2009 – Issue 1
IN THIS ISSUE
PlantPAx is the new name for the
Rockwell Automation Process
Control System. It brings together
our core control and visualization
technologies with technology from
acquisitions, such as Incuity, Pavilion
Technologies, ICS Triplex and partners
like OSIsoft and Endress+Hauser into
a single solution.
Key areas of the PlantPAx system include: System Engineering The PlantPAx system further strengthens oursystem engineering environment. It will offerprocess and batch control users a new libraryof reusable control objects with tools tosimplify deployment. A future release willinclude the ability to populate the PlantPAxsystem with modules from multiple plantdesign and engineering tools.
Control and Visualization Platforms Control strategies and accompanyingvisualization are configured using modularand reusable objects, simplifying design,commissioning and maintenance. Continuedadvances around system high availability serve to minimize or eliminate downtime and process disruptions caused by controlsystem modifications.
Performance and Process Optimization The PlantPAx system extends the scope ofprocess optimization to include Fuzzy Logic,basic and advanced process loop tuning and at the high-end a Model Predictive Control (MPC) suite.
Batch and Sequencing Rockwell Automation provides solutions frombasic sequencing to the most complex anddemanding batch applications. The systemadheres to ISA-88 standards and presents ascaleable batch control capability.
Process Safety and Critical Control Process safety capabilities include a broadrange of safety integrity levels (SIL) and fault-tolerance requirements. Solutionsinclude SIL 3 and TMR options.
Asset Management and Device ConnectivityAs an integral element of the PlantPAx systemour asset management solution provides toolsfor disaster recovery, tracking of user actions,regulatory compliance and improving plant-floor security. The solution includesinstrument configuration, diagnostics andcalibration management.
The system integration with digital fielddevices such as HART, Foundation Fieldbusand Profibus PA for the instrumentation andDeviceNet and EtherNet/IP for industrialcontrol devices. This provides integration easewhen used with our device integration toolsdeveloped jointly with Endress+Hauser.Additional asset management capabilitiesinclude controller code change management,vibration monitoring of rotating equipmentand both instrument and industrial devicemanagement with configuration andcalibration records tracking for other plant-wide assets such as drives and motorcontrol centers.
Plant Information
The PlantPAx system allows plant-wide process data management through itshistorian capability (based on the PI Systemfrom OSIsoft). Further, the new FactoryTalkVantagePoint enterprise manufacturingintelligence and reporting software helpsenable aggregation, analysis and display ofplant information.
To find out more, visit us atwww.discover.rockwellautomation.com/thinkingprocess
In this edition of Thinking Process we focus on techniques to optimize plant performance. You will find information on subjects ranging from loop tuning to model predictive control andexamples of the financial savings that can be made.
Rockwell Automation®
Announces PlantPAx
Page 1 Rockwell Automation AnnouncesPlantPAx Process Automation System
Page 2-4 SPECIAL FEATUREProcess Optimization
Page 5 Rockwell Automation andEndress+Hauser Integration Software and Documents
Page 5 FactoryTalk® ViewPoint Web-HMI
Page 5 FactoryTalk AssetCentre Adds DeviceConfiguration and CalibrationManagement Capability
Page 5 FactoryTalk Batch Version 10
Page 6 Six-Polymer Line Project MarksLargest Polymer Deployment in China
UPDATE
IMC Function Block Configuration Example
The IMC Function Block
SP
CV
PV
Disturbance
Estimate
Process Prediction
1st OrderFilter
1st OrderModel
Inverse ofModel
Process
Process
Disturbance
–
–
2
Concentration
Time
CVPVTime Constant
63%
300250200150100
500
0 20 40 60 80 100
Deadline
Economic Benefits
The IMC algorithm gives more accurate
control of the chemical concentration to
target value. This reduces the cost of
chemicals whilst still meeting specification.
RSTune & RSLoop OptimizerRSTune® and RSLoop Optimizer™ are critical tools
for increasing your product quality. Having your
loops optimized reduces inconsistency, thereby
improving the quality of your product. Better
control means more accurate material
management and less off-specification product,
increasing your profits and reducing energy costs.
RSTune is a sophisticated tuning package that will
optimize your PID loops. It automatically
calculates the best PID values for your application
and supplies you with powerful tools to increase
profitability. RSLoop Optimizer has additional
tools to allow you to identify potential process
equipment deficiencies, analyze valve wear and
optimize more complex loops.
Example – Chemical Dosing
In this example a chemical is dosed into a water
flow with the goal of meeting a certain
concentration. There is a significant delay
between the injection point and the measuring
point. Traditional PID algorithms don’t cope
very well with the delay and typically lead to a
sluggish response or oscillations.
The graph below shows how the process
responds to a step change. The dead-time of
the loop is much larger than the time constant.
In this example, the new Logix Internal Model
Control (IMC) instruction will typically give a
much better response than PID.
The IMC function block controls a single
process variable by manipulating a single
control-variable output. This function block
performs an algorithm where the actual error
signal is compared against that of an internal
first-order lag plus dead-time model of the
process. The IMC function block calculates the
control variable output based on the deviation
from the internal model.
Logix V17 Advanced Process Control – Internal Model Control (IMC)PID is the ‘standard’ solution for most control loops, but it is not a good algorithm for certain
applications. If PID is not suitable for the application no amount of tuning will make the loop
operate efficiently, other techniques like Internal Model Control (IMC) are required.
Other Logix APC Instruction
CC – Coordinated Control
• The CC function block controls
a single process variable with up to
three control variables which need to
act in a coordinated manner
• It is good for situations where multiple
outputs are available for control, and costs
need to be minimized
MMC – Modular Multivariable Control
• The MMC function block controls two
process variables with up to three
control variables
• It is good for situations where there is
significant interaction between the various
control variables and process variables
Application Example and Economic Benefit
For more information, visit:
www.rockwellautomation.com/rockwell
software/design/rslogix5000/
Instruction Application Economic Benefit
Dissolved oxygencontrol bycontrolling flowrate, agitator and air flow
Distillation column bycontrollingcomposition,reflux ratio, steamflow, pressure
CC
MMC
Reduced energycostsIncreased yield
IncreasedthroughputIncreased product to specification
To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess
3
FactoryTalk VantagePoint – Business Intelligence Software FactoryTalk VantagePoint is based on innovative business intelligence software from Incuity,
integrated into the FactoryTalk environment. Business Intelligence Software, such as FactoryTalk
VantagePoint, can help increase productivity by providing workers at every level in the enterprise
with new insight into the manufacturing process to help them to make better decisions. For example:
• At the line level people need to understand how equipment is performing to be able to make
decisions on streamlining operations, and improving efficiency and throughput
• At the plant level people need to understand production as it relates to the customer, so that
they can make intelligent decisions about procurement, production scheduling and shipping
• At the enterprise level people need to see production in its larger business context, and to
understand the impact of fluctuating costs, changing market conditions and asset performance
to make the right decisions about what to make and where
For more information, visit:
www.rockwellautomation.com/rockwellsoftware/performance/vantagepoint/
So how much could you gain from
improving your control system?
Applying Pavilion Technologies’ Model
Predictive Control to a bioethanol plant
reduced energy costs by 2-4% and reduced
variability of product quality by more
than 50%.
Business Intelligence software from Incuity
EMI (a Rockwell Automation Company)
helped a leading speciality chemical
producer to improve efficiency, saving
approximately $300,000 per year.
Rockwell Automation has a range of
solutions to address different needs; some
of them are shown here.
Efficiency losses can be found in any number of
points throughout your process plant. A poorly
performing control loop on a critical piece
of plant can waste energy, waste expensive
raw materials and reduce yield. It has been
estimated that approximately three-quarters of
all control loops are performing below peak
efficiency. Most process plants have multiple
interacting control loops and optimizing each
one individually will not optimize the entire
process. For these applications a more
sophisticated approach such as Pavilion
Technologies’ (a Rockwell Automation
Company) Model Predictive Control
solution is required.
Optimizing control loops is only part of the
story. There are many other areas that require
attention – shortening material addition times,
reducing cycle times and changeover times in
batch manufacturing. You need tools to be able
to pull together the relevant information and
analyze it to find inefficiencies.
Application Example and Economic Benefit
A major paint manufacturer installed Incuity
software to help increase production whilst
reducing costs. The system provided deep
insight into their batch processes and
facilitated information-sharing among the
production and supervisory staff so they
could better monitor production in their
appropriate contexts.
The result has been that within a few months
they have been able to improve production
performance by more than 20% whilst
reducing costs by $500,000 a year.
Process Optimization
Process Optimization is a very important subject in today’s economic climate. It is essential to run your plant as efficiently
as possible to maximize profitability, but how do you know if your system is running at the maximum efficiency? Do you
have the tools to analyze the performance? And do you have a control system that is capable of delivering optimum
performance? In this article we examine a number of techniques from tuning PID loops to Business Intelligence Software
to help you maximize your profits.
To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess
Features
• Hybrid modeling based on
empirical data, first principles
equations, operator
knowledge or any
combination
• Patented, Extrapolated
Gain Constrained Neural
Networks (EGCNN) to ensure
model accuracy beyond the
normal operating range
• Incorporates changing
process dynamics
(dead-time, time constants
and gains) over wide process
operating ranges
Benefits
• Improves product quality
through faster response to
target changes or large
process disturbances
• Expedites deployment by
using all available
information to create
accurate models
• Improves product quality
and flexibility for new grade
and product development
4
Economic Benefits
• Reduce cycle times through faster
response of the control loop
• Reduce energy usage
Application Example and Economic Benefit
Chemical Manufacturer
• Increase prime product yield
by 4.5%
• Reduced variance in product
properties by 35%
• Decreased reactor variability
by 30%
• Reduced waste by 300
tons year
• Reduced frequency of lab
samples by 50%
Ethanol Producer
• Increased Ethanol production
capacity 3-10%
• Increased ethanol yield
by .1-.2%
• Reduced energy use/gallon
by 2-4%
• Reduce compliance risk
Logix – Fuzzy LogicFuzzy Logic is a technique that attempts to
systematically and mathematically emulate
human reasoning and decision-making.
Fuzzy control solutions are especially useful
for complex systems where standard means
such as PID control don’t give the required
level of control. Your operators may already be
‘tweaking’ the process for different conditions
but this can be unreliable.
The Fuzzy Logic tools can be applied to a
wide variety of applications. The following
example is a simple application to adjust gains
in a temperature control loop for a reactor.
Example – Reactor Temperature Control
A reactor is heated to a particular temperature
to produce a product. This may sound
straightforward but if the reactor is used for
different sizes of batches the performance of
the temperature loop will vary significantly
depending on how full the reactor is. If the
loop is tuned when the reactor is half full it
may experience problems at different levels.
It would have a sluggish response when
completely full and may oscillate when only
part filled. Clearly you could write a program
to vary the gains with level but this could
become complicated to ensure you don’t get
disruptions to the process.
Fuzzy Logic provides a tool set to take the
knowledge about how the gains should
be varied and use it to more accurately
control the process. This is done by
continuously adjusting the gains rather with
a step change which is often seen in existing
applications. By doing this it is possible to
avoid the process disruptions that would
otherwise occur.
Pavilion Technology – Model Predictive ControlPavilion Technologies’ Model Predictive
Control (MPC) technology is an intelligence
layer on top of basic automation systems that
continuously drives the plant to achieve
multiple business objectives – cost reductions,
decreased emissions, consistent quality and
production increases – every production
minute. It continuously assesses current and
predicted operational data, compares them to
desired results and computes new control
targets to reduce in-process variability and
improve process performance.
For more information, visit:
www.pavtech.com
To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess
Rockwell Automation andEndress+Hauser IntegrationDocuments and Add-onInstructions Available for DownloadRockwell Automation and Endress+Hauser
have released documentation and Add-on
instructions for HART devices connected to
1756 I/O. The information includes a step-by-
step approach to integrating Endress+Hauser
instruments, including information on
hardware, software, configuring messaging
and asset management software.
You can download the documents and
Add-on instructions from:
www.rockwellautomation.com/solutions/
process/integrationdocs.html
The first phase includes documents for the
following instruments:
• Promass 83 Coriolis Mass Flow
• Promag 53 Electromagnetic Flow
• Prowirl 73 Vortex Flow
• Proline t-mass 65 Thermal Flow
• Levelflex M Guided Radar Level
• Micropilot M Radar Level
• Prosonic M Ultrasonic Level
• Prosonic S Ultrasonic Level
• Liquiline M for Liquid Analysis
• Cerabar S Pressure
• Deltabar S Differential Pressure
• iTEMP TMT 162 Temperature
• iTEMP TMT 182 Temperature
Documentation for Profibus PA via the EN2PA
modules and Flex™ I/O HART is in progress and
will be available early 2009.
Manufacturers now can remotely monitor their
plant-floor operations status using FactoryTalk
ViewPoint software from Rockwell Automation.
FactoryTalk ViewPoint software is one of the first
commercially available, thin-client applications
for manufacturing, built using the new
Microsoft Silverlight technology. The initial
release extends visualization and real-time
decision capabilities beyond FactoryTalk View
clients to browser-based remote users.
FactoryTalk ViewPoint software supports fully
scalable and animated Web displays of existing
FactoryTalk View Site Edition (SE) visualization
software and Allen-Bradley® PanelView™ Plus
applications from the office, home or on the road
via any Internet browser. While the initial release
is Internet Explorer (IE) compatible, additional
browser and device support is planned.
For more information, visit:
www.rockwellautomation.com/rockwell
software/performance/viewpoint/
Internet Explorer Firefox
Mobile Devices
Safari
FactoryTalk ViewPoint Web Clients
FactoryTalk ViewPoint ServerFactoryTalk View SE Server 1 FactoryTalk View SE Server 2
ControlNetwork
InformationNetwork
FactoryTalkView SE Client
5 To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess
FactoryTalk ViewPoint Web-HMI
FactoryTalk AssetCentreAdds Device Configuration and CalibrationManagement CapabilityThe latest release of AssetCentre now includes
the capability to configure and manage
process devices. The solution, jointly
developed with Endress+Hauser is based on
FDT/DTM technology. AssetCentre is an FDT
frame application capable of supporting a
wide variety of process instruments and other
field devices through plug-in drivers (DTMs)
from device manufacturers. This capability
enables online access to device configurations,
device troubleshooting and diagnostics.
Calibration Management capability has also
been added into FactoryTalk AssetCentre. The
software tool is used to efficiently manage
calibration activities that are associated with
process devices. This is useful for enabling
regulatory compliance and good
manufacturing practice.
It allows the user to:
• Schedule calibrations
• Manage calibration standards
• Manage certifications
• Document as found/as left information and
automatically calculates tolerance
• Perform paperless calibrations
For more information, visit:
www.rockwellautomation.com/rockwell
software/assetmgmt/assetcentre/
FactoryTalk Batch Version 10Version 10 of FactoryTalk batch has seen anumber of enhancements to improveproductivity, reduce costs, and simplify recipedevelopment. Enhancements include:
• Smart Binding – Configurable real-timedynamic unit selection for optimal procedural flow
• Timer Steps – Reduce engineering andvalidation effort through use of product timer steps
• Recipe SFC Structure Validation – Testprocedures for recipe structure errors
• Improved Client Capabilities – Simplifiedcontrol recipe configuration options
• RSLinx® Classic OEM – Now included withevery FactoryTalk Batch and Back-up key license
For more information, visit:
www.rockwellautomation.com/rockwellsoftware/production/batch/
6Publication No. PROCES-SA001A-EN-E February 2009
Baseline MPC
108 %
106 %
104 %
102 %
100 %
98 %
96 %
94 %
917.4 918.6 919.2 919.8 920.4 921 921.6918
Before MPCAfter MPC
y
Six-Polymer Line ProjectMarks Largest PolymerDeployment in China The highly dynamic polymer industry presents
major challenges such as high operating
costs, increasing raw materials costs and
growing local and global competition.
In order to maintain its competitive standing
and meet China’s growing market demands,
SECCO defined a long-term strategy of
increasing production rates, reducing costs,
and improving product quality for its six
polymer lines.
Events ACHEMA 2009
ACHEMA is the leading international event
for chemical engineering, environmental
protection and biotechnology in Frankfurt –
11 May to 15 May 2009. At the last event, held
in 2006, around 180,000 professionals from 98
countries attended to find out more about the
latest developments and trends.
This year we will be showcasing the
PlantPAx process automation system and
demonstrating the continued expansion
of the system based on a combination of
the core Rockwell Automation Integrated
Architecture™ technologies and those
leveraged from co-investments with partners
and acquired companies. The PlantPAx process
automation system has built strong interest for
a range of applications across consumer and
resource-based industries.
SECCO chose Pavilion Technologies who
implemented its Pavilion8® Polymer Reactor
and Extruder (MPC) control applications, an
integrated software suite combining powerful
technology for modelling, control, monitoring,
analysis, visualization and integration, to
provide targeted solutions and deliver faster
time-to-value than alternative solutions.
With the help of Pavilion8, SECCO quickly
maximized production rate and quality,
reduced transition time and material costs,
and improved its ability to adapt to changing
market demands and conditions.
Due largely to the success of Pavilion’s
real-time Virtual Online Analyser® (VOA)
coupled to the control and optimization
strategies, Shanghai SECCO Petrochemicals
quickly achieved project goals and realized
a major return on investment in just
four months.
The benefits of Pavilion’s Polymer Solution
directly translates into reduced costs and
improved revenue potential for SECCO,
allowing the plant engineers to better react to
shifting market conditions and growing
market demands. The stability and robustness
of the solution is evident in the 97% control
utilization rate. To sustain benefits and
further leverage the solution, SECCO has
signed a three-year maintenance and support
contract for Pavilion to optimize all six of the
polymer lines.
Economic Benefits
• Increased production capacity by 4%
on average
• Decreased reactor variability by 20%
• Improved product consistency by 35%
on average
• Achieved standard operations
on transitions
• Reduced the reactor purge and cost
Density
1.5
Before MPCAfter MPC
1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4
Variation in Melt Flow Rate
Low Density Polyethylene (LLDPE) Production Capacity