Rockwell Automation Announces PlantPAxftp.gongkong.com/UploadFile/datum/2012-1/... · Rockwell Automation Process Control System. It brings together our core control and visualization

2009 – Issue 1

IN THIS ISSUE

PlantPAx is the new name for the

Rockwell Automation Process

Control System. It brings together

our core control and visualization

technologies with technology from

acquisitions, such as Incuity, Pavilion

Technologies, ICS Triplex and partners

like OSIsoft and Endress+Hauser into

a single solution.

Key areas of the PlantPAx system include: System Engineering The PlantPAx system further strengthens oursystem engineering environment. It will offerprocess and batch control users a new libraryof reusable control objects with tools tosimplify deployment. A future release willinclude the ability to populate the PlantPAxsystem with modules from multiple plantdesign and engineering tools.

Control and Visualization Platforms Control strategies and accompanyingvisualization are configured using modularand reusable objects, simplifying design,commissioning and maintenance. Continuedadvances around system high availability serve to minimize or eliminate downtime and process disruptions caused by controlsystem modifications.

Performance and Process Optimization The PlantPAx system extends the scope ofprocess optimization to include Fuzzy Logic,basic and advanced process loop tuning and at the high-end a Model Predictive Control (MPC) suite.

Batch and Sequencing Rockwell Automation provides solutions frombasic sequencing to the most complex anddemanding batch applications. The systemadheres to ISA-88 standards and presents ascaleable batch control capability.

Process Safety and Critical Control Process safety capabilities include a broadrange of safety integrity levels (SIL) and fault-tolerance requirements. Solutionsinclude SIL 3 and TMR options.

Asset Management and Device ConnectivityAs an integral element of the PlantPAx systemour asset management solution provides toolsfor disaster recovery, tracking of user actions,regulatory compliance and improving plant-floor security. The solution includesinstrument configuration, diagnostics andcalibration management.

The system integration with digital fielddevices such as HART, Foundation Fieldbusand Profibus PA for the instrumentation andDeviceNet and EtherNet/IP for industrialcontrol devices. This provides integration easewhen used with our device integration toolsdeveloped jointly with Endress+Hauser.Additional asset management capabilitiesinclude controller code change management,vibration monitoring of rotating equipmentand both instrument and industrial devicemanagement with configuration andcalibration records tracking for other plant-wide assets such as drives and motorcontrol centers.

Plant Information

The PlantPAx system allows plant-wide process data management through itshistorian capability (based on the PI Systemfrom OSIsoft). Further, the new FactoryTalkVantagePoint enterprise manufacturingintelligence and reporting software helpsenable aggregation, analysis and display ofplant information.

To find out more, visit us atwww.discover.rockwellautomation.com/thinkingprocess

In this edition of Thinking Process we focus on techniques to optimize plant performance. You will find information on subjects ranging from loop tuning to model predictive control andexamples of the financial savings that can be made.

Rockwell Automation®

Announces PlantPAx

Page 1 Rockwell Automation AnnouncesPlantPAx Process Automation System

Page 2-4 SPECIAL FEATUREProcess Optimization

Page 5 Rockwell Automation andEndress+Hauser Integration Software and Documents

Page 5 FactoryTalk® ViewPoint Web-HMI

Page 5 FactoryTalk AssetCentre Adds DeviceConfiguration and CalibrationManagement Capability

Page 5 FactoryTalk Batch Version 10

Page 6 Six-Polymer Line Project MarksLargest Polymer Deployment in China

UPDATE

IMC Function Block Configuration Example

The IMC Function Block

SP

CV

PV

Disturbance

Estimate

Process Prediction

1st OrderFilter

1st OrderModel

Inverse ofModel

Process

Process

Disturbance

–

–

2

Concentration

Time

CVPVTime Constant

63%

300250200150100

500

0 20 40 60 80 100

Deadline

Economic Benefits

The IMC algorithm gives more accurate

control of the chemical concentration to

target value. This reduces the cost of

chemicals whilst still meeting specification.

RSTune & RSLoop OptimizerRSTune® and RSLoop Optimizer™ are critical tools

for increasing your product quality. Having your

loops optimized reduces inconsistency, thereby

improving the quality of your product. Better

control means more accurate material

management and less off-specification product,

increasing your profits and reducing energy costs.

RSTune is a sophisticated tuning package that will

optimize your PID loops. It automatically

calculates the best PID values for your application

and supplies you with powerful tools to increase

profitability. RSLoop Optimizer has additional

tools to allow you to identify potential process

equipment deficiencies, analyze valve wear and

optimize more complex loops.

Example – Chemical Dosing

In this example a chemical is dosed into a water

flow with the goal of meeting a certain

concentration. There is a significant delay

between the injection point and the measuring

point. Traditional PID algorithms don’t cope

very well with the delay and typically lead to a

sluggish response or oscillations.

The graph below shows how the process

responds to a step change. The dead-time of

the loop is much larger than the time constant.

In this example, the new Logix Internal Model

Control (IMC) instruction will typically give a

much better response than PID.

The IMC function block controls a single

process variable by manipulating a single

control-variable output. This function block

performs an algorithm where the actual error

signal is compared against that of an internal

first-order lag plus dead-time model of the

process. The IMC function block calculates the

control variable output based on the deviation

from the internal model.

Logix V17 Advanced Process Control – Internal Model Control (IMC)PID is the ‘standard’ solution for most control loops, but it is not a good algorithm for certain

applications. If PID is not suitable for the application no amount of tuning will make the loop

operate efficiently, other techniques like Internal Model Control (IMC) are required.

Other Logix APC Instruction

CC – Coordinated Control

• The CC function block controls

a single process variable with up to

three control variables which need to

act in a coordinated manner

• It is good for situations where multiple

outputs are available for control, and costs

need to be minimized

MMC – Modular Multivariable Control

• The MMC function block controls two

process variables with up to three

control variables

• It is good for situations where there is

significant interaction between the various

control variables and process variables

Application Example and Economic Benefit

For more information, visit:

www.rockwellautomation.com/rockwell

software/design/rslogix5000/

Instruction Application Economic Benefit

Dissolved oxygencontrol bycontrolling flowrate, agitator and air flow

Distillation column bycontrollingcomposition,reflux ratio, steamflow, pressure

CC

MMC

Reduced energycostsIncreased yield

IncreasedthroughputIncreased product to specification

To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess

3

FactoryTalk VantagePoint – Business Intelligence Software FactoryTalk VantagePoint is based on innovative business intelligence software from Incuity,

integrated into the FactoryTalk environment. Business Intelligence Software, such as FactoryTalk

VantagePoint, can help increase productivity by providing workers at every level in the enterprise

with new insight into the manufacturing process to help them to make better decisions. For example:

• At the line level people need to understand how equipment is performing to be able to make

decisions on streamlining operations, and improving efficiency and throughput

• At the plant level people need to understand production as it relates to the customer, so that

they can make intelligent decisions about procurement, production scheduling and shipping

• At the enterprise level people need to see production in its larger business context, and to

understand the impact of fluctuating costs, changing market conditions and asset performance

to make the right decisions about what to make and where


www.rockwellautomation.com/rockwellsoftware/performance/vantagepoint/

So how much could you gain from

improving your control system?

Applying Pavilion Technologies’ Model

Predictive Control to a bioethanol plant

reduced energy costs by 2-4% and reduced

variability of product quality by more

than 50%.

Business Intelligence software from Incuity

EMI (a Rockwell Automation Company)

helped a leading speciality chemical

producer to improve efficiency, saving

approximately $300,000 per year.

Rockwell Automation has a range of

solutions to address different needs; some

of them are shown here.

Efficiency losses can be found in any number of

points throughout your process plant. A poorly

performing control loop on a critical piece

of plant can waste energy, waste expensive

raw materials and reduce yield. It has been

estimated that approximately three-quarters of

all control loops are performing below peak

efficiency. Most process plants have multiple

interacting control loops and optimizing each

one individually will not optimize the entire

process. For these applications a more

sophisticated approach such as Pavilion

Technologies’ (a Rockwell Automation

Company) Model Predictive Control

solution is required.

Optimizing control loops is only part of the

story. There are many other areas that require

attention – shortening material addition times,

reducing cycle times and changeover times in

batch manufacturing. You need tools to be able

to pull together the relevant information and

analyze it to find inefficiencies.


A major paint manufacturer installed Incuity

software to help increase production whilst

reducing costs. The system provided deep

insight into their batch processes and

facilitated information-sharing among the

production and supervisory staff so they

could better monitor production in their

appropriate contexts.

The result has been that within a few months

they have been able to improve production

performance by more than 20% whilst

reducing costs by $500,000 a year.

Process Optimization

Process Optimization is a very important subject in today’s economic climate. It is essential to run your plant as efficiently

as possible to maximize profitability, but how do you know if your system is running at the maximum efficiency? Do you

have the tools to analyze the performance? And do you have a control system that is capable of delivering optimum

performance? In this article we examine a number of techniques from tuning PID loops to Business Intelligence Software

to help you maximize your profits.


Features

• Hybrid modeling based on

empirical data, first principles

equations, operator

knowledge or any

combination

• Patented, Extrapolated

Gain Constrained Neural

Networks (EGCNN) to ensure

model accuracy beyond the

normal operating range

• Incorporates changing

process dynamics

(dead-time, time constants

and gains) over wide process

operating ranges

Benefits

• Improves product quality

through faster response to

target changes or large

process disturbances

• Expedites deployment by

using all available

information to create

accurate models

• Improves product quality

and flexibility for new grade

and product development

4

Economic Benefits

• Reduce cycle times through faster

response of the control loop

• Reduce energy usage


Chemical Manufacturer

• Increase prime product yield

by 4.5%

• Reduced variance in product

properties by 35%

• Decreased reactor variability

by 30%

• Reduced waste by 300

tons year

• Reduced frequency of lab

samples by 50%

Ethanol Producer

• Increased Ethanol production

capacity 3-10%

• Increased ethanol yield

by .1-.2%

• Reduced energy use/gallon

by 2-4%

• Reduce compliance risk

Logix – Fuzzy LogicFuzzy Logic is a technique that attempts to

systematically and mathematically emulate

human reasoning and decision-making.

Fuzzy control solutions are especially useful

for complex systems where standard means

such as PID control don’t give the required

level of control. Your operators may already be

‘tweaking’ the process for different conditions

but this can be unreliable.

The Fuzzy Logic tools can be applied to a

wide variety of applications. The following

example is a simple application to adjust gains

in a temperature control loop for a reactor.

Example – Reactor Temperature Control

A reactor is heated to a particular temperature

to produce a product. This may sound

straightforward but if the reactor is used for

different sizes of batches the performance of

the temperature loop will vary significantly

depending on how full the reactor is. If the

loop is tuned when the reactor is half full it

may experience problems at different levels.

It would have a sluggish response when

completely full and may oscillate when only

part filled. Clearly you could write a program

to vary the gains with level but this could

become complicated to ensure you don’t get

disruptions to the process.

Fuzzy Logic provides a tool set to take the

knowledge about how the gains should

be varied and use it to more accurately

control the process. This is done by

continuously adjusting the gains rather with

a step change which is often seen in existing

applications. By doing this it is possible to

avoid the process disruptions that would

otherwise occur.

Pavilion Technology – Model Predictive ControlPavilion Technologies’ Model Predictive

Control (MPC) technology is an intelligence

layer on top of basic automation systems that

continuously drives the plant to achieve

multiple business objectives – cost reductions,

decreased emissions, consistent quality and

production increases – every production

minute. It continuously assesses current and

predicted operational data, compares them to

desired results and computes new control

targets to reduce in-process variability and

improve process performance.


www.pavtech.com


Rockwell Automation andEndress+Hauser IntegrationDocuments and Add-onInstructions Available for DownloadRockwell Automation and Endress+Hauser

have released documentation and Add-on

instructions for HART devices connected to

1756 I/O. The information includes a step-by-

step approach to integrating Endress+Hauser

instruments, including information on

hardware, software, configuring messaging

and asset management software.

You can download the documents and

Add-on instructions from:

www.rockwellautomation.com/solutions/

process/integrationdocs.html

The first phase includes documents for the

following instruments:

• Promass 83 Coriolis Mass Flow

• Promag 53 Electromagnetic Flow

• Prowirl 73 Vortex Flow

• Proline t-mass 65 Thermal Flow

• Levelflex M Guided Radar Level

• Micropilot M Radar Level

• Prosonic M Ultrasonic Level

• Prosonic S Ultrasonic Level

• Liquiline M for Liquid Analysis

• Cerabar S Pressure

• Deltabar S Differential Pressure

• iTEMP TMT 162 Temperature

• iTEMP TMT 182 Temperature

Documentation for Profibus PA via the EN2PA

modules and Flex™ I/O HART is in progress and

will be available early 2009.

Manufacturers now can remotely monitor their

plant-floor operations status using FactoryTalk

ViewPoint software from Rockwell Automation.

FactoryTalk ViewPoint software is one of the first

commercially available, thin-client applications

for manufacturing, built using the new

Microsoft Silverlight technology. The initial

release extends visualization and real-time

decision capabilities beyond FactoryTalk View

clients to browser-based remote users.

FactoryTalk ViewPoint software supports fully

scalable and animated Web displays of existing

FactoryTalk View Site Edition (SE) visualization

software and Allen-Bradley® PanelView™ Plus

applications from the office, home or on the road

via any Internet browser. While the initial release

is Internet Explorer (IE) compatible, additional

browser and device support is planned.



software/performance/viewpoint/

Internet Explorer Firefox

Mobile Devices

Safari

FactoryTalk ViewPoint Web Clients

FactoryTalk ViewPoint ServerFactoryTalk View SE Server 1 FactoryTalk View SE Server 2

ControlNetwork

InformationNetwork

FactoryTalkView SE Client

5 To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess

FactoryTalk ViewPoint Web-HMI

FactoryTalk AssetCentreAdds Device Configuration and CalibrationManagement CapabilityThe latest release of AssetCentre now includes

the capability to configure and manage

process devices. The solution, jointly

developed with Endress+Hauser is based on

FDT/DTM technology. AssetCentre is an FDT

frame application capable of supporting a

wide variety of process instruments and other

field devices through plug-in drivers (DTMs)

from device manufacturers. This capability

enables online access to device configurations,

device troubleshooting and diagnostics.

Calibration Management capability has also

been added into FactoryTalk AssetCentre. The

software tool is used to efficiently manage

calibration activities that are associated with

process devices. This is useful for enabling

regulatory compliance and good

manufacturing practice.

It allows the user to:

• Schedule calibrations

• Manage calibration standards

• Manage certifications

• Document as found/as left information and

automatically calculates tolerance

• Perform paperless calibrations



software/assetmgmt/assetcentre/

FactoryTalk Batch Version 10Version 10 of FactoryTalk batch has seen anumber of enhancements to improveproductivity, reduce costs, and simplify recipedevelopment. Enhancements include:

• Smart Binding – Configurable real-timedynamic unit selection for optimal procedural flow

• Timer Steps – Reduce engineering andvalidation effort through use of product timer steps

• Recipe SFC Structure Validation – Testprocedures for recipe structure errors

• Improved Client Capabilities – Simplifiedcontrol recipe configuration options

• RSLinx® Classic OEM – Now included withevery FactoryTalk Batch and Back-up key license


www.rockwellautomation.com/rockwellsoftware/production/batch/

6Publication No. PROCES-SA001A-EN-E February 2009

Baseline MPC

108 %

106 %

104 %

102 %

100 %

98 %

96 %

94 %

917.4 918.6 919.2 919.8 920.4 921 921.6918

Before MPCAfter MPC

y

Six-Polymer Line ProjectMarks Largest PolymerDeployment in China The highly dynamic polymer industry presents

major challenges such as high operating

costs, increasing raw materials costs and

growing local and global competition.

In order to maintain its competitive standing

and meet China’s growing market demands,

SECCO defined a long-term strategy of

increasing production rates, reducing costs,

and improving product quality for its six

polymer lines.

Events ACHEMA 2009

ACHEMA is the leading international event

for chemical engineering, environmental

protection and biotechnology in Frankfurt –

11 May to 15 May 2009. At the last event, held

in 2006, around 180,000 professionals from 98

countries attended to find out more about the

latest developments and trends.

This year we will be showcasing the

PlantPAx process automation system and

demonstrating the continued expansion

of the system based on a combination of

the core Rockwell Automation Integrated

Architecture™ technologies and those

leveraged from co-investments with partners

and acquired companies. The PlantPAx process

automation system has built strong interest for

a range of applications across consumer and

resource-based industries.

SECCO chose Pavilion Technologies who

implemented its Pavilion8® Polymer Reactor

and Extruder (MPC) control applications, an

integrated software suite combining powerful

technology for modelling, control, monitoring,

analysis, visualization and integration, to

provide targeted solutions and deliver faster

time-to-value than alternative solutions.

With the help of Pavilion8, SECCO quickly

maximized production rate and quality,

reduced transition time and material costs,

and improved its ability to adapt to changing

market demands and conditions.

Due largely to the success of Pavilion’s

real-time Virtual Online Analyser® (VOA)

coupled to the control and optimization

strategies, Shanghai SECCO Petrochemicals

quickly achieved project goals and realized

a major return on investment in just

four months.

The benefits of Pavilion’s Polymer Solution

directly translates into reduced costs and

improved revenue potential for SECCO,

allowing the plant engineers to better react to

shifting market conditions and growing

market demands. The stability and robustness

of the solution is evident in the 97% control

utilization rate. To sustain benefits and

further leverage the solution, SECCO has

signed a three-year maintenance and support

contract for Pavilion to optimize all six of the

polymer lines.

Economic Benefits

• Increased production capacity by 4%

on average

• Decreased reactor variability by 20%

• Improved product consistency by 35%

on average

• Achieved standard operations

on transitions

• Reduced the reactor purge and cost

Density

1.5

Before MPCAfter MPC

1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4

Variation in Melt Flow Rate

Low Density Polyethylene (LLDPE) Production Capacity