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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