PlantPAx: Process TalkeNews for the Process Industries

PlantPAxProcess Automation System

Issue 17 – January 2014

In This Issue:• Optimize your Automation System

• Solution Delivers on Promises

• Product and Service Highlights

• New Videos

• Partner Highlights

• Global Events

Upgrade your DCS to achieve superior system performanceIf your plant has an outdated Distributed Control System (DCS) as many process plants do, it may be reaching the end of its useful life and require an upgrade to a new automation system. One of the main factors for upgrading is the expected superior performance of a new automation system as compared to the old DCS. Superior performance results in lower overall plant operating costs, less downtime and lower maintenance costs – providing sufficient return on investment to justify an upgrade.

A new automation system will outperform an older DCS and allow users to implement superior process control in a number of ways.

• Superior PID loop control and auto tuning that is often built-in

• Improved Advanced Process Control

• Improved alarm and event handing, improving operator performance and providing better data to plant engineers charged with analyzing plant operations and improving performance

• More reporting options with easier implementation allowing non-programmers to create a variety of reports, providing superior data in easy-to-understand formats

• Easier integration with third-party software systems

• Easier integration with smart instruments, analyzers and values

• Better remote access

• Lower support costs

• Better access to new features and functions

• Easier to find personnel familiar with the system, making it easier to support

An older DCS will typically not be capable of running a modern process plant at optimum levels. This sub-optimum performance imposes many costs on a plant, including some obvious ones such as excessive downtime.

Some of the hidden costs include less than maximum designed throughput, poor quality, excessive energy consumption, longer response time to alarms and incidents, and excessive demands on plant operating and maintenance personnel.

A modern automation system can more than justify the required investment by eliminating all of these costs – and by adding other benefits such as improved security, better remote access and predictive maintenance.

Optimize your Automation System

PlantPAx: Process Talk eNews for the Process I ndustr iesI s sue 17 - Januar y 2014

If you are ready to upgrade your outdated DCS, Rockwell Automation and its partners will work with you to create a migration plan that fits your application needs and long-term goals. We can help you migrate all at once or in phases, at a pace that is comfortable for you and fits your budget, while leveraging the latest capabilities and technologies of our PlantPAx™ Process Automation System to help you achieve superior system performance.

For more information on automation system optimization, please access our white paper:

Automation System OptimizationReview our Solutions & Services

Solution Delivers on PromisesPavilion® software reduces energy consumption and increases outputIn 2010, a batch processing company was seeking a way to maximize the output of one of their production lines while reducing energy consumption and raw material losses while improving their final product quality.

This required a better way of executing process control. After consulting with the Rockwell Automation Information Software & Process Business (ISPB), the customer agreed on executing an assessment to see if model predictive control (MPC) technology – an intelligence layer on top of basic automation systems – would benefit them.

Our MPC solution leverages the Pavilion8® software platform to deliver industry-specific control and optimization solutions. It provides benefits by reducing process variability and inefficiency, improves product consistency, and allows operations to push constraints to the limits.

MPC is typically and widely used in continuous processes. The challenge with this customer was how to deliver results with a batch-related process. During the assessment, the Rockwell Automation team identified process issues, and analyzed the customer’s process and quality data. Due to the high level of automation in the line and our unique model capabilities we were able to predict the following benefits:

• Increase production line throughput by 4 percent

• Reduce energy consumed per unit produced by 3.5 percent

• Reduce specific steam usage by 2 percent

• Reduce variability in quality by 7.5 percent

After a successful pilot project in one of the customer’s facilities, where our team delivered on promises, the customer proceeded with a roll-out of our solutions to other sites.

Next phase

In the beginning of 2011, we performed an assessment of the production process to determine the potential benefits that can be achieved through a MPC solution for all sites.

Based on time-to-market, benefits and return on investment, the customer decided to start the next MPC implementation in one of their manufacturing facilities, including three production lines.

The success of this project and the first pilot project has opened the doors for potential other Rockwell Automation solutions (MES, ControlLogix ® etc) and the roll-out of MPC into many other sites globally.

For more information please visit our website.

Product and Service Highlights FactoryTalk®EnergyMetrix™FactoryTalk EnergyMetrix is a sophisticated Web-enabled, energy management software package that gives you access to critical energy information from virtually any location. The FactoryTalk EnergyMetrix Software combines data communication, client-server applications, and Microsoft’s advanced .NET™ Web technology to provide you with a complete energy-management decision support tool.

With FactoryTalk EnergyMetrix, you can capture, analyze, store, and share energy data with key stakeholders using a standard web browser. This makes it simple to distribute the knowledge necessary

to optimize energy consumption, manage power quality, correlate energy usage, determine cost to production, negotiate energy rates and improve efficiency.

FactoryTalk EnergyMetrix provides a comprehensive view of energy data in one place. With FactoryTalk EnergyMetrix, you can:

• Provide accurate cost accounting based on consumption

• Generate energy reports and charts for a process, department, facility or enterprise

• Optimize energy procurement and help negotiate better rates

• Monitor harmonics to facilitate targeted maintenance

PlantPAx: Process Talk eNews for the Process I ndustr iesI s sue 17 - Januar y 2014

• Understand the impact of power quality events on your equipment or facility

• Procure and analyze energy information with minimum capital investment

• Assign energy costs to the process that generated those costs

• Generate customized reports to suit your information needs

Watch a useful how-to demonstration of this tool’s functionality

Find more detailed information and benefits

PlantPAx QuickStart The PlantPAx QuickStart is part of the project implementation focus area of the new PlantPAx System Release 3.0. Like the PlantPAx System Estimator which makes it easy to define the system based on rules set out by the PlantPAx Selection Guide, the PlantPAx QuickStart and associated templates makes it easy to build a system

based on the rules set out by the PlantPAx Reference Manual.

• Provides a consistent starting point for system implementation

• Promotes a standardized application framework for control systems and process skids to provide a unified system experience

• Reduces implementation risks and promotes application practices for optimal system performance

Download more detailed information here

PlantPAx Sequencer Object The PlantPAx Sequencer Object provides a flexible controller-based step sequencing solution that allows common operator procedures to be automated, reducing human error. The step-by-step configuration process, provided at the HMI

for credentialed users, makes it easy to create or update a sequence. Features include:

• Up to 32 discrete (BOOL) inputs for monitoring device feedback

• Up to 32 discrete (BOOL) outputs for controlling or commanding devices

• Up to 32 floating-point number (REAL) outputs for setpoints or parameter values

• An unlimited number of sequence steps per sequencer instance (limited by available memory)

• State model consistent with higher-level procedural control, with states for Idle, Starting, Running, Complete, Held, Paused, and Stopped

Download the profile

New Videos Click on the link below to see highlights from the Process Solutions booth at Automation Fair 2013 in Houston.

• PlantPAx Process Automation System, Kris Dornan

• PlantPAx Virtualized Solutions, Greg Hood

• Legacy DCS Migration Program, Mike Vernak

• Process Safety, Julien Chouinard

Find out more information on our process solutions here

Partner HighlightsThe Power of CollaborationWorld-class products, services and solutions are delivered globally through Rockwell Automation. When you choose Rockwell Automation, you also tap into the power of our PartnerNetwork™ program – a framework of well-managed relationships based on your needs. Our program provides you with access to a local, regional and global network of best-in-class companies including distributors, system integrators, machine builders, alliances and complementary product providers.

The keystone of our PartnerNetwork is collaboration that allows a seamless relationship with you, built on mutual trust and shared business values.

Highlighted below are Solution Partners that are part of our ParnerNetwork and who have achieved the Process Discipline.

Automated Control Concepts Interstates Control Systems, Inc.Applied Control Engineering JNE AutomationApplied Control Technology Malisko Engineering, Inc.Bachelor Controls, Inc. Matrix Technologies, Inc.Banks Integration Polytron, Inc.Concept Systems, Inc. Power EngineersCustom Control Mfr. Of Kansas, Inc. PREMIER System Integrators, Inc.Cybertrol Prime ControlsE Technologies River ConsultingElectro Design Engineering, Inc. RoviSys CompanyESE, Inc. Stone TechnologiesGrantek Thermo Systems, Inc.Innovative Controls Solutions Zeppelin Systems USA

More detailed information on our Solution Partners

PlantPAx: Process Talk eNews for the Process I ndustr iesI s sue 17 - Januar y 2014

Global Events 2014 February 6 ePlan – Process at a Glance – Baden, Switzerland

February 6 Cyber Security for Industrial Control Systems Seminar – London, UK

February 11 – 13 Tire Technology Expo 2014 – Cologne, Germany

February 11 – 13 Cfia – Rennes, France

February 25 – 27 RSTechEd – Gold Coast, Queensland, Australia

February 25 – 27 Water and Energy Exchange (WEX) Global 2014 – Madrid, Spain

March 4 – 5 RSTechEd – Auckland, New Zealand

April 1 – 3 Smart Industries – Paris, France

April 8 Water Class Factory – Paris, France

April 16 – 18 Pishcvaya industria – Krasnodar, Russia

May 5 – 8 Offshore Technology Conference (OTC) – Houston, Texas

Publication PROCES-BR030A-EN-P – January 2014 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Allen-Bradley, Automation Fair, ControlLogix, FactoryTalk EnergyMetrix, PartnerNetwork, Pavilion, Pavilion8, PlantPAx, Rockwell Software and Rockwell Automation are trademarks of Rockwell Automation, Inc. All other trademarks are registered trademarks are property of their respective companies.