Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
City of Detroit PlantPAx Process Library and WWW Accelerator Toolkit Save $ for Integrator and City of Detroit
Hassan Ajami PCI General Manager Date – 11/5-6/2012
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PCI is a System Integration firm established in 2000 to serve the Metro Detroit region.
Offices in Detroit, Cleveland, Louisville and Shreveport.
Industry focus is on Water/Wastewater and Automotive
Involvement in projects encompasses both design and construction phases.
Clients include both public and private utilities, major automotive companies, and petro-chemical companies.
Process Control & Instrumentation
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The Detroit Water and Sewerage Department (DWSD), one of the largest water and sewer utilities in the United States, has a rich history as a public utility dating back to 1836.
Serves 35% of Michigan’s Population including Detroit and 76 other communities.
Fresh Water System - 5 water treatment plants pump an average of 596 million gallons of clean drinking water each day. Maximum capacity 1.2BGD
Wastewater System - Treats an average of 707 million gallons of flow per day. Maximum capacity 1.65BGD
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Process Networks and SCADA Systems Division – WWTP & CSO Equipment
Operational Support: 21 freshwater and 10 wastewater pump stations 5 Water and 1 Wastewater treatment plant 5 Combined Sewer Overflow basins
Process Controls equipment from Emerson/Ovation & Rockwell/AB > 95%
21,000 Hard I/O Points > 200,000 Total Points 282 PLC/Controllers 92 PC Workstations
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Common industry situation
Multitude of HMI solutions: Ovation, Wonderware, Ifix, RSView32
Large variety of systems integration implementations Disparate process control implementations Usually only hardware platform specified PLC Code developed using only written narratives No standard control software strategies No standard graphics, other than color standard Implementation varies by Contractor/SI/Programmer
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Goals - Accelerator Tool kits
Reduce the engineering time required to create standard, repeatable process applications
You can focus your energies on the custom aspects of your applications. Increase control system quality and reliability.
The reuse of well tested code conforming to industry standards reduces the likelihood of code bugs.
Drive logical and visual consistency The Process Library aids in producing standard Graphics formats that increase the consistency of your HMI thus reducing the need for Operator Training.
Superior diagnostics Built in process diagnostics will make applications easier for operators and maintenance to troubleshoot and debug without requiring PAC programming tools
Scalability – You can build ever larger systems using the same reusable modules.
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Modular Programming Concept Use industry standard format -ANSI/ISA-S88
Create reusable application code based on “Best in Class” designs
Faster and easier development of application software. Examples of proven software programming techniques and recommended programming styles are provided for programmers to use in their own code.
Faster and easier testing of application software. Standards make testing of modular software objects easier, as there is less chance that new software developments will impact existing software objects that are already proven.
More reliable application software. The standards described ensures that changes to one software object will have little or no impact on another.
Improved maintenance and operation of application software The standardized look and feel of the automation controller programming and the human machine interface (HMI) for graphic objects makes it easier for operators and software personnel to recognize application functionality across applications and suppliers.
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Contents of an Accelerator
• An Accelerator provides a package of tools, which significantly simplifies the Design, Manufacturing, Start-Up and Support of Rockwell Automation control systems.
• An Accelerator CD provides the – selection tools and – basic panel layout, – wiring diagrams, – Logix program, – HMI screens and – Quick Start manual
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The Process Library High-efficiency suite of Control Modules
Mode Selection
Standard Alarm
AI w/ Scaling & Alarms
DI w/ Alarms
Single-Speed Motor
Permissives with Bypass
Protectives with First-Out, Bypass
Run Time and Start Accumulator
Re-start Inhibit for Large Motor
Date/Time Blocks • Solenoid-Operated 2-state Valve
• Motor-Operated 2-state Valve
• PIDE-based PID with Standard Modes and Deviation Alarms
• Analog Output
• Variable-Speed Drive (e.g., PF70-style)
• 2-Speed Motor
• Reversing Motor (e.g., FVR)
• Pulse-Input flow meter dosing with pre-act and in-flight adjustment
• Analog-Input flow meter dosing as above
• Weigh-Scale dosing (Loss-In-Weight and Gain-In-Weight supported)
• Controller CPU Utilization
• Hand-Operated Valve Monitor
• Hand-Operated Motor Monitor
• Cascade and Ratio supported PID
• Advanced AI with High Rate of Change Alarm, Square Root Extraction, and Deviation Alarms
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Benefits of Using Accelerator Toolkit Standardized scalable integrated architecture
Single hardware and software platform Standardized controller logic and HMI graphics
Single Scalable HMI Platform based on FactoryTalk FactoryTalk SOA - Services Oriented Architecture
Standards Based – Use of common reusable code and engineering templates
Creates standards for HMI graphic symbols and operation
Significantly enhanced systems diagnostics Leverages diagnostics built into AOP and HMI Templates
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Case Study City of Detroit- DWSD
PC-761 Control System Upgrade at 2 CSO basins Replacement of obsolete Bailey DCS system
Issues Obsolete Workstation Spare Parts Availability Old Tape Backup Lack of Local Support Complicated ABB PLC Interface between Bailey & Rotork valve
system
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Hubbell/Southfield CSO
Hubbell-Southfield CSO RTB The Hubbell-Southfield CSO RTB is one of DWSD’s most active, longest operating CSO facilities and the largest on the Rouge River. Since August 1999, it has been effectively capturing and treating combined sewage through screening, settling and disinfection to meet discharge permit requirements that protect public health. Sized to fit into the available land and site constraints, the basin has a 22 million gallon storage capacity. Located next to the Tournament Players Championship Golf Course (TPC) in Dearborn, this RTB serves as an example of how these facilities can be good neighbors and blend in with the surrounding environment. The facility features an innovative design component that enables three different operational modes within the RTB and prevents resuspension of solids during large storms with high flow rates.
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Puritan/Fenkell CSO
Puritan-Fenkell CSO RTB Located in Eliza Howell Park, the Puritan-Fenkell CSO RTB is the third Rouge River CSO RTB. This facility successfully demonstrated that a facility sized to provide 20 minutes of detention time for settling and disinfection of the 1-year, 1-hour storm event peak flow is sufficient to meet protection of public health standards. The 2.8-million-gallon facility became operational in August 1999 and eliminated two untreated CSO outfalls.
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Control System Options
1. Bailey Upgrade
2. HMI 3rd Party Upgrade with Bailey hardware
3. Rip & Replace 1. Emerson Ovation DCS 2. Rockwell/Allen Bradley 3. WonderWare/Allen Bradley 4. Intellution/Allen Bradley
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Considerations
Cost (Initial & Life Cycle)
Functionality - DCS vs PLC
Maintainability
System Downtime
Support & Support Options
How many platforms to support: Parts Training
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PC-761 Contract
Scope: Hubbell Southfield CSO Total Points 643 Puritan Fenkell CSO Total Points 374
PlantPAx solution including: Redundant ControLogix L73 PAC with Enhanced Redundancy Redundant Ethernet Network- Stratix 8000 Redundant FTViewSE Windows 7 Workstations Process Library V1.5 W/WW Accelerator Toolkit Rotork Master Stations Added Prosoft Modbus Comms Interface to DWSD Ovation System
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Water/Wastewater Accelerator Toolkit Implementation
Utilized 12 Symbols and Faceplates Pump, ValveMO, ValveSO, ValveHO, Conveyor, Mixer, Agitator,
P_Ain, P_Din, P_AinAdv, P_AinDual, P_Aout Required some modification of graphics to meet DWSD HMI
standards Utilized Chemical Feed and Lead/Lag pump application
Editing the Toolkit Standard
Red vs Green for Run Face Plate Control Modes-symbols Rockwell Enhanced Toolkit – Added Color Change Tool
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Old Bailey Overview Screen Hubbell Southfield
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Followed DWSD Operator Graphic Standards
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New Rockwell Overview Screen Hubbell Southfield
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Construction Issues
Failed field wiring in existing conduit duct bank Added Head Works Building PLC/Panelview Control Panel with fiber
optic connectivity.
Instrumentation and final elements failures Not in original project scope
Delayed project construction
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Results-Total construction costs significantly below estimate
Reduced Deployment Time • Resulted in a 50 percent reduction in design time, contract oversight, and post-contract
documentation and support. • Provided process control with advanced networking and diagnostic capabilities • Increased access to process data for better preventive and predictive maintenance
Reduced Engineering Hours and Costs • Saved estimated $120,000 in configuration and systems integration time • Saved $90,000 in factory-acceptance testing and Startup/commissioning
Drove standardization for DWSD wide graphics FTViewSE/ME platform
Advanced HMI without the associated development cost
Software configuration that is fully documented and tested
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Water Wastewater Accelerator Toolkit on the AB.com IA Tools Website
W/WW Accelerator Toolkit CD-IASIMP-SP012B
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City of Detroit DWSD Success Story
Further documentation on: Hubbell Southfield CSO Puritan Fenkell CSO
Publication Number WATVP-AP014A-EN-P April 2012
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Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Questions
Hassan Ajami Process Control & Instrumentation Ilc [email protected] Detroit, Michigan Ph 313-874-5877
PlantPAx Process Library