Computer Hardware • Workstation

Computer Hardware

Pre-package system software on PC hardware to reduce

project risk
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 16
 And To Ensure System Performance…

Process
ProcessCharacterization
CharacterizationLab
Lab
• A system is considered “working”
when it is performing at a
specified level within established
system boundaries
• How do we determine the System
Performance?
• Implement a specified
architecture class
• Define system boundaries
(loading)
• Measure the system’s response

• This is “characterization.”

An ongoing effort to ensure Process System performance levels

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 32
 System Tools and Utilities

• In support of Design & Development the Rockwell Automation

PlantPAx system comprises:
• A Process Device Library of Logix Add-On Instructions and View
faceplates for commonly used process devices
• Logix Add-On Instructions, View faceplates and Documentation
that simplify the integration of Endress+Hauser HART
instrumentation with PlantPAx Process Automation System
• And….a suite of utilities to help convert legacy DCS platforms to
PlantPAx Process Automation System

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 34

 Our Library Philosophy

Included System Custom

Library Hierarchy in base Add-On Purchase Example
system
• Mixer/Reactor,
Standard Applications etc…

• Level control,
temperature
Control Strategies control, etc.

• Devices (valve,
Control Modules motor,
(Base Library) transmitter, etc.)

• Logix5000
Logix Instructions and Function Blocks
View Tools • Graphical Objects
and Templates

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 35

 Base Process Library
A high-efficiency suite of Control Modules
• Mode Selection
• Standard Alarm
• AI w/ Scaling & Alarms
• DI w/ Alarms
• Single-Speed Motor
• Permissives with Bypass
• Protectives with First-Out,
Bypass
• Run Time and Start
Accumulator
• Re-start Inhibit for Large Motor
• Date/Time Blocks
• Hand-Operated Valve
Monitor
• Hand-Operated Motor
Monitor
• Cascade and Ratio
supported PID
• Advanced AI with High
Rate of Change Alarm,
Square Root Extraction,
and Deviation Alarms
• 2-Speed Motor
• Reversing Motor (e.g., FVR)
• Pulse-Input flow meter dosing
with pre-act and in-flight
adjustment
• Analog-Input flow meter
dosing as above
• Weigh-Scale dosing (Loss-In-
Weight and Gain-In-Weight
supported)
• Controller CPU Utilization
• Solenoid-Operated 2-state
Valve
• Motor-Operated 2-state
Valve
• PIDE-based PID with
Standard Modes and
Deviation Alarms
• Analog Output
• Variable-Speed Drive
(e.g., PF70-style)
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 36
 Rockwell Automation and Endress+Hauser
Preferred Integration of HART Instrumentation
Instrument Display
Instrument & Faceplates
Function Block

• Documentation for setup and

operation
• AOIs for 2-way exchange of data
between View and ControlLogix
• View faceplates for instruments
connected to ControlLogix HART I/O

Integration of E+H fieldbus instruments in progress…

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 37
 Legacy DCS Conversions to PlantPAx

Reduce risk of converting legacy DCS to PlantPAx

• Where possible, preserve engineering investments in legacy DCS
• Reduce production interruptions during conversion

Tier 1: Replace systems from 1970s-80s that are

likely to fail from component failure
> Reduce operations risk

Tier 2: Move customer away from systems

introduced in late 80s, early 90s; Limited,
Why? expensive spares Conver
> Reduce operations risk t to

Tier 3: Migrate systems from older technologies;

Provide process enhancements or expansions for
plantwide automation
> Reduce operations risk

• Continued enhancement of tools:

What’s – E.g., Extract and convert operator graphics to
next? preserve operator interaction with consoles

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 38

 Which legacy DCS systems
are we converting to PlantPAx?
• Tier 1: Replace systems introduced in 1970s-80s
• Bailey Net90 and Infi90
• Honeywell TDC 2000, TDC 3000, TPS
Apply tools and
• Emerson (Fisher Controls) PROVOX methodologies
• Invensys (Foxboro) I/A

• Tier 2: Move customer away systems introduced in late 1980s, early 90s
• Siemens Moore APACS
• Emerson (Rosemount) R/3 Apply tools and
methodologies
• Others

• Tier 3: Migrate systems from older technologies

• DCS platforms from ABB
• Invensys Apply tools and
methodologies
• Honeywell
• Emerson

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 39

PlantPAx System Architecture

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 46