PlantPAx EXTERNAL Presentation

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

Achieving Process Automation Excellence

-System & Solutions Overview

- March 2009

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

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 4(Confidential – For Internal Use Only) Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 4

Satisfy consumer demand, while reducing costs, minimizing waste & improving asset performance.

• Anheuser-Busch• Coca-Cola• Kellogg• Kraft/Nabisco• M&M Mars• Nestlé• PepsiCo/Frito-Lay• SABMiller

Satisfy consumer demand, while reducing costs, minimizing waste & improving asset performance.

• Anheuser-Busch• Coca-Cola• Kellogg• Kraft/Nabisco• M&M Mars• Nestlé• PepsiCo/Frito-Lay• SABMiller

Food & BeverageFood & Beverage

Delivering process solutions with leading customers

Meet regulatory challenges & improve quality, consistency, flexibility & time-to-market.

• 3M• Beiersdorf• Colgate-Palmolive• DuPont• Henkel• Kimberly-Clark• L’Oréal• Procter & Gamble• Unilever

Meet regulatory challenges & improve quality, consistency, flexibility & time-to-market.

• 3M• Beiersdorf• Colgate-Palmolive• DuPont• Henkel• Kimberly-Clark• L’Oréal• Procter & Gamble• Unilever

Household & Personal CareHousehold & Personal Care

Reduce costs while meeting the demands of ever-changing regulations.

• Abbott Laboratories• Eli Lilly• Johnson & Johnson• Merck• Pfizer• Sanofi• Wyeth-Ayerst

Reduce costs while meeting the demands of ever-changing regulations.

• Abbott Laboratories• Eli Lilly• Johnson & Johnson• Merck• Pfizer• Sanofi• Wyeth-Ayerst

Life SciencesLife Sciences

React to changing production conditions while maintaining operations at peak efficiency.

• ConocoPhillips• Exxon/Mobil• CNOOC• CNPC• Shell• PDVSA• Chevron• BP•Sinopec•Petronos

React to changing production conditions while maintaining operations at peak efficiency.

• ConocoPhillips• Exxon/Mobil• CNOOC• CNPC• Shell• PDVSA• Chevron• BP•Sinopec•Petronos

Oil & GasOil & Gas

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 5(Confidential – For Internal Use Only) Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 5

Execute real-time control & maintain critical process parameters to respond to customer demands.

• Alcoa• BHP Billiton• CEMEX • Holcim• Lafarge• Rio Tinto• US Gypsum• Vulcan

Execute real-time control & maintain critical process parameters to respond to customer demands.

• Alcoa• BHP Billiton• CEMEX • Holcim• Lafarge• Rio Tinto• US Gypsum• Vulcan

Mining / Metals / CementMining / Metals / Cement

Achieve low long‑term cost &on-demand engineering expertise with scalable solutions.

• A & E Firms• Consultants• Design Engineer Firms• Design Institutes (Asia)• Global Municipalities• Privatizers (Europe)• Pump OEMs• System Integrators

Achieve low long‑term cost &on-demand engineering expertise with scalable solutions.

• A & E Firms• Consultants• Design Engineer Firms• Design Institutes (Asia)• Global Municipalities• Privatizers (Europe)• Pump OEMs• System Integrators

Water / WastewaterWater / Wastewater

Increase production and quality while reducing risk & total cost of ownership by using a single automation control & information infrastructure.

• Kimberly Clark• International Paper• Abitibi Bowater• Procter & Gamble• Weyerhaeuser• Georgia Pacific• Domtar

Increase production and quality while reducing risk & total cost of ownership by using a single automation control & information infrastructure.

• Kimberly Clark• International Paper• Abitibi Bowater• Procter & Gamble• Weyerhaeuser• Georgia Pacific• Domtar

Pulp & PaperPulp & Paper

We have expertise in your industry & your application!We have expertise in your industry & your application!

Delivering process solutions with leading customers

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

The Essentials

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

PlantPAx represents:PlantPAx represents:


Automation for the Process Industry

Process Informatio

n

System CoreField Device Integration &

Asset Management

Batch Management

& Control

Critical Control & Safety

Strategic PartnersSystem Tools& Utilities


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…

13

Coming Soon

Library Extension

• Manage HMI

objects

• Revision Mgmt

Configuration

Mgmt

• Unified Search &

Deploy

Engineering

Efficiency

• Synchronize with

multiple design

tools


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

14

Coming Soon

Alarm Management• Simple Alarm Reports

• Sub-system guidelines based

on industry standards

System-wide Focus• Additional Supported

Topologies

• Continued Integration Focus

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 15Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 15

Powerful Process Control

• Production Optimization

• Portfolio of Process Optimization Capabilities

• Open & Closed Loop Auto-tuning

• Advanced Regulatory and Unbounded Fuzzy Logic Supervisory Control

• Linear & Nonlinear Multivariable 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

• Continuous, Batch, Discrete, Motion, Safety, Drive Control – One Platform

• Function Block, Sequential Function Chart, Structured Text, Ladder Logic

15

Ongoing focus…• Configuration Enhancements for

improved modularity & reuse

• Additional platforms – put more in a single controller, or pick smaller controllers & distribute your system

Logix APC & Loop Tune

Fuzzy Logic

Supervisory Model-based Control


Process Visualization Bundles

PlantPAx PASS

Process System Server

• Visualization Client Software

• Workstation Computer Hardware

PlantPAx OWS

Operator Station

PlantPAx EWS

Engineering Workstation

• Typically Required Engineering Software

• Workstation Computer Hardware

• Visualization Server Software

• Server Computer Hardware

Pre-package system software on PC hardware to reduce project risk

Pre-package system software on PC hardware to reduce project risk

Current FocusCurrent Focus


And To Ensure System Performance…

An ongoing effort to ensure Process System performance levels

• 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.”

Process Characterization Lab

Process Characterization Lab


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


Our Library Philosophy

Standard Applications

Control Modules(Base Library)

Logix Instructions and View Tools

Control Strategies

Included in base system

System Add-On

Custom Purchas

e

Library Hierarchy

• Devices (valve, motor, transmitter, etc.)

• Level control, temperature control, etc.

• Mixer/Reactor, etc…

• Logix5000 Function Blocks

• Graphical Objects and Templates

Example


Base Process LibraryA 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

• 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)

• 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

• 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


Rockwell Automation and Endress+HauserPreferred Integration of HART Instrumentation

• 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

Instrument Function

Block

Instrument Display &

Faceplates

Integration of E+H fieldbus instruments in progress…


Reduce risk of converting legacy DCS to PlantPAx• Where possible, preserve engineering investments in legacy DCS• Reduce production interruptions during conversion

Legacy DCS Conversions to PlantPAx

Why?

• Continued enhancement of tools:

– E.g., Extract and convert operator graphics to preserve operator interaction with consoles

What’s next?

Tier 2: Move customer away from systems introduced in late 80s, early 90s; Limited, expensive spares> Reduce operations risk

Tier 3: Migrate systems from older technologies; Provide process enhancements or expansions for plantwide automation> Reduce operations risk

Tier 1: Replace systems from 1970s-80s that are likely to fail from component failure> Reduce operations risk

Convert to


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

• Emerson (Fisher Controls) PROVOX

• Invensys (Foxboro) I/A

• Tier 2: Move customer away systems introduced in late 1980s, early 90s• Siemens Moore APACS

• Emerson (Rosemount) R/3

• Others

• Tier 3: Migrate systems from older technologies

• DCS platforms from ABB

• Invensys

• Honeywell

• Emerson

Apply tools and methodologies




PlantPAx System Architecture

PlantPAx EXTERNAL Presentation

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