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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Rev 5058-CO900C

PROCESS SKID INTEGRATION SOLUTIONS

Damon SepeRockwell Automation Process OEM- Business Development [email protected] 2012

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

PROCESS SKID INTEGRATION SOLUTIONSAgenda

Rockwell Automation Resources

Process Control Applications & Equipment

Application Examples

Customer Challenges / Industry Trends

Rockwell Automation Process Control System

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

What Are Process Control Applications ?

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Water Treatment Booster Pumps, Chemical Storage, Effluent Pump, Hypochlorite Generator, Influent Pumps, Solids Handling, Chlorination Systems, Coagulation, Condensing Systems, Dehumidifier, Deionization, De-Mineralization, De-Scaling, Dewatering, Digester, Distillation, Flocculation, Heat Exchangers, Humidifier, Ion Exchange, Membrane Bioreactor, Ozone, Purification, Sedimentation, UV Systems, Well and Lift Pumping Stations

Changing Temperature Autoclaves, Blanchers, Bottle Washers, Burners, Clean in Place, Cookers, Direct Steam, Injection, Dryers, Freeze Dryers, Freezers, Fryers, Furnaces, Heat Exchangers, Kettles, Kilns, Lyophilizers, Ovens, Pasteurizers, Preheaters, Refrigerators, Retorts, Roasters, Scalders, Steam In Place, Sterilizers

Changing Pressure Compressor Systems, Condensation Systems, Fractionation, Lift Stations, Pump Stations, Recovery, Turbine Control Systems

Changing Composition Anodizing, Bioreactors, Duct Burners, Fermenters, Gasification, Neutralization, Plating, Reactor, S.C.R.s, Thermal Oxidizer, Urea Systems

Combining Agitators, Arbitration, Batch Systems, Blending, Dosing, Emulsifiers, Homogenizers, Mixing, Routing, Slurry

Separating Bag Houses, Bar Screens, Centrifuge, Chemical Separation, Chromatography, Clarifiers, Cleaners, Concentrators, Cracking, Cyclones, Distillation Column, Drying, Evaporators, Emulsifiers, Extractors, Filter Presses, Grit Removal, Membrane Filtration, Proportioners, Separators, Shakers, Sludge treatment, Supercritical Fluid, Washers

Specialty Systems Ball Mills, Chemical Delivery, Classifiers, Coating, Enrobing, Extruders, Seasoning, Vacuum Systems, Steam Turbines

Plant Utilities & Building Automation

Boilers, Burner Management, CEMS, Chillers / Coolers, Co-Gen, Combustion Control, Compressor Systems, Cooling Towers, Dust Collectors / Control, Environmental Chambers, Environmental Monitoring, Explosion Protection Systems, Fire and Gas Systems, HVAC, Lubrication Systems, PEMS, Pollution Control Equipment, Refrigeration, Seal water systems

Process OEM Equipment Types by Category / Unit

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MiningWater/Waste Water

Filtration

OEM Skid Equipment Examples

Packaged Boilers

Steam Systems Bio Reactors

Oil & GasChillers


Agenda







Plant & Equipment Operators have shared that today they must leverage their automation investments for continuous improvement at all stages of the plant lifecycle

Production processes must be flexible and efficient, compliant and sustainable

Return on Assets Flexible Operations Innovative Engineering

• Risk Mitigation

• Time To Market

• Supply Chain Efficiency

• Globalizing Footprint

•Sustainable Processes

• Asset Efficiency

• Resource Optimization

• Production Intelligence

• Utilization, Productivity

• Quality, Yield

• Decision Support

• Continuous Improvement

• Safety, Productivity

• Total Lifecycle cost

• Global/ Local Standards

Ends User Challenges


End User Trends

• Ongoing sustainability / Process efficiency• Reducing Water, Air, Gas, Electricity, & Steam (WAGES)• Using less raw material & improving yield

• Producing wider offerings to their customers• Scalable outputs / Flexible processes

• Shifting to modular, skid-based plants• Shorten start-up time• Reduce Skid Integration Cost Impact• Consistency from Plant to Plant• Ability to easily move equipment

• Inter or Intra facility• Shrinking Engineering Staffs

• Aging Workforce / Knowledgeable Staff Retiring• Lean workforce & support staff

• Difficulty in finding resources to support equipment• Spare Parts• Maintenance & Engineering Staff and System Integrators

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Equipment Builders have shared they are challenged to differentiate themselves amidst global competition and rapidly evolving technology

To achieve greater profitability, OEMs must improve their overall operational performance

• Commissioning• Global Service & Support• Safety, Reliability &

Quality• Machine Performance

Design• Design Productivity • Extensible Engineering• Scalability• Global Standards • Risk Assessment• Design for Sustainability

Develop Deliver

• Time to Market

• Supply Chain Efficiency

• Safe, Flexible Equipment Models

• Simplified Integration

• Design Optimization

OEM Challenges

9


OEM Trends

• Modular Equipment• Skid based equipment / Self contained control system• FAT/SAT accomplished prior to site installation

• Design Flexibility & Productivity• Equipment meets current & future requirements• Consistency across platforms• Fit for purpose vs. One size fits all• Reusable Libraries / Objects

• Remote Access & Support• Access to operational info and parameters• Diagnosis and troubleshooting• Plug & Play equipment

• Equipment Automation• Consistent production outputs• Intelligent equipment vs. Operator “fine tuning”

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Agenda







PlantPAx Process Automation System

Scalable high availability throughout the architecture

• Protect only what you need without over-investing• Focused not only on availability and uptime, but also

maintainability

Information-based solution for operations productivity

• Decision support, production analysis, and optimization drive profitability

Plant-wide control, performance tuned for process applications

• Standards-based architecture enables multi-disciplined control• Extends EtherNet/IP as control backbone

PlantPAx: Plant-wide optimization solution for the process industries

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PlantPAx: Plant-wide optimization solution for end users & plant operators


Customer Voice

Archer Daniels Midland Colorado Springs Utilities Dupont Gerrie Process Group Industrial Furnace Company JNE Automation

Kimberly Clark Kraft Foods Pacific Gas and Electric Pfizer Premier Systems Integrators Procter & Gamble Shell Global Solutions

Represents a broad base of customers and industries:

Process Customer Advisor Board (CAB) directs the success of the Process Solution User Group (PSUG)

Over 500 customers vote annually on PlantPAx system development direction and features


PlantPAx Process Automation System

PlantPAx equipment solutions quickly & easily integrate into the Plant Control System

Integrated Architecture System - Premier Integration of power, control, safety and networks

Product life cycle longevity of O.T.S. components Networking capabilities meet application

demands including: Time Synchronization (Sequence Of Events) Remote Diagnostics, monitoring and programming via EtherNet/IP Stratix EtherNet/IP Switch capability

Solutions from our PartnerNetwork specialists Instrumentation – Endress & Hauser Solution Providers – EPC Firms and Systems Integrators Encompass Partners – Products/Components that enhance the platform

Global Support/Network of Technical Consultants

PlantPAx: Scalable equipment control & information platform for OEMs

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Customer VoiceCompany Level OEMs North America

Company Level OEM Partners advise on regional programs and services


Scalable Platform: PlantPAx

Process Skids• Small, self-contained systems that are

tested prior to shipment and easily integrated into overall production facility

PlantPAx Process Automation System• Scalable architecture from small single unit to large multi area applications• Easily integrate systems across the plant, mill or manufacturing facility with

one architecture

User defined Systems Small to large Distributed PlantPAx Systems

Single Server / Single Client

Single Server / Multi Client(Process Area)

Multi Server / Multi ClientFor Large applications(Multi Area/ Plant)Local HMI, SCADA

(OEM Machine, Balance of Plant, etc) Small process

applications (Process Unit)

Medium sized process applications (Process Unit)

OR


Typical Process Skid Control Architecture


Flexibility:Logix Controllers for Process Control

L23E L35E L62 L63 L72 L73 L74User Memory, MB 0.5 1.5 4 8 4 8 16

Total I/O recommended , max* 80 250 750 1500 750 1500 2250

Number of defined tags, max** 4000 12800 31250 62500 31250 62500 112500

Recommended Loop CS, max*** 10 30 125 250 125 250 450

Loop CS @ 250ms, max 10 30 125 125 125 250 250

Loop CS @ 500ms, max 10 30 125 250 125 250 450

Tags/sec delivered to Data Servers****

3K 3K 10K 10K 20K 20K 20K

* Total I/O include all I/O channels delivered through I/O modules, network bridges and process instruments** Recommended number of tags is application dependent*** Representative PID loop control strategy: 1 AIN, 1PIDE, 1AOUT, 8 Logic/Math instructions, 22 Alarms (using PlantPAx Objects)**** Numbers provided for RSLinx Enterprise 5.30 (10K/sec per instance of Data Server)


Reliability & Performance:PlantPAx System Characterization

Critical System Attributes• Display Update: < 1 sec• Steady State Alarms: > 20/sec• Alarm Burst: < 3 sec/1000 alarms• Alarm Resolution: 1 sec timestamp• Keyboard Entry: < 1 sec to controller• Control Loop Closure: <100msec

Distributed System - Tested• Process Areas: 4• Clients: 32• Control Loops: 6000• Controllers: 50• Points: 50,000• Alarms: 80,000

∑ Components+Critical System Attributes +Testing=System Performance


Logix Batch & Sequence Manager has been designed to enable skid-based equipment to be developed, tested,

and delivered as a fully functioning stand-alone solution. If needed, it can seamlessly integrate into a larger

plant-wide control system.

Scalable:Batch Solution

Logix Batch & Sequence Manager


Logix Batch & Sequence Manager

• Batching– Skid-based process control– Single stand-alone mixers, blenders, reactors– Multiple, independent batching vessels

• Sequencing– Equipment sequencing applications– Continuous process startup/shutdown– Cleaning (CIP) Skids

Logix Batch & Sequence Manager can be used in both batch applications as well as equipment

sequencing activities


ControlLogix

CompactLogix

FTView SE

FTViewME

Logix Batch & Sequence ManagerController-Based Sequence Management and Procedural Control

Since the application is built using standard capabilities of the Logix and View platforms, it

provides a common way to configure, control, and visualize the process across different hardware and

software platforms.

Common Platform


Process Efficiency:Advanced Process Control

Real-time Optimization

Supervisory Model Predictive Control

Nonlinear Multivariable Control

Linear Multivariable Control

Inferential Sensors

Advanced Regulatory Control

Regulatory ControlIncr

easi

ng E

ffort

& In

crea

sing

Val

ue

OEM

Foc

used

PlantPAxDynamic MPC

PlantPAx Fuzzy Designer

PlantPAx Model Builder

Rock

wel

lDel

iver

ed

Logix IMC, CC, MMC

Logix PID, PIDE, AOI

Why APC: Improve yield, increase throughput, reduce costs, improve qualityWhy Rockwell Automation: Scalable to meet a wide range of process requirements


When process variation is “too high” And we know from data, experience or tests that smarter control actions will reduce variation And we know that reduced variation will produce economic benefits

When routine operator actions directly influence variation, performance Key decisions are made on lab sample results, periodically, infrequently Measured conditions are visible to operator, however, not accounted for in controls

When process is known to be “difficult to control” Process sensitivity to control actions changes with operating conditions Conditions change continuously and/or frequently (e.g. day-night temperature) Process takes long time to respond to control actions

When operation “in spec” is not good enough Stay is spec while minimizing cost Stay in spec while maximizing feed rate Optimize process performance

When Advanced Process Control?


Portfolio of Advanced Controls

Regulate

Optimize

Control

Predict

Single Loop

Single Loop

Multiple Loops

Multiple Loops

Process Unit -Inferentials

Process Unit -Inferentials

Multiple Units

Multiple Units

Plant-wideMPC

Plant-wideMPC

Value-Add

AreaArea

Span of

Control


Design Productivity: modularity using Add On Instructions (AOI)

Benefits to using Add-On Instructions:

Reuse code AOI’s promote consistency, Incorporate logic that is used

multiple times in to make it modular

Provide an easier to understand interface Reduce documentation development time through automatically generating instruction help.

Protect intellectual property Encapsulate proprietary logic inside AOI, then use Source Protection to prevent others from

viewing or changing your code.

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Create new instructions for sets of commonly-used logic, provide a common interface to this logic, and provide documentation

Add-On Instructions are tools for building a modular software program


Design Productivity: Reusable Process Library

Suite of Control & HMI objects to accelerate project engineering

Built-in troubleshooting features

Fully documented & supported by RA Tech Support

PlantPAx Standard Library

“Out of the box”


What is the Process Library? Add-On Instructions for

Logix

Graphic Symbols and Faceplate Displays for FTView (SE or ME) For a variety of valves, motors,

pumps, drives, inputs, outputs and other devices

Supporting instructions for modes, alarms, permissives, interlocks, statistics

Reference Manuals

Supported by Tech Support


What is the Process Library? Instructions, Graphics and Faceplates for numerous devices, plus their modes,

alarms, interlocks, permissives, statistics, etc.

• Motors– Single Speed– Two Speed– Reversing– Variable Speed– Hand Operated

• Valves– Single Solenoid– Motor Operated– Hand Operated– Mix-Proof– Analog Control

• Interlocks, Permissives• Modes, Alarms, Reset• Tank Strapping Table• Analog Fanout• P/T Comp. Flow

• Discrete Devices– Single Input– Single Output– 2-, 3- or 4-State– n-Position (up to 8)– Discrete Logic

• Analog Inputs– Single Basic– Single Advanced– Dual Sensor– Multiple (up to 8)

• Analog Output

• Dosing– With Flowmeter– With Weigh Scale

• Statistics– Motor Run Times/Counts– Valve Stroke Times/Counts


Process Library 2.0: Above items,Plus New Instructions and Functions

• Multiple Analog Input (up to 8 sensors for 1 PV)

• Discrete 2-, 3-, or 4-State Device (fully configurable)

• Mix-Proof Valve (configurable for seat lift and CIP/SIP states)

• Multi-position Device (up to 8 positions, linear or circular)

• Analog Fanout (one CV to up to 8 secondaries, handles split-range)

• Discrete Output • Discrete Logic with Snapshot

(up to 8 inputs, 8 gates)• 2-State Valve Statistics

(stroke times and counts)• Tank Strapping Table• Analog / Pulsed Control Valve

with Position Feedback• Updates to existing Dosing

instructions for equipment feedback monitoring

• Logix Task Monitor• Redundant Controllers

Monitor

• Pressure / Temperature Compensator (ideal gas)

• Steam Table Instructions:Saturation curve –

Given T, provide PsatGiven P, provide Tsat

Full five-region ASME table:Given P and T, provideEnthalpy, Entropy andSpecific Volume

• Logix V18 or later• FactoryTalk View SE and ME V6.0 or later

Extending general library

• Enumerations and typeinformation for Historian, VantagePoint

Power Gen. Basic Phase 1

System Diagnostics

Interface to Process Information Software

Compatibility


Design Productivity:Add On Profiles

Add devices directly from RSLogix 5000 design environment

Use text based Electronic Data Sheets

Provides configuration, input, and output tags, and configuration screens

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Fully configured profiles for devices you plan to integrate into a Logix based processor. These configurations are graphical in nature and create the structure (tags) used to communicate to the device.

Easily integrate EtherNet/IP devices into Logix


Example of Encompass Partner Add on Profile

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Add-On Profiles enable developer to easily add new (3rd party) devices into Logix application


Simplified Integration: Endress+Hauser and RA Strategic Alliance

The Alliance brings together two independent companies with high quality offerings and solutions Interoperability between products Preferred Integration is the goal

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Joint Integration Documents

Comprehensive and easy guidance to system design and setup

Installation Connect instrument to controls

Configuration Offline and online configuration Configure network interface Configure instrument

Visualization Pre-engineered and

standardized Faceplates


VSE discovers end-customer technical issues before the customer does

VSE automates routine manual support tasks decreasing Mean Time To Repair

• The Virtual Support Engineer is the equivalent of staffing your best support engineer at every end-customer site on a continuous basis

− Alerting− Collecting

− Detecting− Distributing− Fixing

− Monitoring− Preventing− Reporting

Remote Access & SupportTechConnect Virtual Support Engineer

VSE predicts end-customer technical issues enabling the customer to prevent them

VSE provides automated collection of data for reporting and Premium Services Sales

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TechConnectVirtual Support Engineer (VSE)

Simple and Secure Connectivity Connect to your machine from any internet

connection Secure Socket Layer No inbound packet transfer

Real-time Alarming Alarms delivered via email or text message Alarms can go to end user, machine builder or

Rockwell Automation Remote Applications Engineer Data Collection & Analytics Scalable, Low-Cost Solution

Small footprint, din rail mounted Remotely Configurable Application Embedded Help


Design Productivity:Integrated Architecture Tools

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www.rockwellautomation.com/solutions/integratedarchitecture/resources.html

Tools to assist in understanding, planning and configuring an Integrated Architecture™ System. New Tools added on regular basis


Reduced Downtime: Automatic Device Configuration (ADC)

Reduce Downtime when replacing a drive

Configure you Logix system to automatically download a “large” device’s configuration -typically after it has been replaced Device configuration data exists in the ACD file and has to be manually

downloaded in v16-v19 by the user via the AOP of the respective device

Works with Firmware Supervisor, which flashes the drive and/or peripherals if desired for the application

EtherNet/IP

2:00 AM scenario

FlashConfiguration

Current support onPowerFlex 755 drives

on EtherNet/IP

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• Assist with system definition and procurement

• Ties in with Process System Estimator tool and Characterization

• Defines how to select system for optimal performance

PlantPAx Reference Manual

PlantPAx Selection Guide

• Concentrates on the implementation recommendations that apply to all PlantPAx Systems

• Defines how to configure a system for optimal performance

PlantPAx Reference Manual


Agenda







Services & SupportGlobal Support. Local Address. Peace of Mind.

Optimize Plant Assets

Maximize Productivity

Improve Financial

Performance

80 Countries I 20 Languages I 6 Remote Support Centers I 10 Remanufacturing Depots I 9 Exchange Hubs I Average 13+ Years Experience

Meet Your Everyday Technical NeedsOnline & Phone Support

Training ServicesOnSite ServicesRepair Services

Maximize Your Automation InvestmentMRO Asset Management

Safety ServicesEnergy Services

Network & Security ServicesLegacy System Migration Plans

Legacy System Migration Turn-Key Projects


Global Solutions Organization Process Plant Solutions Focus

Specializing in:– Turnkey Modular Process Facilities & Skids– High Containment Facilities– Distillation and Abatement Plant– Pharmaceutical Processes– Solvent Recovery / Regeneration– Energy Monitoring & Targeting

General Services– Front End Studies – Budget Development & ROI Studies– Basic & Detailed Design– HAZOP’s– SIL Assessments, HAC Studies– Process Simulations (AspenPlus®)– Pressure Vessel & Pipe Design– Control Panel Design, Build & Test


OEM Program

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Part of Rockwell Automation’s PartnerNetwork Program Capitalize on business opportunities and turn

commercial partnering into a collective competitive advantage

Collaborate and leverage joint market position and technical capabilities Increase new business opportunities Increase market awareness Expand into new market sectors Improve technical competency and functional

excellence in applying Rockwell Automation products


Continuum to “Value beyond Costs”


Participation Levels

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Developer Level Entry level, project focused customers Ideal for companies looking to leverage

Rockwell Automation software & productivity toolsets

Machine Level Companies that use extensive Rockwell Automation

content in their machine(s) bill-of-material (BOM)

Company Level Companies who show a commitment to use

Rockwell Automation as their standard offering on all machine(s) bill-of-material

Company Level Logos

Machine / Equipment Level Logo


OEM Technical Consultants

Modular Programming methodologies that follow industry standards Leveraging PlantPAx libraries – process and power generation applications

Templates for quick code development while allowing creativity Technical Consultants can support in applying the correct solution

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Technical Consultants• Senior engineers with

extensive field experience• Focus: technical support

and cost reduction• Machine innovation• Best practice sharing• Training, examples, side by

side engineering, experience, knowledge


• Provide Value to the End Users• Consolidate End User Voice of Customer Issues:

• Organize VOC across industry• Provide conduit to OEMs

• Assist End User in driving industry standards throughout OEM community

• Assist end users in driving down their #1 cost – Skid Integration

• Provide Value to the OEMs• Educate OEMs on latest automation hardware, software and trends• Help OEMs drive & meet End User Standards that maximize

customer base for standard equipment designs• Provide Resources & Tools that drive down time and cost for OEMs

to design and deploy new equipment• Leverage new technologies to drive differentiation – such as

advanced process control

Program Focus for Process OEMs

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

www.rockwellautomation.com

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Rev 5058-CO900C

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