Applying Best Practices to Achieve Superior Results with the PlantPAx System

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

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Applying Best Practices to Achieve Superior Results with the PlantPAx® SystemSizing, Selection and Best Practices

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2

Agenda

Seven Most Common Mistakes in PlantPAx System Sizing

Best Practices When Designing PlantPAx System

System Architecture and Elements

PlantPAx – Process Automation System


PlantPAxProcess Automation System

3

PlantPAx is a Modern DCS

� Integrates with your Enterprise IT systems enabling the Connected

Enterprise

� Provides Faster Time to Market and Lower Total Cost Of Ownership

� Enables improved Asset Utilization and Enterprise Risk Management.

� Uses open communications standards and leverages Ethernet/IP as its

backbone to make real-time information available based on throughout the

organization for better business decisions PlantPAx

Combines the plant-wide control technologies and unmatched

scalability of Integrated Architecture with all the core capabilities

expected in a world-class distributed control system (DCS) and more…


Plant-wide control technologies

• Standards-based architecture using Integrated ArchitectureTM 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

PlantPAx is our Rockwell Automation Process Automation System:Plant-wide control technologies in a DCS Platform

PlantPAx Process Automation System


Where to Get More Information?PlantPAx Technical Documentation

Selection Guide:” “How do I define a system?”

http://literature.rockwellautomation.comKeyword PROCES-SG001

Reference Manual: “How do I build a system?”

http://literature.rockwellautomation.comKeyword 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 ControlEtherNet/IP

Asset Management

OperatorWorkstations

EngineeringWorkstations

Process AutomationSystem Server and

Application Servers – HMI

BatchManagement

InfoManagement

ProcessControllers

Variable Speed Drives

Local, Distributed, and Intelligent I/O

Valves andInstrumentation

IntegratedProcess 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 Performance1. Size System Properly


Keys to System Performance1. Size System Properly

11

PlantPAx Selection Guide (PROCES-SG001) provides high level guidelines to properly size system


Keys to System Performance2. 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 Performance3. 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



16

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.



17

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 utilizes 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



18

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 Performance4. 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 Performance5. Follow Infrastructure Guidelines

20

� Optimize your operating system settings

� Turn off automatic updates (follow Rockwell patch recommendations:

KB Aid 35530)

� Disable Windows Error Reporting

� Disable operating systems themes

On virtualized systems, use the PlantPAx Virtual Image Templates



21

� 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



22

� Use managed switches

� Use static IP addresses on your workstations, servers, and controllers

� 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


PlantPAx 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 PlantPAx

Library revision is shown in the table below:

Logix Diagnostic Object Description 1.0 1.5 2.0

L_CPU Controller Usage Monitor Y Y Y

L_TaskMonitor Controller Task Monitor Y Y Y

L_Redun Redundant Controller Monitor N N Y

L_ChangeDet Controller Change Detector N N 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)

30

� “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


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

31

� “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 sub-systems provided by multiple suppliers. There

was no “system responsibility”

� This is the most difficult case. Sub-system 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.)


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

era

tor

Ala

rm

Ala

rm C

on

fig

Ma

inte

na

nce

En

gin

ee

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

To

tal

Tags per Process Object

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PlantPAx System Tools and Utilities

34

When you think that IAB

recommended “way too many

servers or controllers”, please

check your rate of execution

and system limits

34

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 sub-systems that could be connected should be accounted for and estimated

New Skids

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PlantPAx System Tools and Utilities

39

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!


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Applying Best Practices to Achieve Superior Results with the PlantPAx System