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• Description of the system before change (FT setup, network )
• Why change the setup ( Startup phase of the factory versus running factory, users demands)
• What options did we look at
• Our choice ( One FT directory with 9 areas, each with Data, HMI and FTAE servers)FTAE servers)
• Server redundancy
• Implementation of selected solution to a running smelter
• Experience .
The Factory Process Control System
Potline system:PLCs: 179Tags: About 200.000
Nine different process areasPLCs: 128 Tags: about 110.000Alarms: about 37.000SCADA Server hardware: 18
Process control
PLC Controllers:• 1756-L62/63, Control Logix• 1794-L34, FlexlogixEthernet Cards:• 1756-ENBT • 1794-AENTRemote I/O :• Ethernet I/O• Ethernet I/OHMI L1:• Panel View Plus Series 700 and 1000SCADA Servers FTView• Rack mounted server macines
Network:• Media: Fiber and Copper Cat 6• Cisco routers• RuggedCom industrial managed
Ethernet switches• RuggedCom Fiber Converters
Architecture of process area – nine FT Directories
Level 2 NWKServer #1
• (1) FT Directory ServerServer #2
• (1) HMI Server
RSView SE Clients WinXP Pro
Data storagePi node
Level 2 NWKServer #1
• (1) FT Directory ServerServer #2
• (1) HMI Server
RSView SE Clients WinXP Pro
Data storagePi node
CLx2CLx1
Level 1 NWK
Level 0 NWK
IOs
PLCs
• (1) FT Directory Server
• (1) HMI Server
• (2) Data Servers
• (1) RSLinx Enterprise
• W2K3 Server O/S
• (1) HMI Server
• (2) Data Servers
• (1) RSLinx Enterprise
• W2K3 Server O/S
CLx2CLx1
Level 1 NWK
Level 0 NWK
IOs
PLCs
• (1) FT Directory Server
• (1) HMI Server
• (2) Data Servers
• (1) RSLinx Enterprise
• W2K3 Server O/S
• (1) HMI Server
• (2) Data Servers
• (1) RSLinx Enterprise
• W2K3 Server O/S
One facility – 9 directoriesTime to do some change?
• User demands
– User demands sharing information across a facility.
– User demands on access HMI client applications outside of the plant.plant.
• IT demands
– Reducing the hardware required
– Improving reliability
– Improving redundancy
– Simplify the administration of the system
– Use of virtual environment if possible
Recomendations FTView Studio 6.1
Factory Talk Directory
• FactoryTalk Directory on its own server.
Hot redundant
server pair
Directory Server
Hot redundant
server pair
• Can be removed from the system.
Recommended tested limits FTView Studio 6.1
FactoryTalk View• 5 hot redundant server pairs per FTD. • Multiple areas can be on one FT directory.• For redundancy only one Area per server.• 1 HMI server per area • 1 HMI server per area • 1 Data server per area• 20.000 tags on scan per hmi server
FactoryTalk Alarm & Events
• Alarm limit that can be displayed per FTAE server is 2,000.• Alarm limit per FTAE server is 10,000.• Alarm limit per FT directory is 20,000.• The maximum number of alarm clients connected to an alarm server
Recommended tested limits FTView Studio 6.1
• The maximum number of alarm clients connected to an alarm server is 20.
• The referenced limit of FTAE servers is 2 per FT directory.
Terminal / ViewPoint Servers
• Terminal services / ViewPoint servers can only communicate to 1 FTD
Recommended tested limits FTView Studio 6.1
Options
Two directories• Hot redundant• Easier to upgrade (patches)• Not optimal for information
sharing• Need extra hardware for terminal
server and View point server
One directory• Harder to control the backup• Optimal for information sharing• Optimal solution terminal server• No alarm synchronization• Not hot redundant• Harder to upgrade
The design – one FT Directory
Existing nine directory's changes to nine areas in one Factory Talk Doman
Hard limits:• 1 Area per server.
Hot redundant server pairs
• One Area
• HMI Server
• Data Servers
• FTAE Server
FTView SE Clients Data storage Pi node
Directory Server Terminal server
• 1 Area per server.• 1 HMI server per area • 1 Data server per area
Use of virtual environment:• Two servers per server
hardware
Redundancy and use of Virtual environment
Hot redundant server pairs
• One Area
• HMI Server
FTView SE Clients Data storage Pi node
Directory Server Terminal server
• Data Servers
• FTAE Server
Pri Sec
The result
• Can open client applications from different areas in same client
• Easy access to all areas through one terminal server
• Redundant SCADA servers in different areas• Better administration of the system• Better administration of the system• Access to all areas from same workstation • Hardware reduced using virtual environment• We exceeded the recommedations limits without
experiencing any lack of performance.• Supported system FTView 7.1 from Rockwell