Transcript
The Digital Sugar Mill
Seminar on Sugar & Ethanol Automation
PlantPAx Capabilities & Functional Overview
M. Ali Omer Technical Project Manager
PlantPAxProcess
Agenda
What is PlantPAx
System Sizing and Characterization
PlantPAx Logic Add-Ons
PlantPAx HMI Functionality
PlantPAx Components
Process Safety
Batch Management
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It’s a process automation system thatgives you everything you want in aworld-class, contemporary DCS and waymore.
PlantPAx – It’s More Than a Distributed Control System (DCS)PlantPAx
Plant Process Automation Excellence
Word Class DCS
Plant-wide control capabilities
Open, flexible, scalable, modular architecture
Integrated control (process and machine), power, safety, and information
24/7 local support available through Avanceon
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PlantPAxCapabilities
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Capability PlantPAx
Plant wide Control Disciplines
Discrete
Motion
Process & Machine Safety
Continuous Process
Batch
Drives
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PlantPAxCapabilities
Capability PlantPAx
Control System Features
Controller Redundancy
Remote I/0
System Scalability with Single Platform/Control Engine(Single Machine to Large Plant
Hot swappable I/0
Broad I/0 capability (Rack mounted, field based distributed I/0 and hazardous form factors
Full digital integration with drivers
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PlantPAxCapabilities
Capability PlantPAx
Configuration and Programming
Object Oriented
All IEC 61131-3 Programming Languages
Online Editing/Configuration
Tag Based Addressing & Programming
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PlantPAxCapabilities
Capability PlantPAx
Visualization
Fully Integrated Client/ Server HMI with Redundancy
Panel Based HMI
Web based HMI Interface
Historical Data Collection (SOE, EVENTS, TRENDING, REPORTS)
Alarms and Events
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PlantPAxCapabilities
Capability PlantPAx
System Communication and Field Buses
Ethernet (I/P)
Standard Ethernet Infrastructure (Cisco Alliance)
Control Net
Device Net
MODBUS RTU/TCP/IP
AS/I (Actuator Sensor Interface)
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PlantPAxCapabilities
Capability PlantPAx
Process Control
Regulatory
Logic Function Block
Sequence
Batch
Controller based ISA-S88 phase support
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PlantPAxCapabilities
Capability PlantPAx
Advanced Control
Fuzzy Logic
Auto tune technology
Model predictive control
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PlantPAxCapabilities
Capability PlantPAx
Process Fieldbuses
Foundation fieldbus
Profibus PA
HART
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PlantPAxCapabilities
Capability PlantPAx
Process Safety
Scalable Process Safety
Integrated Process Safety
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PlantPAxCapabilities
Capability PlantPAx
Service and Support
Project Engineering and Solution provider Network
24 x 7 Technical support
Configuration Services
Hardware Maintenance Services
Installation Services
Software Support and Upgrade Support
Training
Single Source Supplier
PlantPAx – Distributed Architecture
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Al Moiz PlantPAx System Architecture
PlantPAx System Characterization
PlantPAx supports all widely spread Process Networks I/O
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PlantPAx Process Networks I/OMain goal of PlantPAx SystemCharacterization is:
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.
PlantPAx system is carefully testedand designed to ensure bestpossible performance.
Controller Wall 50 + PACs
Distributed System 4 servers
Virtual System
Centralized System 1 server
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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.
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Characterizing the System Loading by Using “Control Strategies”Using the control strategy model, weare able to estimate these systemparameters:
HMI server tags on scan (alarm tags, display tags, data log tags, event detector tags, and derived tags)
Controller memory usage
Controller execution time
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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
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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 Trend A 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 Time The 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 .
Measuring System PerformanceThe Operator Interface is theCritical Element and has threemain features:
Display Call Up Time
Data Update Rate
Operator Command
The Operator Interface is the critical element
Display Call up
Data Update
Operator Command
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Example of PlantPAx Characterization Report
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PlantPAx Interface
PlantPAx – Harmony between Logic and HMI
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PlantPAxAvailable Instructions
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PlantPAx Library of Logix Diagnostic Objects L-CPU: Controller Usage MonitorPlantPAx offers extensive CPUDiagnostics and allinformation is available fromwithin the HMI interface
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PlantPAx EtherNet/IP Network Monitoring
• Complete Information of Stratix Switches
• Complete Information of DLR Network
• Complete Information of EtherNet/IP Nodes
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PlantPAx Process Ad-OnsPlantPAx has extensive built
in Add-Ons for all Process
Devices.
Add-Ons significantly
reduces Engineering time
and Maintenance activities
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PlantPAx Process Faceplates PlantPAx has detailed
Faceplates corresponding to Logic Add-Ons.
Complete Information available from within Faceplates.
Setting Alarms, Bypassing Interlocks, Simulating devices, enabling/disabling alarms, detailed Help.
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PlantPAx Modes & 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, bypassable interlocks and
permissive and feedback checks can by bypassed.
Hand: Tracks controlled by hardwired local
station..
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Operations Layer
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Operations: Maintenance and Troubleshooting Made Easy!
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New shelve alarm
capability per
ISA 18.2
Enter shelve time
duration and
comments
Better integration
with PlantPAx Library
Operations: Standards-based alarming
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Operations: Standards-based alarmingProvides method for gating threshold
alarms or indications includes:
Gate Input
Gate Delay
On-Delay
Off-Delay
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Operations: Standards-based alarmingEasily navigate from motor
to interlock to cause
Interlocks with first-out
Access to logic for complex
interlocks
Quick Troubleshooting for
improved MTTR
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Operations: Automation of Operator ProceduresPlantPAx sequencer object:
Easily configurable to
capture critical sequences
Rich visualization provided
to the operator
Built-in Exception Handling
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Asset Management & System MaintenanceExtensive Asset Management and System Maintenance Tools
InstrumentDiagnostics
InstrumentManagement
Instrument Health
Inst
rum
enta
tio
n
Device Diagnostics DeviceManagement
Device HealthPo
wer
Co
ntro
l
Operator: “Is it OK?”
Maint: “How bad is it?”
Tech: “How do I fix it?”
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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
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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
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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
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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
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SIL 0Process
SIL 1Fail Safe
SIL 2Fail Safe
SIL 2Fault Tolerant
SIL 3Fail Safe
SIL 3Fault Tolerant
Basic Process ControlSystem
Safety Instrumented 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.
PlantPAx based on Logix Platform
Redundant Logix Platform
Redundant Logix Platform with
Redundant I/Os
GuardLogix SIL3 Fail Safe
Aadvance
Aadvance Trusted TMR
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Question & AnswersThank You for Your Valuable Time
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Lahore, Pakistan
Headquarters South East Asia
19 Km Main Multan Road
Lahore, Punjab 54660
Pakistan
Phone : + 92 42 111 940 940
Dubai, UAE
Headquarters Middle East And Asia
Office FZS1 BD04, Jebel Ali Free Zone
PO Box 18590, Dubai
United Arab Emirates
Phone: +971 4 88 60 277
Exton, USA
Headquarters Americas
180 Sheree Boulevard, Suite 1400
Exton, PA 19341
United States of America
Phone +1 610 458 8700
Regional Offices and Global Headquarters
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