T30 New Connectivity and Reporting Client for Factorytalk Historian

7/31/2019 T30 New Connectivity and Reporting Client for Factorytalk Historian

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Copyright 2011 Rockwell Automation, Inc. All r ights reserved.

T30New connectivity andreporting client for

FactoryTalk HistorianJan Pingel

Product Manager, FactoryTalk Historian

Rockwell Automation

Automation Fair 2011

November 16-17, 2011

Chicago, IL McCormick Place


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FactoryTalk Historian

Announcement with OSIsoft

FactoryTalk HistorianSite Edition

Released

2006

2007

2008

2009

2010

2011

2012


Site Edition 2.1

Update


Machine Edition

Released


Site Edition 2.2

Update


Machine Edition 2.2

Update

Copyright 2011 Rockwell Automation, Inc. All rights reserved. 2


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Soon Launching

updated version of

Historian SE with latest

version of

PI Server 2010

New

version 3.0

2006

2007

2008

2009

2010

2011

2012


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And launching


Enterprise Edition

New

version 3.0

2006

2007

2008

2009

2010

2011

2012


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Agenda

2. Typical Challenges for Historian systems

5. Wrap-up

1. Introduction

4. New solutions for Information Software

3. Information solutions with Historian today


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INTRODUCTION




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Turning Process Data intoManufacturing Intelligence

A single, information management application server is the central data

point for process information. The information management serverapplication offers these features:


Control Systems

HMIs

Production

SchedulingAlarms/Events

Other Database

Systems

Computerized

Maintenance

Management

Systems

Performance

Quality

Systems

Data Historians

Laboratory

Information

Management

Systems

Supports both data

management anddecision support

Manages several

different data sets flows

into the server Supports data analysis

from the server.


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Decision Support Data Management

Data Management

A distributed, data management strategy enables different focuses of

data by various users. Operator viewing data from the machine directly in the HMI

Supervisor viewing data to make plant-wide decisions

Manager viewing key KPIs from each plant and evaluating plant performance


ExcelDashboards

Trend ReportsPortal

KPIs

Data Collection

Data StorageProcess Book

Batch Analysis

DataLink

SQC


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Decision Support

Decision Support

A decision support strategy addresses the need to rapidly capture and

evaluate information to make business decisions. This starts by efficiently and reliably collecting data and integrates

the support

tools necessary to analyze, view, and summarize that data. Portals and dashboards

are key to presenting users the information they need, when they need it.


Decision Support Data Management

ExcelDashboards

Trend ReportsPortal

KPIs

Data Collection

Data StorageProcess Book

Batch Analysis

DataLink

SQC


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What is a Historian?

Time Series Data collection

Data Historian

Plant Historian

Process Historian

All different names for the same function
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Process Historian

Traditional Historians for Continuous Process

Collection continuous process data from the equipment

Temperatures

Pressures

Speed

Etc.

Trending process data over time

used by in industrial and manufacturing environments to record and report on historical data over time, which

can include process and product information, as well as network performance and IT monitoring. Automated

Results provides historian application and database consulting, support, integration, user and administrator

training, custom application development, and reporting services.

Process Trend View



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What is NOT a Historian(s task)

Not trending the data

Probably not going to use a Historian !!

Collecting records of data

Data should be stored outside a time series data store

i.e. Batch Records, Production lots, Orders, Shipments, etc.

Records with multiple columns (elements)

Should be stored in a relational database



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The Hybrid Model

The Data Model in a comprehensive plant data base Incorporates:

Real Time Data

Relational Production Data

Time Series Data

A Data Historian cant replace a

complete plant database, and

A Relational Database is not a

replacement for a good Historian

There will always be room for both technologies in a good plant data

model.

Production Data

Process Data



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The Hybrid Model

Merging both Technologies

Adding Context / Model

Moving away from a flat data structure

to an organizational structure

Link time series data to assets Adding: asset properties, events, analytics etc.

Event Framing

Store events like: Batches (full S88 model),

shifts, material flow, alarm and events etc,

Visualize the process data within those

events (fence posting)

Use analytics: Totalize data over the event

/ time boxCopyright 2011 Rockwell Automation, Inc. All rights reserved. 16


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The Hybrid Model

The connected Historian

Connecting:

The traditional Time Series Data with

Event data (Event Framing / Fence Posting)

Asset Data (Context / Properties / Analysis )

Production Data Manufacturing Data

ERP Data

Etc.

Time Series

Data

Event Data

Asset Data

Analysis

Production Data

Manufacturing Data

ERP Data



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TYPICAL CHALLENGES FORHISTORIAN SYSTEMS




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Historian Challenge

Collecting the data

Identifying what to collect

Configure the data collection

Visualizing the data

Navigating the data structure Correlated Historical data with other data types

Finding the right way to present the information




Data Historian Users

Complex configuration Many different interfaces

Many potential architectures

Time consuming

Hard to make repeatable

With multiple layers ofHistorians makes it more

complex.

Flat data structure Complex tag names

Often times 1000s of tags

Not easy for all levels of user

in an enterprise

Require lots of pre-configured content

Not easy to run quick Ad hoc

analysis from the data


http://www.my-vending-uncle.com/index.htmlmailto:[email protected]:[email protected]:[email protected]


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INFORMATION SOLUTIONS WITHHISTORIAN TODAY

FactoryTalk Historian Data Collection



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Deployment and Configuration made easier

Premier Integration to FactoryTalk

Pre configured: Users, Data sources, databases, systems

Auto Discovery / Auto Configuration

Standardization of code and data structures can get systems up and running quicker

Configuration Rules

Can make deployment repeatable

When a similar skid, system, line is deployed the data collection can be configured

by repeating the previous configuration.



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MOTOR1.SPEEDTANK1.TEMP

TANK1.PRESSURE

TANK1.TEMP

TANK1.SIZE

TANK1.PRESSURETANK1.VOL

TANK2.SIZE

TANK2.VOL

MOTOR1.ACC

MOTOR1.SPEED

MOTOR1. PREMOTOR1.PID.SP


Auto Discovery and Configuration based on


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Auto Discovery and Configuration based onrules defined in included rule tool

Auto Configuration based on:

Easy to configure rules

Based on consistent naming

convention at customers

Allows to discover individual tags

and structures

Multiple rule files can be defined

for different purposes

Types of machines

Areas in customer plant

From different vendors

Etc.


Tags discovery are also


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Tags discovery are alsoautomatically configured

For each discovery rule:

A configuration can be defined

That defines the way the tags

discovered by the rule will be

configured.

Which means that no fine tuning

of the tags will be needed after

the configuration wizard is done.

Configuration includes:

Description, units

Range, typical value

Exception and Compression

Etc.


C l l i E i d A l i


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Calculation Engine and Analytics

Internal calculation engine

Performance equations Totalizers

ACE Advanced Computing Engine

Real-time SPC alarming on server

Including SQC client to display SQC charts Development tools

Open data access methods

OPC

OLEDB


R d d d Hi h A il bilit


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System

Management

Tools

Thin Clients: VantagePoint, Portals,

Rich Clients: View, ProcessBook, DataLink, FactoryTalk

Applications, Custom Application

PI SDK

SecondaryHistorian

Configuration

Changes

Redundancy and High Availability

Data Buffering

Services

Historian Interfaces

Data Buffering

Services

Historian Interfaces

Secondary

Historian(s)PrimaryHistorian

If your customer wants high availability,

then you need to specify redundant

historian servers

If your customer wants redundancy,

then you need to specify redundant

interface nodes


H b t di t ib ti f d t ll ti ?


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How about distribution of data collection?



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Multi tiered

Architecture

High Speed at

machine level with

local trending

Plant Historian with

Analysis, Calculation

and Consolidation

Enterprise Historian with multi

site aggregation capability and

enterprise visibility

With integration into Universal

Production ModelYou dontneed to know where the data

physically resides system

finds data on request



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New Embedded Historian Module for ControlLogix

Capability for High Speed data collection in the backplane



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Where traditional data

collection is done

through interfaces anddata servers



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Where traditional data

collection is done

through interfaces anddata servers

Data Transfer

transfer's archive

data directly from the

ME module to Plant

Historian



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Enterprise Historian for large scale data aggregation

Capability for collection millions of tags


FactoryTalk Historian Enterprise Edition 3 0


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FactoryTalk Historian Enterprise Edition 3.0

Final piece to the Distributed Historian strategy now being released

Completing the architecture with the Enterprise level data aggregation

Based on latest PI Server 2010

Will be commercialized in partnership with OSIsoft

EE Customer will have access to both vendors support teams

Target Release Date: January 2012


FactoryTalk Historian EE Positioning


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FactoryTalk Historian EE Positioning

FactoryTalk Historian ME

Machine / Line Historian Temporary Storage

Limited to circular buffer in Flash memory

Requires Plant Historian for long term storage

Reliable data collection If the machine and chassis is powered and the

controller is running the machine, the data gets

collected

Backplane data collection Scan rates down to 10 msec

Embedded Historian Module No OS or patches to maintain

Full Historian Capability Built-in Basic Calculation Engine for

Performance Equations and

Statistical Totalizers

Low Deployment cost Easy to buy, Easy to own

Up and running in less than an hour

FactoryTalk Historian SE

Plant / Site Historian Persistent Storage

As much as Drive space allows

Archive / backup strategy can be put in place for

long term storage

Redundancy required for reliability If minimal data loss is required, redundant

architectures has to be applied from the

controller and up.

Data collection based on Network Scan rates down to 100-250 msec max

Significant 3rd party connectivity

DA Component (OPC, OLE DB)

Windows Server Based Historian Maintaining a Windows Server OS

World Class Historian Added Advanced Calculations

VB.Net Adv. Calculation Engine

Analysis Framework

Easy to deploy Up and running in less than a day

FactoryTalk Historian EE

Enterprise Historian Persistent Storage

As much as Drive space allows

Archive / backup strategy can be put in place for

long term storage

Redundancy required for reliability If minimal data loss is required, redundant

architectures has to be applied from the controller

and up.

Data collection based on Network Scan rates down to 100-250 msec max

Significant 3rd party connectivity

DA Component (OPC, OLE DB)

Supports data aggregation over WAN

Windows Server Based Historian Maintaining a Windows Server OS

World Class Historian Added Advanced Calculations

VB.Net Adv. Calculation Engine

Analysis Framework

Typically requires services Complex Architectures

Multiple server connection setups etc.



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NEW SOLUTIONS FORINFORMATION SOFTWARE

FactoryTalk Historian Data Visualization


Talk about getting data to users


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Talk about getting data to users

How to visualize data

So it make sense to the users Brings valuable insight about the process and production

In formats appropriate for the solution

FactoryTalk VantagePoint !!! Advanced trend tool

XY Plotter

Excel Add-in

Advanced Dashboards

Portal for thin client access


Trending Made Easy


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Trending Made Easy

Compare data over different

time periods including

historical, pre-set and real time

Analyze and display multiple

tags/items from the model

concurrently

Powerful trend functionality -

drag and drop, pan, zoom,

stack and synchronize

Publish and share trends withothers through the portal


FactoryTalk VantagePoint XY Plotter


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FactoryTalk VantagePoint XY Plotter

Analyze one value with respect

to another over time periods

including- historical, pre-

defined or real-time

Display and compare multipletag pairs concurrently

Powerful functionality including-

drag & drop, pan, zoom and

scale


Excel Reports Available to Everyone


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Excel Reports Available to Everyone

Easily retrieve data from

Historian to use in Excel

Calculate, analyze and

format reports using Excel

functionality

Only one version of the

truth because Excel reports

are built within VantagePoint

and are saved in the model

Published reports can be

viewed by anyone with

access to a browser

Retrieve

Data From Any

Source

Calculate,

Analyzeand Format

Publish to the

VantagePoint

Portal


Powerful Easy-to-read Dashboards


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Powerful Easy to read Dashboards

Create powerful dashboards

that monitor key

manufacturing KPIs

Dashboards can update

dynamically and on demand

Published dashboards can

be viewed by anyone with

access to a browser


All You Need is a Browser


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All You Need is a Browser

No client install is needed to

view trends, reports and

dashboards

Simply publish reports in the

portal to allow access


Composite Reports for Greater Visibility


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Composite Reports for Greater Visibility

Reusable

Components

Dashboard

Builder Trend

Excel

Plot


Access From All Systems andC t t B d U R l


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Context Based on User Roles

Access to ALL plant floor, production and business systems

Integrate and organize time series and transactional data

Users at all levels of enterprise can view role-based KPIs, reportsand dashboards


Manufacturing Intelligence via VantagePoint


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Manufacturing Intelligence via VantagePoint

The Unified Production Model is:

Logical layer oforganized information created by instances of types & theirproperties

Examples of Types include:

It can also be collections / hierarchies of types Standard set of types provided

Ability to create custom types to represent your business / manufacturing process

Reports / visualization are built on the UPM, not the source data

AssetsPump

Extruder

Tank

Filler

Welding Cell

Utility Meter

Structures

Production LineProduction Area

Plant

Enterprise

Production Schedule

Operator

Process

Quality AuditRepairs

Test / Inspection

Batch

Product Parameters

Shift

Type Example: A Pump


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Type Example: A Pump

Process Control Engineer Pressure

Flow

Speed

Production Manager Volume pumped

Product throughput

Operation history

Power consumed

Maintenance Manager Running hours

Performance spec

Manufacturer data

Spares on hand

Maintenance date

Process Engineer

Related equipment

Rating

Vibration data

Asset Manager

Purchase date

Cost

Warranty Manufacturer

Engineering specsQuality Assurance

Batch record

Leak test data

Lab sample

Live Data: Control System/HMI

Historian

Asset

Database

ERP, LMS, SQL

Database

MaintenanceManagement

System

Scalability via the Unified Production Model


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Scalability via the Unified Production Model

LogicalModel

(UPM)

Physical

Data

Sources

Site 1

Plant/Area 1 Data Sources Plant/Area2 Data Sources

VantagePoint Unified Production Model

Site 2


Plant Model enhancement for Historian


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Plant Model enhancement for Historian

VantagePoint Historian Connector functionality:

Context Enhancement to replace the flat name structure in Historian

Logical model of the data points

Instances of types allows for quick deployment of new Historian tags to report on

Inter correlation of real time tags and historical tags

Real time tags that are historized are automatically detected

User can drag a real time tag onto a trend and automatically the system will show

historical data


Functionality of VantagePoint since version 3.0

Plant Model enhancement for Historian (cont.)


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Plant Model enhancement for Historian (cont.)

Inter correlation of historical tags

When tags are historized in multiple historians the system can find the best sourceof information needed for a report / trend.

Makes reporting completely transparent to the end user

they only need to know one reference point (logical) for a data value

Aggregations of data are automatically handled in Historian

When users request aggregated results in VantagePoint

Requests that can be handled faster and more efficient by Historian, are

automatically forwarded to Historian for processing.

Significantly reduces the calculation loads on the VantagePoint Server

Allows for processing of aggregations at the best performing server.


Historian to Historian tag correlation


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System selects the correct Historian tag when:

A real time tag is pulled into a trend Best historian tags is selected

A high speed historian tags is pulled into a trend

But data is no longer stored locally

Data is aggregated to Plant Historian

A plant historian tags is pulled into a trend

But newer data is available elsewhere

Etc.




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g

What does it really mean?



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Correlating live data tag to best match Historian tag



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Inter correlating Historian tags based on time window



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Adding the Logical model (UPM)



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SoCAL

Area 1

Tank 1

TemperatureTemperature

Data aggregation handled by Historian


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gg g y

System diverts aggregations and calculations to Historian where

appropriate:

Interpolated values instead of raw values

Summarizations

Statistical Analysis

Etc.




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gg g y

What is the significance?

Performance improvements !!!



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Allows us to add more clients to VantagePoint without adding significant

to the overall performance requirements !!



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WRAP UPFactoryTalk Historian


Summary: Scalable, performance Historian


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Scalable data collection

From in-chassis high speed to Advanced Plant Historian to

Enterprise level aggregation

Easiest Historian to deploy especially on a Logix platform

High Availability

Extensive calculations and aggregations included


Summary: Informed Decision making


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Comprehensive Historian client

Excel reports, Advanced trends, dashboards, composite reports All available from a think client portal all you need is a browser

Brings context to Historian data

From complex flat data model to logical, easy to navigate Universal Production Model

Connect disparate data sources to live and historical data Makes the information valuable and relevant

And now

Seamless correlation of data points collected in various data sources

Executing presentation layer aggregations in the Historian

Summary: What results can you expect?


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Decreased overhead costs

Reduction in data collection and informationtransformation (data prep)

Increased utilization of fixed assets

Information rather than data

Advanced portal, reporting, and analytical

capability

Increased productivity, revenue, and profit

Decrease in manufacturing costs

Better understand your process, then optimize it

Reduced materials, labor, and energy

Decrease in cost of quality

Higher accuracy and agility via process control

Less scrap and material losses

Increased productivity by 10 percentin less than one year, allowing the

company to get more product to the

market at a lower price point and be

more competitive - CPG

With premier integration to our controls,

and auto configuration and tagbrowsing, we can get a system up and

running in about an hour

Pipeline company

720 man-hours saved annually ingeneration of regulatory and ad hoc

reports, estimated savings of one

man-yearin automation of billing

process - Water Wastewater

For more information on VantagePoint


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Copyright 2011 Rockwell Automation, Inc. All r ights reserved.

Thank You

For more information:


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Jan Pingel

Product Manager, FactoryTalk Historian

[email protected]+1 704 665-6026

http://discover.rockwellautomation.com/

Brian Porter

Product Manager, Information Software

[email protected]+1 440 646-6508

Documents

T30 New Connectivity and Reporting Client for Factorytalk Historian