Choosing PlantPAx vs DeltaV - Rockwell Automation an existing DeltaV user, the plant expected the new solution to function as a system just like a “true DCS” STANDARDS

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Choosing PlantPAx vs DeltaV Benefits for end users and integrators

Alan Stanfill Stone Technologies – MES Project Manager November 2012

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Agenda

Wrap Up / Q&A

Project Specifics

Situation / Goals

Customer Information

Introductions


Introductions

Alan Stanfill – MES Project Manager Stone Technologies

Audience – How Many … End Users System Integrators Rockwell Automation Distributor Other

Experience with PlantPAx Various DCS solutions

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Customer Information

Make products for food, pharmaceutical, agriculture, and industrial applications Very competitive Tight profit margins Sound familiar?

Mix various products, prepare for final product format (granulated or powder) , and send to finished goods bin for packaging

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Midwest plant (company name and other details withheld at their request) of a chemical manufacturing company needed to move production from an existing facility – drive was to improve efficiency and reduce costs to produce product

Had a GREAT functional specification as a starting point!


Goals

Get the new production facility up and running quickly

Run as efficiently as possible

Have a unified control system

Include mixing tanks and other process related items – system stopped short of packaging in this case

Mix various products, prepare for final product format (granulated or powder) , and send to finished goods bin for packaging

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Customer Focus Areas

SYSTEM As an existing DeltaV user, the plant expected the new solution to

function as a system just like a “true DCS”

STANDARDS A conscious decision was made to follow the out of the box PlantPAx

standards very closely

SUPPORTABLE Both by Rockwell and a wide variety of system integrators

SAVINGS Initial solution cost as well as ongoing support – as always, cost was

a significant concern

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What is PlantPAx anyway?

Utilizes standard Rockwell products ControlLogix FactoryTalk View SE

Object and code libraries to create full solutions

Tested and implemented as a SYSTEM Predictable and repeatable performance Allows an integrator and end user to work on the system rather than

all of the individual components

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Approach - boring or effective?

Stick to standard objects as much as possible Customer’s request Stone’s preference Allows for greatest advantage from the objects as well as “future

proofing” of the solution

Hit the ground running Start with the customer’s functional specification

Two engineers working concurrently PLC HMI PlantPAx was a huge advantage when using this approach

Required VERY little extra communications / status

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Challenges

Lack of historical trending on standard objects Real-time trending functioned well but historical based trends were

required No real “ad hoc” trending functionality built in

Unlike some DCS solutions, ViewSE was somewhat limited in the functionality for creating trends on the fly

Small items needed on faceplates that did not exist Various small items that the customer wanted to see but weren’t in

the standard objects

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Challenges

PlantPAx alarms (priority 1-4) were not related to FT Alarm and Event alarms (1-1000) Needed a manual work around to maintain continuity between both

lists No “global” color change settings for various uses

Alarms Warnings Hold Still have to manage these across multiple global objects

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Sample - Navigation

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Add Ons

Sequential Function Charts in ControlLogix were used for sequencing of multiple ladder based phases

Needed a way to view / track the status from the HMI Built a view of the SFC in the HMI Used the PlantPAx permissive to drive these steps Made things easy for the operator or maintenance to track the

process without leaving the HMI Historical and customizable trending

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Sample – SFC Monitoring

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Results - SYSTEM

The starting point for every functionality decision was the same: “Here is what DeltaV does” Need to mimic that for ease of operator use and minimal retraining

The customer was very adaptable and wanted to be sure of long term functionality for the system

Overall decisions were made based on features, functions, and also ease of implementation and support for future A considerable amount of weight was given to future upgrades and

support when looking at additional features

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Results - STANDARDS

The customer’s strong preference was to stick to standard objects over custom code or additions as much as possible This worked well as it is also Stone’s standard operating procedure

12 primary PlantPAx objects were utilized to build the solution

PLC code followed the standards as much as possible Make the standards fit if you can and only add on where required

HMI screens used standard objects with very minimal customization around them for critical features SFC monitoring Historical trending

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Results - SUPPORTABLE

While the project was successfully implemented by Stone, it is critical to the customer that they not be reliant on Stone for future support

With standard objects used almost exclusively, Rockwell has been able to help with some support issues

Stone personnel (even ones new to the system) can support the standard objects

Should the customer ever need it – there are MANY other integrators who can support the standard PlantPAx implementation Not stuck with a single provider as they were with the DCS solution

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Results - SAVINGS

Initial purchase price was significantly lower than the DCS solution

Ongoing support costs (DeltaV support vs TechConnect) are also lower

Implementation costs for the integration were far less

All adds up to a substantial TCO difference

Customer can do their own adds / changes

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Benefits of PlantPAx - Customer

Support is easier if new people are introduced to the project

Let Rockwell support the underlying objects and layout while the integrator focuses on the specific application

TIME – standard objects shorten implementation time frames significantly

MONEY Out of the box cost Ongoing support Integration

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Benefits of PlantPAx - Integrator

Focus more on the customer and their process

Less of the repetitive work to get PLC / HMI integration working

Support is easier if new people are introduced to the project

Ease of communications between PLC and HMI engineering resources

TIME

MONEY

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Summary

Goals Get new production up and running quickly and efficiently Keep the solution cost effective

Approach Stick to standard objects as much as possible Integrate around those objects as needed for functionality

Results SYSTEM – the PlantPAx solution does operate as a system STANDARDS – PlantPAx standard objects were used extensively SUPPORTABLE – Rockwell and other integrators can support if ever

needed SAVINGS – the system ultimately costs less than the DCS to

implement and maintain 20


Stone Technologies Information

Founded in 1996 Of our top 20 clients since

the inception of the company in 1996: Doing business with ALL of

them today Average of 50 projects per

client Average adding 2 – 3 new

clients a year Focused on the F&B,

Consumer Products Industry, Fine Chemical, Medical Device, Power Generation industries

Technology Focus and experience 22 engineers focused on

process and other controls systems

14 engineers focused on MES and information solutions

7 dedicated project managers

The technical staff has an average of 22 years of technical experience

Our least experienced employee has 12 years of industry experience

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Stone Technologies Expertise

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Questions

Alan Stanfill Stone Technologies – MES Project Manager November 2012

Thank you for your time!

Documents

Choosing PlantPAx vs DeltaV - Rockwell Automation an existing DeltaV user, the plant expected the new solution to function as a system just like a “true DCS” STANDARDS