PR02 - Applying Best Practices to Achieve Superior Results with the PlantPAx System

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

Applying Best Practices to Achieve Excellent Results with the PlantPAx® System


Agenda

Seven Most Common Mistakes in PlantPAx® System Sizing

Best Practices When Designing PlantPAx® System

System Architecture and Elements

PlantPAx® – Process Automation System

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 3

PLANT-WIDEControl and Optimization

SCALABLEand Modular

SECUREOpen and Information-enabled

FLEXIBLEDelivery and Support


PlantPAx® is our Rockwell Automation® Process Automation System:

Plant-wide control technologies in a DCS Platform

PlantPAx® Process Automation System

4

Plant-wide control technologies• Standards-based architecture using Integrated Architecture®

components enables multi-disciplined control

• Scalable high availability throughout the architecture

• Extends EtherNet/IP as control backbone

Optimized for performance in process• Characterized for performance

• Documented architectures, defined system elements, detailed

sizing rules and application guidelines

Extended with tools and utilities• System definition and sizing tools

• Standard application components

• Deployment and configuration tools

• System health and diagnostic tools


Where to Get More Information?PlantPAx® Technical Documentation

5

Selection Guide:

” “How do I define a system?”

http://literature.rockwellautomation.com

Keyword PROCES-SG001

Reference Manual:

“How do I build a system?”

http://literature.rockwellautomation.com

Keyword PROCES-RM001

PlantPAx® TOC on the Rockwell Automation® KB: 62366


Agenda






PlantPAx® Architecture Classes and System

Elements

7

System

Element

Description Station Distributed – Single

Server

Distributed - Multiple Server

Process

automation

system server

(PASS)

Required system element

that may host displays,

alarms, and data

connections to controllers

Single computer

serves as PASS,

EWS, and OWS

One PASS required

and includes:

• FTD Server

• HMI Server

• Data Server

• A&E Server

One PASS required and includes:

• FTD Server

• HMI Server

• Data Server

• A&E Server

Addl. PASS as needed (up to 10)

Operator

workstation

(OWS)

Provides an interactive

graphical interface to

monitor and control

process

10 OWS10 OWS per PASS; up to 50 per

system

Engineering

Workstation

(EWS)

Central location for

configuring the system and

maintaining operations

1 EWS required (can

have as many as 5)

1 EWS required (can have as

many as 5)

Process

ControllerLogix-based controller

1...5 Logix

controllers1...8 Logix controllers 1...8 Logix controllers per PASS

Application

Servers

Information management,

asset management, batch

Application servers

as neededApplication servers as needed

Domain

ControllerN/A Optional Required if there more than 10 PC


Agenda






Design Recommendations for Performance

9

Asked Global Process Technical Consultants (GPTC), what are the

most common design mistakes that lead to performance problems?

Didn’t size system properly

Controller tasks not configured correctly

Controller tags not structured optimally

Exceeded system / performance limits

System infrastructure not built according to specifications

System performance is not monitored


App

Process Control

EtherNet/IP

Asset

Management

Operator

Workstations

Engineering

Workstations

Process Automation

System Server and

Application Servers – HMI

Batch

Management

Info

Management

Process

Controllers

Variable Speed Drives

Local, Distributed, and Intelligent I/O

Valves and

Instrumentation

Integrated

Process Skids

• # of Tags on

Scan

• # of OWS

• # of Alarms

• CPU %

• Memory %

• # of Tags on

Scan

• I/O

• Control

Strategies

• Controller types

• # of OWS

Keys to System Performance:1. Size System Properly


PlantPAx® Selection Guide (PROCES-SG001) provides high level guidelines to

properly size system

Keys to System Performance:1. Size System Properly


Keys to System Performance:2. Configure Controller Tasks Properly

Do not use continuous task

Organize your periodic tasks so fastest tasks has highest priority and avoid multiple

tasks with the same priority

Do not use task as an organization method. Task is an execution marker.

Allow for time for CPU Communications

Includes; alarms, display tags, faceplate tags, DL tags and historian tags and

MSG(s)

Continuous communication task slice selection does not apply when using

periodic tasks


Do not use continuous task

Reduces task switching improving application and system performance

Continuous task not good for time-based operations like PID

Improves predictability and ability to monitor the controller free-time

available for communication

Configure faster tasks with higher priority (lower number)

1756-RM094, Logix5000™ Controllers Design Considerations



Minimize number of periodic tasks

150 PID Loops @ .1 sec

L7, 1 task: 70% CPU

L7, 20 tasks: 90% CPU

Best practice, use few tasks, organized by speed fast/slow

Inhibit/Delete unused tasks

Example:

Fast Loops: 100ms, Priority 6

Flows, valves, motors Typical Loops: 500ms, Priority 8

Temperatures, levels, etc.



Keys to System Performance:3. Optimize Your Controller Tags

15

The organization of data in the controller can impact performance:

Tag types (e.g. DINT vs INT)

Affects efficiency of CPU by reducing type casting

Affects efficiency of memory utilization

Tag structures and arrays

Improves efficiency of memory utilization

Can help improve HMI performance

Organization of tag structures also important to performance


Use DINT and REAL data types whenever possible

A Logix5000™ controller typically compares or manipulates values as 32-bit

values (DINTs or REALs).

The controller typically converts a SINT or INT value to a DINT or REAL

value before it uses the value.

If the destination is a SINT or INT tag, the controller typically converts the

value back to a SINT or INT value.

The conversion to or from SINTs or INTs occurs automatically with no extra

programming. But it takes extra execution time and memory.



Define tags in arrays and a UDT whenever possible

The minimum memory allocation for a tag is four bytes. When you create a tag

that stores data that requires less than four bytes, the controller allocates four

bytes, but the data only fills the part it needs.

Arrays act as single tags and uses memory more efficiently

Use of tag structures, such as UDT’s, AOI’s can also help efficient memory

utilization

Better memory utilization helps HMI and controller redundancy performance

Single atomic tag has a the same security and service overhead as Array or

UDT type tags



When creating user-defined or add-on-defined data types, group BOOL

tags together whenever possible: uses less memory and communication

bandwidth.

BOOL tags must align on 8-bit boundaries. But, if they are placed adjacent

to each other they can share the same byte



Keys to System Performance:4. Understand System Limits

19

Understand product limits, system limits, and your performance limits

Product limits are what products have been qualified to do What is possible with the products?

Discovered in product documentation

System limits are what the system have been proven to do Proven limits based on system characterization

Discovered in PlantPAx® Reference Manual

Your performance limits is what your system should be expected to do based on your application

# of I/O, tags, OWS, controller types, server layout

Guidance in PlantPAx® Reference Manual

Enabled by sizing tools


Keys to System Performance:5. Follow Infrastructure Guidelines

20

Optimize your operating system settings

Turn off automatic updates (follow Rockwell Automation® patch

recommendations: KB Aid 35530)

Disable Windows Error Reporting

Disable operating systems themes

On virtualized systems, use the PlantPAx® Virtual Image Templates


Use a domain

One place to manage users, groups and security settings

Required for systems with more than 10 computers

All workstation and server system elements in a single

PlantPAx® system must be members of same domain

Use DNS and time synchronization



Use managed switches

Disable power saving on the Network Interface Card (NIC) that connects

the servers and workstations to other devices on the network

Logically segregate your networks

I/O

Control System

Enterprise

For more recommendations, see the PlantPAx® Reference Manual PROCES-RM001



Key to System Performance: 6. Monitor System Utilization

When defining the application code, make sure the CPU utilization of the

process controller can accommodate these values:

In the development environment, CPU utilization should be less than

50% to allow for the additional CPU load that will be experienced in the

production environment

During the operation of the system, the CPU utilization should be

monitored and should never exceed 75% during normal operations


Rockwell Automation® Library of Logix Diagnostic Objects

L_CPU: Controller Usage Monitor


What Logix Diagnostic Objects are Available?

A summary of the Logix Diagnostic Objects available in each Rockwell Automation® Library revision is shown in the table below:

Logix DiagnosticObject

Description 1.0 1.5 2.0 3.0 3.1

L_CPU Controller Usage Monitor Y Y Y Y Y

L_TaskMonitor Controller Task Monitor Y Y Y Y Y

L_RedunRedundant Controller Monitor

N N Y Y Y

L_ChangeDet Controller Change Detector N N Y Y Y



26

Task Monitor Tool Upgrade V20

Version 3.0 merges Logix5000™

Task Monitor Tool and Logix

Diagnostics Tool and adds additional

functionality

Better GUI representation

Better analysis of tasks and

communication bandwidth



27

Make sure that Server and Controller CPU utilization and

controller memory utilization is within our recommended limits

Verify there are no errors when calling the display by reviewing

IIS and FactoryTalk® Diagnostics logs


Agenda







29

System sizing was not performed

Memory usage was underestimated

Application requirements were overestimated (more or faster than needed)

Not accounting for all I/O delivered through data and process networks

Not accounting for communication with legacy networks

Not accounting for all data

Did not spend (any) time learning the tools


1. System Sizing Was Not Performed(The Most Common Issue)

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“I have 30 years of experience, I know…” Every application is unique, based on scope of supply, distribution of responsibilities, expected

longevity, local requirements, etc.

Between two regions, number of I/O for the same application (oil rig, compressor station, remote pump station) could be

very different (30-50%)

By splitting application between 2 suppliers, communication requirements could increased dramatically

“I did this application 5 years ago. I still remember…” Number of variables expected to be displayed on OWS and/or historized almost doubled in last 5 years.

Number of “requested” alarms almost doubled after several recent accidents

End Users try to take advantage of extra asset diagnostic data available on control level


“Loop is a loop, is a loop… It is the same for Food Industry as for Oil and

Gas” Average number of tags (control, visualization and historization) per I/O point for heavy industries in 2-4

times higher than for CPG and Pharma

System was built out of subsystems provided by multiple suppliers. There

was no “system responsibility” This is the most difficult case. Subsystem and OEM skid suppliers almost never aware of complete

system architecture. EU or EU engineering company should hire RA or SI to perform system sizing

(Cont.)

1. System Sizing Was Not Performed(The Most Common Issue)


2. Memory Usage Was Underestimated

32

“I estimated system with a simplex (controller or server) and it does not work with redundant (controller or/and server)…”

Redundant Logix requires almost 2x of application memory in controller (see 1756-UM523E…)

Secondary Data server, once connected, requires the same amount of memory in controller as the Primary server

“I did not use arrays, UDT and AOI types, but a lot of individual tags instead and I am out of memory…”

Every tag (atomic or complex type) has the same overhead (about 100 bytes). Estimate in PSE assumes memory usage by PlantPAx® process library (primarily AOI and UDT type tags)


2. Memory Usage Was Underestimated

33

“Before I start using PlantPAx® Process Objects my Controller memory

utilization was lower ” PlantPAx® Library built for a typical “process” use when all object operation configurations and

parameters , interlocks, permissives, etc. could be done from an Operator Workstation (OWS). This

functionality requires high quantity of tags.

(Cont.)

Op

erat

or

Ala

rm

Ala

rm C

on

fig

Mai

nte

nan

ce

Engi

nee

rin

g

P_AIn 70 37 21 25 14 35 202

P_AInAdv 92 60 35 37 18 45 287

P_AInDual 111 58 33 28 16 45 291

P_AInMulti 136 51 29 43 37 36 332

P_AOut 38 16 9 31 14 23 131

P_Din 21 4 6 12 8 13 64

P_DOut 58 30 17 28 17 16 166

P_DoseFM 69 30 17 18 22 34 190

P_DoseWS 65 30 17 16 24 33 185

P_VSD 81 38 21 30 59 23 252

P_Motor 47 31 17 24 14 35 168

Faceplate

Gra

ph

ic O

bje

ct

Tota

l

Tags per Process Object


When you think that IAB recommended “way too many servers or controllers”, check your rate of execution and system limits

System and location preferences allows you to customize the tool to your requirements.

3. Application Requirements Were Overestimated (More or Faster Than Needed)


4. Not Accounting for All I/O Data Delivered Through Networks

35

Selected configuration of smart field device can very significantly change number of tags. This

data will be processed or/and displayed and, therefore, should be considered in estimation

Examples of DeviceNet parameter groups for E3 Overload Relay

E+H Promag on EtherNet/IP & Logix tags


5. Not Accounting for Communication Through Legacy Networks

36

Communications between Logix Controllers and legacy Analog I/O on legacy networks (RIO) or legacy Controllers on legacy networks (DH+) implemented through Logix MSG instruction.

If configuration has 30 1771 analog I/O modules that should be scanned every 100ms then:

30* 10 msg/sec = 300 msg/sec

300 msg/sec ~ 35% of CPU utilization for L7x

Additional controller communication capacity is required when RIO I/O connected to PlantPAx®


6. Not Accounting for All Data You thought your system was…

37

System was sized and verified with IAB PSE, but there was a disconnect between EU and SI


6. Not Accounting for All DataBut your system really was…

38

Existing

Controllers

Existing and new

corporate

software

3d party

DCS

All subsystems that could be connected should be accounted for and estimated

New Skids


7. Did Not Spend Time Learning the Tools

Project Preferences allow changing the System calculation defaults

39

Preferences allows you to customize tool to your requirements. Use it wisely!


Coming soon …Detailed Sizing Spreadsheet (Input Data)

40


Coming soon …Detailed Sizing Spreadsheet (Output Data)

41


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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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PR02 - Applying Best Practices to Achieve Superior Results with the PlantPAx System