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


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Agenda

Project Successes

System Design/Implementation

Concerns/Decision Factors

End-User Overview

Cybertrol Engineering Overview


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Agenda

Project Successes



End-User Overview



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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)


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Agenda

Project Successes



End-User Overview



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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


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Agenda

Project Successes



End-User Overview



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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”)


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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


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Unit Operations Controlled

Electric Generators

Gas Turbine Generators

RO Polisher

Cooling Towers

Weather Station


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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


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Decision Factors – Performance

Full ethernet connectivity

Ease of programming

Redundant processors

Redundant I/O network

Enhanced reporting

Virtualization

Remote support


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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


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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


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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


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Agenda

Project Successes



End-User Overview



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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


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System Design - Network


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System Design - Servers

Process Automation System Server (PASS)

Two Hosts

Virtualized Servers

Redundant Network Switches

Thin Clients

Engineering Workstation

Network Attached Storage

Remote Access


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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


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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


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System Design – PlantPAx

PlantPAx objects

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


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System Design – Reports

• Trends

• Daily/Monthly Flow Totals

• Energy Usage

• Easy to develop custom reports

Develop custom reports


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System Implementation – Panels

Re-used existing field wiring

Used Point I/O chassis to fit in

same space

Every I/O point individually

fused

Clean plant – enclosures could

remain open for an extended

period

Hung new chassis on door

temporarily


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System Implementation – Cutover

All new chassis powered up on

device-level ring

I/O swapped over from existing

panel to new chassis, point-by-

point

Old modules removed and new

chassis relocated to inside of

cabinet


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Agenda

Project Successes



End-User Overview



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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


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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”


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Learn more at www.cybertrol.com

Mark Visness, Engineering Manager

[email protected]

Phone: (763) 519-7834

November 2014

http://www.cybertrol.com/

mailto:[email protected]

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

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