PlantPAx System Overview

Transcription

PlantPAx System
Overview
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Jason P. Wright
Product Marketing Manager
PlantPAx System Core
Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL – McCormick Place West
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
PlantPAx System Overview Introduction
This session is an introduction to the PlantPAx Process Automation
System:
– Review of PlantPAx System capabilities
– Examples of PlantPAx System applications
– Summary of PlantPAx System benefits
– Where to go for more information
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Manufacturing Challenges
Globalization, Sustainability, Productivity, Innovation
Solution: Plant-Wide Optimization
New pressures are driving manufacturers across
their enterprise on continuous improvement
at all stages of the plant lifecycle.
Manufacturers today must leverage their
automation investment to create an
architecture for continuous optimization.
Maximize Return on Assets
• Risk Mitigation
• Time To Market
• Supply Chain Efficiency
• Globalizing Footprint
• Demand Forecasting
Flexible Operations
• Asset Efficiency
• Cost Management
• Production Intelligence
• Utilization
• Quality, Yield, Productivity
Innovative engineering
• Decision Support
• Advanced Process Control
• Design Productivity
• Total Lifecycle cost
• Global/ Local Standards
PlantPAx Process Automation System
Protection of plant personnel
…equipment
…production
…and the environment
Scalable high availability throughout the architecture
• Protect only what you need without over-investing
• Focused not only on availability and uptime, but also
maintainability
Information-based solution for operations productivity
• Decision support, production analysis, and optimization drive
profitability
Plant-wide control, performance tuned for process
applications
• Standards-based architecture enables multi-disciplined control
• Extends EtherNet/IP as control backbone
PlantPAx: Plant-wide optimization solution
for the process industries
Control and I/O Portfolio
Scalable Controller Portfolio
… From ten loops to
hundreds per controller
Robust Network Infrastructure
… CISCO technology and EtherNet/IP
with redundancy options at every level
Comprehensive Integration
… The broadest range of traditional I/O
and intelligent devices
Modern infrastructure via the most cost effective design
Operator Efficiency
Integrated Visualization
… Intuitive displays, objects, and
faceplates with integrated diagnostics
Decision Support Tools
… Dashboards help identify opportunities
for continuous improvement
Scalable Architecture
… Solutions for on-process, mobile, and stand-alone applications up to
large distributed systems—deployed traditionally or virtualized
Operators should spend their time controlling the plant,
not being distracted by the control system
Engineering and Configuration
Consolidated Deployment Tools
… Comprehensive system configuration environment
and tools for library management and
bulk system engineering
Modular Object Library
… Predefined logic and HMI objects shorten
development and testing time
Defined System Architectures
… Minimizes risk of mid-sized
systems and ensures system
performance
Shorten development time and minimize human error
Instrumentation
Asset Management and System Maintenance
Instrument
Health
Instrument
Diagnostics
Instrument
Management
Valves and
Instrumentation
… Comprehensive
management enabled
by industry standards
Tech:“How do I fix it?”
Maint: “How bad is it?”
Power Control
Operator: “Is it OK?”
Devices
Device Health
Device
Diagnostics
Device
Management
… Intelligent drives
and MCCs as native
system components
Ensure process uptime via asset performance
management and predictive maintenance
Intelligent Motor Control
Control
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Communicate
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Protect
Variable speed AC drives
• Electronic overload protection relays
Packaged & pre-engineered solutions • Soft starters
LV and MV motor control solutions
• Condition monitoring
Asset management
Supporting capital investments long term
Safety and Critical Control
High Availability Process Control
… High availability solutions
from redundant I/O to redundant controllers,
resilient networks to redundant HMI servers
Scalable Process Safety
… Integrated BPCS and scalable
SIS solutions, including TMR for
the highest availability
SIL 0
Process
Control
SIL 1
Fail Safe
SIL 2
Fail Safe
SIL 2
Fault
Tolerant
SIL 3
Fail Safe
SIL 3
Fault
Tolerant
Risk reduction by protecting only critical assets
Batch Management
Integrated Analysis Tools
… Batch reports, material usage, genealogy,
and solutions to optimize batch production
Native ISA-88 Structure
… Simplify change management
and regulatory compliance
Scalable Platform
… From simple, single unit scale to highly complex, integrated batch solutions
Flexibility to respond to external pressures – regulatory
compliance, yield optimization, production agility
Operations Productivity
Scalable Data Collection
Decision Support Portal
… Chassis-based, plant-wide or
enterprise-wide historian
… Track production KPIs to manage
cost, quality, resources
Actionable information in the hands of decision makers
Process Optimization
Broad Advanced Control Portfolio
… From simple model-based control to fuzzy logic,
soft sensors to complex model predictive control
IMC_01
IMC
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Internal Model Control
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Flexible Deployment
… From loop and unit-level optimization in the controller
to plant-wide economic optimization at the supervisory layer
Proven economic gains – increase production, reduce
costs, improve quality, reduce environmental risks
Industrial Security
Reduce Risks to Safe and Reliable Operation
…Control system architecture with layered security to
help maintain operational integrity under threat
Protect Assets & Information
…Product and system features to
help control access, tamper-proof
and limit information exposure
Government and Standards Alignment
…Responsible disclosure with control system solutions
that follow global standards and help fulfill independent
& regulatory security requirements
Address risk to helps protect people, assets and
information from accidental and malicious threats.
Lifecycle Support: Protect Your Investment
On-Site and
Continuous Remote
Managed Service:
Monitoring and
• Instructor-led
24x7 Support:
• On-site
• Application Support
• Integrated Parts &
Labor Services
• System-level Support
System Training:
• Assessments
Process Device
Management:
Consulting
Services:
• Device Calibration
• Safety & Energy
• Field Device Integration
• Network & Security
& Asset Management
• System Migration
• Spare Parts Management
• Disaster Recovery
Consumer-Driven Industries
Food & Beverage
Household & Personal Care
• Anheuser-Busch
• Coca-Cola
• Kellogg
• Kraft/Nabisco
• M&M Mars
• Nestlé
• PepsiCo/Frito-Lay
• SABMiller
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3M
Beiersdorf
Colgate-Palmolive
DuPont
Henkel
Kimberly-Clark
Procter & Gamble
Unilever
Life Sciences
• Abbott Laboratories
• Johnson & Johnson
• Merck
• Pfizer
• Sanofi
• Wyeth-Ayerst
True Plant-Wide Control
Continuous Improvement
OEM Scalability
… Drives total cost of
ownership savings
… Provides plant-wide
manufacturing intelligence
… Cost effective in
skid integration
Total Cost of Ownership (TCO) savings and
continuous process improvements
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Life Sciences
New Active Pharmaceutical Ingredient Plant
Application:
• Primary (API)
production plant
Solution:
•Recipe-based
operation & EBR
•Workflow
automation
•Design,
engineering,
startup and
operator training
Exception
review
Exception
closing
Weigh and
Dispense
Batch
execution
Technology:
• PlantPAx DCS
• FactoryTalk
PharmaSuite (MES)
PlantPAx batch control & MES integration for production flexibility
Resource-Driven Industries
Water / Wastewater
• A & E Firms
• Consultants
• Design Engineer Firms
• Design Institutes
• Global Municipalities
• Privatizers
• Pump OEMs
• System Integrators
Mining / Metals / Cement
• Alcoa
• BHP Billiton
• CEMEX
• Holcim
• Lafarge
• Rio Tinto
• US Gypsum
• Vulcan
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Oil & Gas
Semiconductor
BP
Chevron
ConocoPhillips
Exxon Mobil
Shell
• Agilent
• Applied Materials
• ATS Automation
• Axcelis
• IDC / CH2M
• KLA-Tencor
• Novellus
• Praxair
• Seagate
High Availability
Operational Excellence
Sustainability
… Ensures uptime and
safe operation
… Provides critical asset
performance information
… Reduces cost associated
with W.A.G.E.S.
Optimized approaches for engineering,
operations and maintenance
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Water:
DCS migration for water authority
Application:
• Complete upgrade of
a water purification
plant
Solution:
•Controls for filter
beds, fluoride and
pumping
•Design, engineering,
startup and
operator training
Technology:
• PlantPAx DCS
• Smart instruments
Commissioned without interruption in city water supply
Pulp & Paper:
DCS migration for paper mill
Application:
• Stock prep
• Paper machine control
Solution:
•Process and power
control
•Network design
•Design, engineering,
startup and operator
training
Technology:
• PlantPAx DCS
• MV Drives, MCC
US$5 million CapEx reduction for plant reconfiguration
Driving Differentiation
Plant-wide Control and Optimization
… Process, Power, Information and Safety
… Enables vendor rationalization (lowers total cost)
… Real-time information for continuous improvement
… Scalable across applications, operations and environments
Lower Total Cost of Ownership
… Common plant platform - reduced downtime
… Lower IT integration costs
… Reduce operator error and training costs
… Lower licensing renewal costs
Unified IT Infrastructure
… Easy plug-in to EtherNet/IP
… Information enable for decision support
… Cisco partnership and standards
… IT friendly (decision partner for large projects)
OEM Scalable
… DCS-compliant, easy integration of skids to DCS
… Supports multi-vendor integration in projects
… Cost-effective in design, development and deployment
… Rapid field device integration
Where to find more information
PlantPAx Selection Guide (Proces-SG001)
• Assist with system definition and
procurement
• Ties in with PSE and Characterization
• Defines how to procure a system for
optimal performance
PlantPax Reference Manual (Proces-RM001)
• Concentrates on the implementation
recommendations that apply to all
PlantPAx Systems
• Defines how to configure a system for
optimal performance
PlantPAx TOC on KnowledgeBase: 62366
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Customer Voice – Thank you!!!
Process Customer Advisor Board (CAB) directs the success of the
Process Solution User Group(PSUG)
Represents a broad base of customers and industries:

Archer Daniels Midland

Kraft Foods

Colorado Springs Utilities

Pacific Gas and Electric

Dupont

Pfizer

Gerrie Process Group

Premier Systems

Industrial Furnace Company

Procter & Gamble

JNE Automation

Others

Kimberly-Clark
Each year at PSUG, you help define
PlantPAx system development direction and features
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Questions?
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Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL – McCormick Place West