Cybertrol Engineering: Hospital Utilities Plant Upgrades to PlantPAx with Zero Downtime

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Cybertrol Engineering: Hospital Utility Plant Upgrades to PlantPAx with no Downtime

Mark Visness, Engineering Manager

Michael Owczarek, Project Engineer

November 2014

Agenda

Project Successes

System Design/Implementation

Concerns/Decision Factors

End-User Overview

Cybertrol Engineering Overview

Agenda

Project Successes

End-User Overview

Overview

Founded 1996

50 employees, 34 engineers

Automation and IT Services

UL508 Panel Shop

Thousands of projects for over 400 clients

Rockwell Solution Partner

(Control/Process/Information)

Agenda

Project Successes

End-User Overview

Major hospital campus

in Minnesota

Utility plant for 8 buildings,

including administration and

patient care

Three boilers, five chillers,

and auxiliary systems

Heating and/or cooling required

24/7/365

Agenda

Project Successes

End-User Overview

Dated Legacy DCS System

Rosemount RS/3 System, vintage 1993

4 Operator Control Stations

6 Marshaling Cabinets with a total of eighteen 19” racks, 90” high

Approximately 900 I/O points (500 “loops”)

Unit Operations Controlled

Three Boilers 80,000 pph each 250 psig steam @ 600 °F Dual fuel: oil, natural gas

Two Steam-Driven Chillers

2000 Ton each One on 250 psig steam One on 8.5 psig steam SLC 5/05 PLCs

Three Electric Chillers

2000 Ton each CompactLogix PLCs

Unit Operations Controlled

Electric Generators

Gas Turbine Generators

RO Polisher

Cooling Towers

Weather Station

System Concerns

Parts no longer available from distributor

Parts only available on 2nd-hand market

Risk to operations (spares not on hand)

Obsolete magnetic tape backup system

Expensive vendor support

Decision Factors – Performance

Full ethernet connectivity

Ease of programming

Redundant processors

Redundant I/O network

Enhanced reporting

Virtualization

Remote support

Decision Factors – Cost of Ownership

DCS System licensed by loops

Rockwell PAC – no loop licensing

FactoryTalk View SE HMI System licensed by # of displays, not loops

License for this system: 250 display

Approx. 125 displays used

Can be upgraded to unlimited

Decision Factors – Industry Acceptance

System integrators with Rockwell experience are plentiful

Hiring Rockwell-experienced maintenance staff is easier

Rockwell Automation has 60%+ automation market share in North America

Decision Factors – Support

Components stocked by local distributor

Other Rockwell equipment already in plant;

maintenance staff familiar, have Rockwell

Studio licensing

Local SI support or via remote connection

Plentiful support resources

Agenda

Project Successes

End-User Overview

System Design - Controllers

Redundant ControlLogix PACs:

Identical redundant racks Instantaneous failover to

secondary Simple check box

Device-Level I/O Ring (DLR)

Redundant pathways for I/O communications

Any one I/O cable can fail without disruption to I/O

Operator is notified of comm fault

System Design - Network

System Design - Servers

Process Automation System Server (PASS)

Two Hosts

Virtualized Servers

Redundant Network Switches

Thin Clients

Engineering Workstation

Network Attached Storage

Remote Access

System Design – Software

Operating System Microsoft Windows Server

Virtualization VMWare ESXi / VSphere

Visualization: FTView SE Server with

redundancy PlantPAx

Historian & Reporting FactoryTalk Historian FactoryTalk VantagePoint

Backups VEEAM Backup & Recovery

System Design – Virtual Machines

PASS HOST 1 Domain

Controller 1 FTView SE

Server 1 RSLinx

Enterprise 1 RDP Server 1 FactoryTalk

Directory FactoryTalk

Historian

PASS HOST 2 Domain

Controller 2 FTView SE

Server 2 RSLinx

Enterprise 2 RDP Server 2 FactoryTalk

VantagePoint Backup &

Recovery System

System Design – PlantPAx

PlantPAx objects

Motor/VFD Valve/Analog Valve PID Loop Digital Input/Output Interlocks/Permissives

System Design – Reports

• Trends

• Daily/Monthly Flow Totals

• Energy Usage

• Easy to develop custom reports

Develop custom reports

System Implementation – Panels

Re-used existing field wiring

Used Point I/O chassis to fit in

same space

Every I/O point individually

Clean plant – enclosures could

remain open for an extended

period

Hung new chassis on door

temporarily

System Implementation – Cutover

All new chassis powered up on

device-level ring

I/O swapped over from existing

panel to new chassis, point-by-

Old modules removed and new

chassis relocated to inside of

cabinet

Agenda

Project Successes

End-User Overview

Project Successes

Reduced Total Cost of Ownership (TCO)

Improved features and performance

No interruption to plant operations

System is easier to support and maintain

Remote support

Project Successes

System regularly backed up

Local distributor less than 3 miles away

Standard computer hardware

Less expensive, more easily sourced

support

“This system is so much more user-

friendly and flexible. Also we are going

to save a lot in the long term in

maintenance and support costs”

Tweet About It Using #PSUG

Learn more at www.cybertrol.com

Mark Visness, Engineering Manager

mvisness@cybertrol.com

Phone: (763) 519-7834

November 2014

Cybertrol Engineering: Hospital Utilities Plant Upgrades to PlantPAx with Zero Downtime

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