2009 – Issue 1 IN THIS ISSUE PlantPAx is the new name for the Rockwell Automation Process Control System. It brings together our core control and visualization technologies with technology from acquisitions, such as Incuity, Pavilion Technologies, ICS Triplex and partners like OSIsoft and Endress+Hauser into a single solution. Key areas of the PlantPAx system include: System Engineering The PlantPAx system further strengthens our system engineering environment. It will offer process and batch control users a new library of reusable control objects with tools to simplify deployment. A future release will include the ability to populate the PlantPAx system with modules from multiple plant design and engineering tools. Control and Visualization Platforms Control strategies and accompanying visualization are configured using modular and reusable objects, simplifying design, commissioning and maintenance. Continued advances around system high availability serve to minimize or eliminate downtime and process disruptions caused by control system modifications. Performance and Process Optimization The PlantPAx system extends the scope of process optimization to include Fuzzy Logic, basic and advanced process loop tuning and at the high-end a Model Predictive Control (MPC) suite. Batch and Sequencing Rockwell Automation provides solutions from basic sequencing to the most complex and demanding batch applications. The system adheres to ISA-88 standards and presents a scaleable batch control capability. Process Safety and Critical Control Process safety capabilities include a broad range of safety integrity levels (SIL) and fault-tolerance requirements. Solutions include SIL 3 and TMR options. Asset Management and Device Connectivity As an integral element of the PlantPAx system our asset management solution provides tools for disaster recovery, tracking of user actions, regulatory compliance and improving plant-floor security. The solution includes instrument configuration, diagnostics and calibration management. The system integration with digital field devices such as HART, Foundation Fieldbus and Profibus PA for the instrumentation and DeviceNet and EtherNet/IP for industrial control devices. This provides integration ease when used with our device integration tools developed jointly with Endress+Hauser. Additional asset management capabilities include controller code change management, vibration monitoring of rotating equipment and both instrument and industrial device management with configuration and calibration records tracking for other plant-wide assets such as drives and motor control centers. Plant Information The PlantPAx system allows plant-wide process data management through its historian capability (based on the PI System from OSIsoft). Further, the new FactoryTalk VantagePoint enterprise manufacturing intelligence and reporting software helps enable aggregation, analysis and display of plant information. To find out more, visit us at www.discover.rockwellautomation.com/ thinkingprocess In this edition of Thinking Process we focus on techniques to optimize plant performance. You will find information on subjects ranging from loop tuning to model predictive control and examples of the financial savings that can be made. Rockwell Automation ® Announces PlantPAx Page 1 Rockwell Automation Announces PlantPAx Process Automation System Page 2-4 SPECIAL FEATURE Process Optimization Page 5 Rockwell Automation and Endress+Hauser Integration Software and Documents Page 5 FactoryTalk® ViewPoint Web-HMI Page 5 FactoryTalk AssetCentre Adds Device Configuration and Calibration Management Capability Page 5 FactoryTalk Batch Version 10 Page 6 Six-Polymer Line Project Marks Largest Polymer Deployment in China UPDATE
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2009 – Issue 1
IN THIS ISSUE
PlantPAx is the new name for the
Rockwell Automation Process
Control System. It brings together
our core control and visualization
technologies with technology from
acquisitions, such as Incuity, Pavilion
Technologies, ICS Triplex and partners
like OSIsoft and Endress+Hauser into
a single solution.
Key areas of the PlantPAx system include: System Engineering The PlantPAx system further strengthens oursystem engineering environment. It will offerprocess and batch control users a new libraryof reusable control objects with tools tosimplify deployment. A future release willinclude the ability to populate the PlantPAxsystem with modules from multiple plantdesign and engineering tools.
Control and Visualization Platforms Control strategies and accompanyingvisualization are configured using modularand reusable objects, simplifying design,commissioning and maintenance. Continuedadvances around system high availability serve to minimize or eliminate downtime and process disruptions caused by controlsystem modifications.
Performance and Process Optimization The PlantPAx system extends the scope ofprocess optimization to include Fuzzy Logic,basic and advanced process loop tuning and at the high-end a Model Predictive Control (MPC) suite.
Batch and Sequencing Rockwell Automation provides solutions frombasic sequencing to the most complex anddemanding batch applications. The systemadheres to ISA-88 standards and presents ascaleable batch control capability.
Process Safety and Critical Control Process safety capabilities include a broadrange of safety integrity levels (SIL) and fault-tolerance requirements. Solutionsinclude SIL 3 and TMR options.
Asset Management and Device ConnectivityAs an integral element of the PlantPAx systemour asset management solution provides toolsfor disaster recovery, tracking of user actions,regulatory compliance and improving plant-floor security. The solution includesinstrument configuration, diagnostics andcalibration management.
The system integration with digital fielddevices such as HART, Foundation Fieldbusand Profibus PA for the instrumentation andDeviceNet and EtherNet/IP for industrialcontrol devices. This provides integration easewhen used with our device integration toolsdeveloped jointly with Endress+Hauser.Additional asset management capabilitiesinclude controller code change management,vibration monitoring of rotating equipmentand both instrument and industrial devicemanagement with configuration andcalibration records tracking for other plant-wide assets such as drives and motorcontrol centers.
Plant Information
The PlantPAx system allows plant-wide process data management through itshistorian capability (based on the PI Systemfrom OSIsoft). Further, the new FactoryTalkVantagePoint enterprise manufacturingintelligence and reporting software helpsenable aggregation, analysis and display ofplant information.
To find out more, visit us atwww.discover.rockwellautomation.com/thinkingprocess
In this edition of Thinking Process we focus on techniques to optimize plant performance. You will find information on subjects ranging from loop tuning to model predictive control andexamples of the financial savings that can be made.
Rockwell Automation®
Announces PlantPAx
Page 1 Rockwell Automation AnnouncesPlantPAx Process Automation System
Page 2-4 SPECIAL FEATUREProcess Optimization
Page 5 Rockwell Automation andEndress+Hauser Integration Software and Documents
Page 5 FactoryTalk® ViewPoint Web-HMI
Page 5 FactoryTalk AssetCentre Adds DeviceConfiguration and CalibrationManagement Capability
Page 5 FactoryTalk Batch Version 10
Page 6 Six-Polymer Line Project MarksLargest Polymer Deployment in China
UPDATE
IMC Function Block Configuration Example
The IMC Function Block
SP
CV
PV
Disturbance
Estimate
Process Prediction
1st OrderFilter
1st OrderModel
Inverse ofModel
Process
Process
Disturbance
–
–
2
Concentration
Time
CVPVTime Constant
63%
300250200150100
500
0 20 40 60 80 100
Deadline
Economic Benefits
The IMC algorithm gives more accurate
control of the chemical concentration to
target value. This reduces the cost of
chemicals whilst still meeting specification.
RSTune & RSLoop OptimizerRSTune® and RSLoop Optimizer™ are critical tools
for increasing your product quality. Having your
loops optimized reduces inconsistency, thereby
improving the quality of your product. Better
control means more accurate material
management and less off-specification product,
increasing your profits and reducing energy costs.
RSTune is a sophisticated tuning package that will
optimize your PID loops. It automatically
calculates the best PID values for your application
and supplies you with powerful tools to increase
profitability. RSLoop Optimizer has additional
tools to allow you to identify potential process
equipment deficiencies, analyze valve wear and
optimize more complex loops.
Example – Chemical Dosing
In this example a chemical is dosed into a water
flow with the goal of meeting a certain
concentration. There is a significant delay
between the injection point and the measuring
point. Traditional PID algorithms don’t cope
very well with the delay and typically lead to a
sluggish response or oscillations.
The graph below shows how the process
responds to a step change. The dead-time of
the loop is much larger than the time constant.
In this example, the new Logix Internal Model
Control (IMC) instruction will typically give a
much better response than PID.
The IMC function block controls a single
process variable by manipulating a single
control-variable output. This function block
performs an algorithm where the actual error
signal is compared against that of an internal
first-order lag plus dead-time model of the
process. The IMC function block calculates the
control variable output based on the deviation
from the internal model.
Logix V17 Advanced Process Control – Internal Model Control (IMC)PID is the ‘standard’ solution for most control loops, but it is not a good algorithm for certain
applications. If PID is not suitable for the application no amount of tuning will make the loop
operate efficiently, other techniques like Internal Model Control (IMC) are required.
Other Logix APC Instruction
CC – Coordinated Control
• The CC function block controls
a single process variable with up to
three control variables which need to
act in a coordinated manner
• It is good for situations where multiple
outputs are available for control, and costs
need to be minimized
MMC – Modular Multivariable Control
• The MMC function block controls two
process variables with up to three
control variables
• It is good for situations where there is
significant interaction between the various
control variables and process variables
Application Example and Economic Benefit
For more information, visit:
www.rockwellautomation.com/rockwell
software/design/rslogix5000/
Instruction Application Economic Benefit
Dissolved oxygencontrol bycontrolling flowrate, agitator and air flow
Process Optimization is a very important subject in today’s economic climate. It is essential to run your plant as efficiently
as possible to maximize profitability, but how do you know if your system is running at the maximum efficiency? Do you
have the tools to analyze the performance? And do you have a control system that is capable of delivering optimum
performance? In this article we examine a number of techniques from tuning PID loops to Business Intelligence Software
to help you maximize your profits.
To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess
Features
• Hybrid modeling based on
empirical data, first principles
equations, operator
knowledge or any
combination
• Patented, Extrapolated
Gain Constrained Neural
Networks (EGCNN) to ensure
model accuracy beyond the
normal operating range
• Incorporates changing
process dynamics
(dead-time, time constants
and gains) over wide process
operating ranges
Benefits
• Improves product quality
through faster response to
target changes or large
process disturbances
• Expedites deployment by
using all available
information to create
accurate models
• Improves product quality
and flexibility for new grade
and product development
4
Economic Benefits
• Reduce cycle times through faster
response of the control loop
• Reduce energy usage
Application Example and Economic Benefit
Chemical Manufacturer
• Increase prime product yield
by 4.5%
• Reduced variance in product
properties by 35%
• Decreased reactor variability
by 30%
• Reduced waste by 300
tons year
• Reduced frequency of lab
samples by 50%
Ethanol Producer
• Increased Ethanol production
capacity 3-10%
• Increased ethanol yield
by .1-.2%
• Reduced energy use/gallon
by 2-4%
• Reduce compliance risk
Logix – Fuzzy LogicFuzzy Logic is a technique that attempts to
systematically and mathematically emulate
human reasoning and decision-making.
Fuzzy control solutions are especially useful
for complex systems where standard means
such as PID control don’t give the required
level of control. Your operators may already be
‘tweaking’ the process for different conditions
but this can be unreliable.
The Fuzzy Logic tools can be applied to a
wide variety of applications. The following
example is a simple application to adjust gains
in a temperature control loop for a reactor.
Example – Reactor Temperature Control
A reactor is heated to a particular temperature
to produce a product. This may sound
straightforward but if the reactor is used for
different sizes of batches the performance of
the temperature loop will vary significantly
depending on how full the reactor is. If the
loop is tuned when the reactor is half full it
may experience problems at different levels.
It would have a sluggish response when
completely full and may oscillate when only
part filled. Clearly you could write a program
to vary the gains with level but this could
become complicated to ensure you don’t get
disruptions to the process.
Fuzzy Logic provides a tool set to take the
knowledge about how the gains should
be varied and use it to more accurately
control the process. This is done by
continuously adjusting the gains rather with
a step change which is often seen in existing
applications. By doing this it is possible to
avoid the process disruptions that would
otherwise occur.
Pavilion Technology – Model Predictive ControlPavilion Technologies’ Model Predictive
Control (MPC) technology is an intelligence
layer on top of basic automation systems that
continuously drives the plant to achieve
multiple business objectives – cost reductions,
decreased emissions, consistent quality and
production increases – every production
minute. It continuously assesses current and
predicted operational data, compares them to
desired results and computes new control
targets to reduce in-process variability and
improve process performance.
For more information, visit:
www.pavtech.com
To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess
Rockwell Automation andEndress+Hauser IntegrationDocuments and Add-onInstructions Available for DownloadRockwell Automation and Endress+Hauser
have released documentation and Add-on
instructions for HART devices connected to
1756 I/O. The information includes a step-by-
step approach to integrating Endress+Hauser
instruments, including information on
hardware, software, configuring messaging
and asset management software.
You can download the documents and
Add-on instructions from:
www.rockwellautomation.com/solutions/
process/integrationdocs.html
The first phase includes documents for the
following instruments:
• Promass 83 Coriolis Mass Flow
• Promag 53 Electromagnetic Flow
• Prowirl 73 Vortex Flow
• Proline t-mass 65 Thermal Flow
• Levelflex M Guided Radar Level
• Micropilot M Radar Level
• Prosonic M Ultrasonic Level
• Prosonic S Ultrasonic Level
• Liquiline M for Liquid Analysis
• Cerabar S Pressure
• Deltabar S Differential Pressure
• iTEMP TMT 162 Temperature
• iTEMP TMT 182 Temperature
Documentation for Profibus PA via the EN2PA
modules and Flex™ I/O HART is in progress and
will be available early 2009.
Manufacturers now can remotely monitor their
plant-floor operations status using FactoryTalk
ViewPoint software from Rockwell Automation.
FactoryTalk ViewPoint software is one of the first
commercially available, thin-client applications
for manufacturing, built using the new
Microsoft Silverlight technology. The initial
release extends visualization and real-time
decision capabilities beyond FactoryTalk View
clients to browser-based remote users.
FactoryTalk ViewPoint software supports fully
scalable and animated Web displays of existing
FactoryTalk View Site Edition (SE) visualization
software and Allen-Bradley® PanelView™ Plus
applications from the office, home or on the road
via any Internet browser. While the initial release
is Internet Explorer (IE) compatible, additional
browser and device support is planned.
For more information, visit:
www.rockwellautomation.com/rockwell
software/performance/viewpoint/
Internet Explorer Firefox
Mobile Devices
Safari
FactoryTalk ViewPoint Web Clients
FactoryTalk ViewPoint ServerFactoryTalk View SE Server 1 FactoryTalk View SE Server 2
ControlNetwork
InformationNetwork
FactoryTalkView SE Client
5 To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess
FactoryTalk ViewPoint Web-HMI
FactoryTalk AssetCentreAdds Device Configuration and CalibrationManagement CapabilityThe latest release of AssetCentre now includes
the capability to configure and manage
process devices. The solution, jointly
developed with Endress+Hauser is based on
FDT/DTM technology. AssetCentre is an FDT
frame application capable of supporting a
wide variety of process instruments and other
field devices through plug-in drivers (DTMs)
from device manufacturers. This capability
enables online access to device configurations,
device troubleshooting and diagnostics.
Calibration Management capability has also
been added into FactoryTalk AssetCentre. The
software tool is used to efficiently manage
calibration activities that are associated with
process devices. This is useful for enabling
regulatory compliance and good
manufacturing practice.
It allows the user to:
• Schedule calibrations
• Manage calibration standards
• Manage certifications
• Document as found/as left information and
automatically calculates tolerance
• Perform paperless calibrations
For more information, visit:
www.rockwellautomation.com/rockwell
software/assetmgmt/assetcentre/
FactoryTalk Batch Version 10Version 10 of FactoryTalk batch has seen anumber of enhancements to improveproductivity, reduce costs, and simplify recipedevelopment. Enhancements include:
• Smart Binding – Configurable real-timedynamic unit selection for optimal procedural flow
• Timer Steps – Reduce engineering andvalidation effort through use of product timer steps