Central Process Utility Plant controls upgrade required 100% uptime

Utility Plant Upgradewith Redundant, PlantPAx Platform

Tom Brown – Program Manager, Banks Integration Group, Inc.June 8, 2016

Agenda

Lessons Learned

System Design

System Selection Process

Project Overview

Banks Integration Group Background

Who is Banks Integration Group?

Rockwell Automation Solution Partner

Focus on Process Automation primarily in Life Sciences

Located in Northern California – Servicing the West Coast

Project Overview

Central Process Utility Plant – CPUP

Refrigerated Water(5) Chillers

(6) Cooling TowersCompressed Air

(4) 300 HP Compressors

Control System Upgrade Justification Mixed I/O between RW and CA systems

Obsolete PLC and HMI Hardware with numerous code issues Winview HMI platform on desktop PCs with PLC-5® controllers Dead code and legacy configuration still on system due to difficulty of

making changes to existing system

No remote access or individual user logins

DH+ communication bandwidth issues

Controllers/Racks in with 480V power on compressors or MCC’s

Original Control System Architecture

Hardware 2 Allen-Bradley ® 5/80 PLC’s shared between the RW/CA systems 4 Allen-Bradley SLC PLC’s, one per compressor 2 HMI Stations shared between buildings

Software RSLogix™ 5, RSLogix 500 Winview HMI Software

Network 3 DH+ networks spanning several buildings

1 SCADA and Inter-Processor Communications Network 2 Remote I/O Networks with a Modbus Interface

NO

REDUNDANCY

Project Challenges

The control system is large and spread across many buildings Project impacted 22 control panels (either new or existing) required

the upgrade of 7 VFDs

100% uptime on all utilities throughout the upgrade

Existing process equipment had a large number of existing failures

Large number of drawings and documents

Project Challenges

Desire to use new technologies Server Virtualization Pre- tested control modules – Process Objects for Life Science Ethernet/IP (DLR) instead of existing campus ControlNet standard

Agenda

Lessons Learned

System Design

System Selection Process

Project Overview

System Selection

Client specified a Rockwell Automation Control System

Two Pre-design studies were completed to select the best approach for the upgrade

PlantPAx® for Life Science Study Network Comparison Study

PlantPAx for Life Science Study

Study Objective Evaluate if PlantPAx Process Objects were a “good fit” for the utilities

upgrade Are they robust? Are they modular? Do they increase visibility and ease of troubleshooting?

Banks Integration Group gave an interactive presentation discussing the advantages and disadvantages of the Process Objects

PlantPax for Life Science

Rockwell Automation Library – “Out of the Box”

Advantages of PlantPAx for Life Science Solution

Aligned with S88.01 Batch Control Standard Able to divide equipment by Area and Unit

Decreased programming and validation cost Modules are preprogrammed and customized for the life sciences Modules are pre-tested by Rockwell

Increased system visibility PlantPAx built-in displays give operations the ability to more easily

troubleshoot abnormal conditions

Process Objects for Life Science Benefits

Pre-programmed modules

Process Objects for Life Science Benefits

Pre-validated following GAMP Life Cycle Model

Process Objects for Life Science Benefits

Increased visibility

Process Objects for Life Science Benefits

Reusable Global Object Library

Process Objects for Life Science Benefits

Disadvantages of PlantPAx for Life Science Solution

With flexibility comes increased complexity Each module is designed to accommodate several device

configurations, which leads to a more complicated configuration

Module PLC code is locked

PlantPAx Process Objects for Life Science is licensed per PLC

Faceplates were more complicated than existing design

Network Comparison Study

Collaborated with Rockwell Automation Network & Security Services

Network Study Objective Evaluate control system network technologies for:

Peer-to-peer communications I/O Communications

Scope Deliverables Merits and disadvantages of EtherNet/IP and ControlNet Network diagrams and design Network Calculations Summary and recommendation

Network Calculations – ControlNet

Network Bandwidth Calculation – 16.5% Utilization

Network Calculations – EtherNet/IP

Network Bridge Module is the bottleneck – 17.9% Utilization

Ultimately Chose EtherNet/IP

EtherNet/IP with a Device Level Ring topology

Three networks created based on equipment Refrigerated Water Compressed Air Shared Equipment

Fiber media used in segments connecting buildings or distances greater than 300 ft.

DLR Design

DLR Diagnostics

Status screen created for each network

Agenda

Lessons Learned

System Design

System Selection Process

Project Overview

System Design

System Design

SCADA Architecture

SCADA Components

Virtual servers hosted on an HP blade server system

Wyse Thin Clients Wyse ThinOS, based on Linux

platform Touch screen OIT’s

New Control System Architecture

Hardware 2 Redundant ControlLogix® L73 processors for the RW system 1 ControlLogix L72 processor for the CA Supervisor system 4 ControlLogix L72 processors, one per compressor 6 HMI Client Stations distributed between 3 buildings RW and CA I/O is completely segregated

Software RSLogix 5000, v20.03 FactoryTalk View SE, v7.00.00

Network All PLC’s now on Automation Network 3 Device Level Rings (DLR’s) used for Remote I/O and VFD’s

PlantPAx Simplified the System

Existing System PLC code - 5000 rungs HMI - 1050 graphics Electrical Drawings - 400

Updated System PLC code – 2000 rungs HMI – 143 graphics

77 Process Object graphics 66 Custom graphics

Electrical Drawings - 450

System Features

Remote Interface Remote connections via Terminal Server View only connection via FactoryTalk® Viewpoint

System Redundancy SCADA Servers, PLC’s, Network Power Supplies

Network and Power Supply Diagnostics

Node Based Security

Ethernet VFD’s providing increased visibility for troubleshooting

Agenda

Lessons Learned

System Design

System Selection Process

Project Overview

Lessons Learned

As-Built existing design documents prior to starting detailed design

Graphic Standards for Common Plant Interface

VM’s allowed for easy “on-site” migration

Working with local Electrical Subcontractor eased installation

Lessons Learned

Executing a DLR Hardware FAT reduced startup time

Questions

Tom Brown – Program Manager, Banks Integration Group, Inc.June 8, 2016