PlantPAx Process

Automation Symposium 2015

1. Tomorrow’s Automation, Today
A Symposium on Virtualization For the Process &
ManufacturingIndustries

2. TR03A -PlantPAxProcess
Ali Omer
Technical Project Manager

3. PlantPAx
Process
Agenda
What is PlantPAx
System Sizing and Characterization
PlantPAxLogic Add-Ons
PlantPAxHMI Functionality
PlantPAxComponents
Process Safety
Batch Management
3

4. It’saprocessautomationsystemthat
givesyoueverythingyouwantina
world-class,contemporaryDCSandway
more.
PlantPAx–It’s More
Than a Distributed
Control System (DCS)
PlantPAx
Plant Process Automation
Excellence
Word Class DCS
Plant-wide control capabilities
Open, flexible architecture
Integrated control, power,
safety, and information
Support by a global network
of local experts
4

5. PlantPAx
Capabilities
5
Capability PlantPAx
Plant wide Control Disciplines
Discrete 
Motion 
Process &Machine Safety 
Continuous Process 
Batch 
Drivers 

6. 6
PlantPAx
Capabilities
Capability PlantPAx
Control System Features
Controller Redundancy 
RemoteI/0 
System Scalability with Single
Platform/Control Engine(Single Machine
to LargePlant

Hot swappableI/0 
Broad I/0 capability (Rack mounted, field
based distributed I/0and hazardous form
factors

Full digital integration with drivers and
MOC

No loop or point lie sensing 

7. 7
PlantPAx
Capabilities
Capability PlantPAx
Configuration and Programming
Object Oriented 
All IIC 63131 Programming Languages 
OnlineEditing/Configuration 
Tag Based Addressing &Programming 

8. 8
PlantPAx
Capabilities
Capability PlantPAx
Visualization
Fully IntegratedClient/ Server HMI with
Redundancy

Panel Based HMI 
Webbased HMI Interface 
Historical DataCollection (SOE, EVENTS,
TRENDING, REPORTS)

Controller based historian 
Alarms and Events 

9. 9
PlantPAx
Capabilities
Capability PlantPAx
System Communication and Field Buses
Ethernet (I/P) 
Standard EthernetInfrastructure (Cisco
Alliance)

Control Net 
Device Net 
Mod Bus 
AS/I 

10. 10
PlantPAx
Capabilities
Capability PlantPAx
ProcessControl
Regulatory 
Logic Function Block 
Sequence 
Batch 
Controller based ISA-SBB phasesupport 

11. 11
PlantPAx
Capabilities
Capability PlantPAx
Advanced Control
Fuzzy Logic 
Auto tunetechnology 
Model predictivecontrol 

12. 12
PlantPAx
Capabilities
Capability PlantPAx
Process Fieldbuses
Foundation fieldbus 
ProlibusPA 
HSE 
HA-RT 

13. 13
PlantPAx
Capabilities
Capability PlantPAx
Process Safety
Scalable Process Safety 
Integrated ProcessSafety 

14. 14
PlantPAx
Capabilities
Capability PlantPAx
Service and Support
Project Engineering and Solution provider
Network

24x 7 Technical support-Worldwide 
Configuration Services 
Hardware Maintenance Services 
Installation Services 
Software Supportand Upgrade Support 
Training 
Single Source Supplier 

15. 15
PlantPAx
Capabilities
Capability PlantPAx
OtherCapabilities
Global Namespace acrossmultiple
applications

DCS-PLC Integration 

16. PlantPAx–Distributed Architecture
16

17. PlantPAxSystem
Characterization
PlantPAxsupports all widely
spread Process Networks I/O
17

18. PlantPAxProcess
Networks I/O
MaingoalofPlantPAxSystem
Characterizationis:
To provide a recommended
architecture and information
[boundaries] regarding a system
operation and/or performance
early in the sales cycle to reduce
To eliminate perceived risk of the
system being able to provide the
needed performance.
PlantPAxsystemiscarefullytested
anddesignedtoensurebest
possibleperformance.
Controller Wall
50 + PACs
Distributed System
4 servers
Virtual
System
Centralized
System 1 server
18

19. Characterizing the System Loading by Using “Control
Strategies”
A control strategy identifies the relationship between the loop
control code and its data requirements. A control strategy can
represent any control code, such as process control, I/O, data flow,
and visualization for a control entity. A control strategy can be a 2-
state device, a PID loop, a sequencing block.
19

20. Characterizing the
System Loading by
Using “Control
Strategies”
Usingthecontrolstrategymodel,we
areabletoestimatethesesystem
parameters:
HMI server tags on scan (alarm
tags, display tags, data log tags,
event detector tags, and derived
tags)
Controller memory usage
Controller execution time
20

21. 1
Display Call up A HMI Display “Paint Time” is the time it takes to call up a new screen
(not cached) and must be operational in less than 2 seconds
2
Display Data Update A change in a active value within any controller is displayed on a
graphic screen on the OWS (HMI client) in less than 1 second.
3
Steady State Alarms The System must support a Steady State alarm condition, consisting
of twenty new alarms being generated every second, with the
difference between the time an alarm is triggered and its timestamp
not exceeding one (1) second (cannot miss any alarm)
4
Alarm Burst The System must support an Alarm Burst condition, consisting of one
thousand (1000) new alarms generated all at once, with the
difference between the time any alarm is triggered and its alarm
timestamp not exceeding three (3) seconds (cannot miss any alarms)
5
System Recovery Within five (5) minutes after a failed System Element is restored, the
system should recover and perform as it did before the system
element failure
System Performance Criteria in “Operational” Terms
21

22. 22
6
Data Logging The system will be capable of continuously data logging a minimum of
200 independent points once a second
7
Paint Time for Datalog TrendA data log trend display will present 12 hours of historical data of any
data logged point on the OWS within 30 seconds of the operators
display request.
8
Operator Control The operator will be able to interact with the process by changing tag
values in the controller within 2 seconds.
9
Control Loop Update TimeThe system will be capable of supporting 125 Complex Regulatory
Control Loops (cascaded) within a 250ms periodic task. This time is
from instrument to actuator.
10
Batch Server: Operator Action
Time
An operator initiated Batch command will be responded to by the PAC
with 1 second.
11
Batch Server: Server Action
Time
A batch server initiated Batch command will be responded to by to
the PAC with 1 second.
12
Batch Server: Controller
Action Time
A batch Event in the Controller will provide the operator with
feedback in 1 second .

23. Measuring System
Performance
TheOperatorInterfaceisthe
CriticalElementandhasthree
mainfeatures:
Display Call Up Time
Data Update Rate
Operator Command
The Operator Interface is the
critical element
Display Call up
Data Update
Operator Command
23

24. Example of PlantPAxCharacterization Report
24

25. PlantPAxInterface

26. PlantPAx–Harmony between Logic and HMI
26

27. PlantPAx
Available
Instructions
27

28. PlantPAxLibrary of
Logix Diagnostic
Objects L-CPU:
Controller Usage
Monitor
PlantPAxoffersextensiveCPU
Diagnosticsand all
informationisavailablefrom
withintheHMIinterface
28

29. PlantPAxProcess
Ad-Ons
PlantPAxhas extensive built
in Add-Ons for all Process
Devices.
Add-Ons significantly
reduces Engineering time
and Maintenance activities
29

30. PlantPAxProcess
Faceplates
PlantPAxhas detailed
Faceplates corresponding to
Logic Add-Ons.
Complete Information
available from within
Faceplates.
Setting Alarms, Bypassing
Interlocks, Simulating devices,
enabling/disabling alarms,
detailed Help.
30

31. PlantPAxModes &
Security
Operator: .Commanded from the HMI
Program: Commanded by the application logic
Override: Commanded by application logic for
abnormal operation, supersedes Program and
Operator modes.
Maintenance: Commanded from the HMI for
maintenance, bypassableinterlocks and
permissive and feedback checks can by bypassed.
Hand: Tracks controlled by hardwired local
station..
31

32. Operations Layer
32

33. Operations: Maintenance
and Troubleshooting
Made Easy!
33

34. New shelve alarm
capability per
ISA 18.2
Enter shelve time
duration and
comments
Better integration
with PlantPAxLibrary
Operations: Standards-based alarming
34

35. Operations: Standards-
based alarming
Provides method for gating threshold
alarms or indications includes:
Gate Input
Gate Delay
On-Delay
Off-Delay
35

36. Operations:
Standards-based
alarming
Easily navigate from motor
to interlock to cause
Interlocks with first-out
Access to logic for complex
interlocks
Quick Troubleshooting for
improved MTTR
36

37. Operations:
Automation of
Operator
Procedures
PlantPAxsequencer object:
Easily configurable to
capture critical sequences
Rich visualization provided
to the operator
Built-in Exception Handling
37

38. Asset Management
&
System Maintenance
Extensive Asset Management
and System Maintenance Tools
Instrument
Diagnostics
Instrument
Management
InstrumentHealth
Instrumentation
DeviceDiagnostics
Device
Management
DeviceHealth
Power
Control
Operator:“IsitOK?”
Maint:“Howbadisit?”
Tech: “How do I fix it?”
38

39. SIL 0
Process
SIL 1
Fail Safe
SIL 2
Fail Safe
SIL 2
Fault Tolerant
SIL 3
Fail Safe
SIL 3
Fault Tolerant
BasicProcessControl
System
SafetyInstrumented Systems
(SIS)
PlantPAx
(Logix)
EtherNet/IP communication:
AADvance™ & PlantPAx™
Trusted
TMR
AADvance
Scalable
Safety
Process Safety
Provides Integrated and scalable
SIS Solutions, including TMR for
the highest availability.
PlantPAxbased on Logix Platform
Redundant Logix Platform
Redundant Logix Platform with
Redundant I/Os
GuardLogixSIL3 Fail Safe
Aadvance
AadvanceTrusted TMR
39

40. Batch
Management
Provides Scalable Platform From
simple, single unit scale to highly
complex, integrated batch
solutions.
Integrated Analysis Tools Batch
reports, material usage, genealogy,
and solutions to optimize batch
production
Native ISA-88 Structure Simplify
change management and
regulatory compliance
40

41. Operations
Productivity
Scalable Data Collection Chassis-
based, plant-wide or
enterprise-wide historian
Decision Support Tools Trends,
dashboards, and reports
Users Collaboration to make
actionable decisions
41

42. Process
Optimization
Broad Advanced Control Portfolio
From advanced regulatory to simple
model-based control, soft sensors to
complex model predictive control
Flexible Deployment From loop and
unit-level optimization in the
controller
to plant-wide economic optimization
at the supervisory layer
IMC_01

IMC
...

Internal Model Control

0.0

PV

0.0

SPProg

0.0

SPCascade

0.0

RatioProg

0.0

CVProg

0.0

HandFB

0

ProgProgReq

0

ProgOperReq

0

ProgCasRatReq

0

ProgAutoReq

0

ProgManualReq

0

ProgOverrideReq

0

ProgHandReq

CVEU

0.0

SP

0.0

ProgOper

0

CasRat

0

Auto

0

Manual

0

Override

0

Hand

0
MMC_01

MMC
...

Modular Multivariable Control

0.0

PV1

0.0

PV2

0.0

SP1Prog

0.0

SP2Prog

0.0

CV1Prog

0.0

CV2Prog

0

CV3Prog

0

ProgProgReq

0

ProgOperReq

0

ProgCV1AutoReq

0

ProgCV2AutoReq

0

ProgCV3AutoReq

0

ProgCV1ManualReq

0

ProgCV2ManualReq

0

ProgCV3ManualReq

0

ProgCV1OverrideReq

0

ProgCV2OverrideReq

0

ProgCV3OverrideReq

CV1EU

0.0

CV2EU

0.0

CV3EU

0.0

SP1

0.0

SP2

0.0

ProgOper

0

CV1Auto

0

CV2Auto

0

CV3Auto

0

CV1Manual

0

CV2Manual

0

CV3Manual

0

CV1Override

0

CV2Override

0

CV3Override

0
CC_01

CC
...

Coordinated Control

0.0

PV

0.0

SPProg

0.0

CV1Prog

0.0

CV2Prog

0

CV3Prog

0

ProgProgReq

0

ProgOperReq

0

ProgCV1AutoReq

0

ProgCV2AutoReq

0

ProgCV3AutoReq

0

ProgCV1ManualReq

0

ProgCV2ManualReq

0

ProgCV3ManualReq

0

ProgCV1OverrideReq

0

ProgCV2OverrideReq

0

ProgCV3OverrideReq

CV1EU

0.0

CV2EU

0.0

CV3EU

0.0

SP

0.0

ProgOper

0

CV1Auto

0

CV2Auto

0

CV3Auto

0

CV1Manual

0

CV2Manual

0

CV3Manual

0

CV1Override

0

CV2Override

0

CV3Override

0
42

43. Skid & Process
Equipment
Solutions
Overall System Performance
Proven, tested architectures for not
only DCS
applications, but skid-sized solutions
as well
to ensure total system performance.
Machine Automation functionality and
full support built in
43

44. Question & Answers
Thank You for Your Valuable Time
44

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