PlantPAx Process

Tomorrow’s Automation, Today

A Symposium on Virtualization For the Process & Manufacturing Industries

TR03A - PlantPAx Process

Ali Omer Technical Project Manager

PlantPAxProcess

Agenda

What is PlantPAx

System Sizing and Characterization

PlantPAx Logic Add-Ons

PlantPAx HMI Functionality

PlantPAx Components

Process Safety

Batch Management

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It’s a process automation system thatgives you everything you want in aworld-class, contemporary DCS and waymore.

PlantPAx – It’s More Than a Distributed Control System (DCS)PlantPAx

Plant Process Automation Excellence

Word Class DCS

Plant-wide control capabilities

Open, flexible architecture

Integrated control, power, safety, and information

Support by a global network of local experts

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PlantPAxCapabilities

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Capability PlantPAx

Plant wide Control Disciplines

Discrete

Motion

Process & Machine Safety

Continuous Process

Batch

Drivers

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Capability PlantPAx

Control System Features

Controller Redundancy

Remote I/0

System Scalability with Single Platform/Control Engine(Single Machine to Large Plant

Hot swappable I/0

Broad I/0 capability (Rack mounted, field based distributed I/0 and hazardous form factors

Full digital integration with drivers and MOC

No loop or point lie sensing

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Capability PlantPAx

Configuration and Programming

Object Oriented

All IIC 63131 Programming Languages

Online Editing/Configuration

Tag Based Addressing & Programming

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Capability PlantPAx

Visualization

Fully Integrated Client/ Server HMI with Redundancy

Panel Based HMI

Web based HMI Interface

Historical Data Collection (SOE, EVENTS, TRENDING, REPORTS)

Controller based historian

Alarms and Events

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Capability PlantPAx

System Communication and Field Buses

Ethernet (I/P)

Standard Ethernet Infrastructure (Cisco Alliance)

Control Net

Device Net

Mod Bus

AS/I

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Capability PlantPAx

Process Control

Regulatory

Logic Function Block

Sequence

Batch

Controller based ISA-SBB phase support

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Capability PlantPAx

Advanced Control

Fuzzy Logic

Auto tune technology

Model predictive control

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Capability PlantPAx

Process Fieldbuses

Foundation fieldbus

Prolibus PA

HSE

HA-RT

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Capability PlantPAx

Process Safety

Scalable Process Safety

Integrated Process Safety

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Capability PlantPAx

Service and Support

Project Engineering and Solution provider Network

24 x 7 Technical support-Worldwide

Configuration Services

Hardware Maintenance Services

Installation Services

Software Support and Upgrade Support

Training

Single Source Supplier

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Capability PlantPAx

Other Capabilities

Global Namespace across multiple applications

DCS-PLC Integration

PlantPAx – Distributed Architecture16

PlantPAx System CharacterizationPlantPAx supports all widely spread Process Networks I/O

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PlantPAx Process Networks I/OMain goal of PlantPAx SystemCharacterization is:

To provide a recommended architecture and information [boundaries] regarding a system operation and/or performance early in the sales cycle to reduce

To eliminate perceived risk of the system being able to provide the needed performance.

PlantPAx system is carefully testedand designed to ensure bestpossible performance.

Controller Wall 50 + PACs

Distributed System 4 servers

Virtual System

Centralized System 1 server

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Characterizing the System Loading by Using “Control Strategies”

A control strategy identifies the relationship between the loop control code and its data requirements. A control strategy can

represent any control code, such as process control, I/O, data flow, and visualization for a control entity. A control strategy can be a 2-

state device, a PID loop, a sequencing block.

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Characterizing the System Loading by Using “Control Strategies”Using the control strategy model, weare able to estimate these systemparameters:

HMI server tags on scan (alarm tags, display tags, data log tags, event detector tags, and derived tags)

Controller memory usage

Controller execution time

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1 Display Call up A HMI Display “Paint Time” is the time it takes to call up a new screen (not cached) and must be operational in less than 2 seconds

2 Display Data Update A change in a active value within any controller is displayed on a graphic screen on the OWS (HMI client) in less than 1 second.

3 Steady State Alarms The System must support a Steady State alarm condition, consisting of twenty new alarms being generated every second, with the difference between the time an alarm is triggered and its timestamp not exceeding one (1) second (cannot miss any alarm)

4 Alarm Burst The System must support an Alarm Burst condition, consisting of one thousand (1000) new alarms generated all at once, with the difference between the time any alarm is triggered and its alarm timestamp not exceeding three (3) seconds (cannot miss any alarms)

5 System Recovery Within five (5) minutes after a failed System Element is restored, the system should recover and perform as it did before the system element failure

System Performance Criteria in “Operational” Terms

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6 Data Logging The system will be capable of continuously data logging a minimum of 200 independent points once a second

7 Paint Time for Datalog Trend A data log trend display will present 12 hours of historical data of any data logged point on the OWS within 30 seconds of the operators display request.

8 Operator Control The operator will be able to interact with the process by changing tag values in the controller within 2 seconds.

9 Control Loop Update Time The system will be capable of supporting 125 Complex Regulatory Control Loops (cascaded) within a 250ms periodic task. This time is from instrument to actuator.

10 Batch Server: Operator Action Time

An operator initiated Batch command will be responded to by the PAC with 1 second.

11 Batch Server: Server Action Time

A batch server initiated Batch command will be responded to by to the PAC with 1 second.

12 Batch Server: Controller Action Time

A batch Event in the Controller will provide the operator with feedback in 1 second .

Measuring System PerformanceThe Operator Interface is theCritical Element and has threemain features:

Display Call Up Time

Data Update Rate

Operator Command

The Operator Interface is the critical element

Display Call up

Data Update

Operator Command

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Example of PlantPAx Characterization Report

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PlantPAx Interface

PlantPAx – Harmony between Logic and HMI

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PlantPAxAvailable Instructions

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PlantPAx Library of Logix Diagnostic Objects L-CPU: Controller Usage MonitorPlantPAx offers extensive CPUDiagnostics and allinformation is available fromwithin the HMI interface

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PlantPAx Process Ad-OnsPlantPAx has extensive built

in Add-Ons for all Process

Devices.

Add-Ons significantly

reduces Engineering time

and Maintenance activities

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PlantPAx Process Faceplates PlantPAx has detailed

Faceplates corresponding to Logic Add-Ons.

Complete Information available from within Faceplates.

Setting Alarms, Bypassing Interlocks, Simulating devices, enabling/disabling alarms, detailed Help.

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PlantPAx Modes & Security Operator: .Commanded from the HMI

Program: Commanded by the application logic

Override: Commanded by application logic for

abnormal operation, supersedes Program and

Operator modes.

Maintenance: Commanded from the HMI for

maintenance, bypassable interlocks and

permissive and feedback checks can by bypassed.

Hand: Tracks controlled by hardwired local

station..

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Operations Layer

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Operations: Maintenance and Troubleshooting Made Easy!

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New shelve alarm

capability per

ISA 18.2

Enter shelve time

duration and

comments

Better integration

with PlantPAx Library

Operations: Standards-based alarming

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Operations: Standards-based alarmingProvides method for gating threshold

alarms or indications includes:

Gate Input

Gate Delay

On-Delay

Off-Delay

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Operations: Standards-based alarmingEasily navigate from motor

to interlock to cause

Interlocks with first-out

Access to logic for complex

interlocks

Quick Troubleshooting for

improved MTTR

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Operations: Automation of Operator ProceduresPlantPAx sequencer object:

Easily configurable to

capture critical sequences

Rich visualization provided

to the operator

Built-in Exception Handling

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Asset Management & System MaintenanceExtensive Asset Management and System Maintenance Tools

InstrumentDiagnostics

InstrumentManagement

Instrument Health

Inst

rum

enta

tio

n

Device Diagnostics DeviceManagement

Device HealthPo

wer

Co

ntr

ol

Operator: “Is it OK?”

Maint: “How bad is it?”

Tech: “How do I fix it?”

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SIL 0Process

SIL 1Fail Safe

SIL 2Fail Safe

SIL 2Fault Tolerant

SIL 3Fail Safe

SIL 3Fault Tolerant

Basic Process ControlSystem

Safety Instrumented Systems (SIS)

PlantPAx(Logix)

EtherNet/IP communication:

AADvance™ & PlantPAx™ Trusted TMR

AADvance Scalable Safety

Process Safety

Provides Integrated and scalable

SIS Solutions, including TMR for

the highest availability.

PlantPAx based on Logix Platform

Redundant Logix Platform

Redundant Logix Platform with

Redundant I/Os

GuardLogix SIL3 Fail Safe

Aadvance

Aadvance Trusted TMR

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Batch Management Provides Scalable Platform From

simple, single unit scale to highly

complex, integrated batch

solutions.

Integrated Analysis Tools Batch

reports, material usage, genealogy,

and solutions to optimize batch

production

Native ISA-88 Structure Simplify

change management and

regulatory compliance

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Operations Productivity Scalable Data Collection Chassis-

based, plant-wide or

enterprise-wide historian

Decision Support Tools Trends,

dashboards, and reports

Users Collaboration to make

actionable decisions

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Process Optimization

Broad Advanced Control Portfolio

From advanced regulatory to simple

model-based control, soft sensors to

complex model predictive control

Flexible Deployment From loop and

unit-level optimization in the

controller

to plant-wide economic optimization

at the supervisory layer

IMC_01

IMC ...

Internal Model Control

0.0

PV

0.0

SPProg

0.0

SPCascade

0.0

RatioProg

0.0

CVProg

0.0

HandFB

0

ProgProgReq

0

ProgOperReq

0

ProgCasRatReq

0

ProgAutoReq

0

ProgManualReq

0

ProgOverrideReq

0

ProgHandReq

CVEU

0.0

SP

0.0

ProgOper

0

CasRat

0

Auto

0

Manual

0

Override

0

Hand

0

MMC_01

MMC ...

Modular Multivariable Control

0.0

PV1

0.0

PV2

0.0

SP1Prog

0.0

SP2Prog

0.0

CV1Prog

0.0

CV2Prog

0

CV3Prog

0

ProgProgReq

0

ProgOperReq

0

ProgCV1AutoReq

0

ProgCV2AutoReq

0

ProgCV3AutoReq

0

ProgCV1ManualReq

0

ProgCV2ManualReq

0

ProgCV3ManualReq

0

ProgCV1OverrideReq

0

ProgCV2OverrideReq

0

ProgCV3OverrideReq

CV1EU

0.0

CV2EU

0.0

CV3EU

0.0

SP1

0.0

SP2

0.0

ProgOper

0

CV1Auto

0

CV2Auto

0

CV3Auto

0

CV1Manual

0

CV2Manual

0

CV3Manual

0

CV1Override

0

CV2Override

0

CV3Override

0

CC_01

CC ...

Coordinated Control

0.0

PV

0.0

SPProg

0.0

CV1Prog

0.0

CV2Prog

0

CV3Prog

0

ProgProgReq

0

ProgOperReq

0

ProgCV1AutoReq

0

ProgCV2AutoReq

0

ProgCV3AutoReq

0

ProgCV1ManualReq

0

ProgCV2ManualReq

0

ProgCV3ManualReq

0

ProgCV1OverrideReq

0

ProgCV2OverrideReq

0

ProgCV3OverrideReq

CV1EU

0.0

CV2EU

0.0

CV3EU

0.0

SP

0.0

ProgOper

0

CV1Auto

0

CV2Auto

0

CV3Auto

0

CV1Manual

0

CV2Manual

0

CV3Manual

0

CV1Override

0

CV2Override

0

CV3Override

0

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Skid & Process Equipment Solutions

Overall System Performance

Proven, tested architectures for not

only DCS

applications, but skid-sized solutions

as well

to ensure total system performance.

Machine Automation functionality and

full support built in

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Question & AnswersThank You for Your Valuable Time

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Lahore, Pakistan

Headquarters South East Asia

19 Km Main Multan Road

Lahore, Punjab 54660

Pakistan

Phone : + 92 42 111 940 940

Dubai, UAE

Headquarters Middle East And Asia

Office FZS1 BD04, Jebel Ali Free Zone

PO Box 18590, Dubai

United Arab Emirates

Phone: +971 4 88 60 277

Exton, USA

Headquarters Americas

180 Sheree Boulevard, Suite 1400

Exton, PA 19341

United States of America

Phone +1 610 458 8700

Regional Offices and Global Headquarters

Technology

PlantPAx Process