Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900D L30 - Sizing PlantPAx System Architectures for Optimal Performance Sizing & Selection

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Agenda 2 PlantPAx System Characterization and Sizing Tools System Architecture and Elements PlantPAx – Process Automation System

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx – Process Automation System

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx – It’s More Than a Distributed Control System (DCS) It’s a process automation system that gives you everything you want in a world-class, contemporary DCS plus...  Plant-wide control capabilities  Open, flexible architecture  Integrated control, power, safety, and information  Support by a global network of local experts It’s a process automation system that gives you everything you want in a world-class, contemporary DCS plus...  Plant-wide control capabilities  Open, flexible architecture  Integrated control, power, safety, and information  Support by a global network of local experts 4

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Plant-wide control technologies Standards-based architecture using Integrated Architecture TM 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

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Where to Get More Information? PlantPAx Technical Documentation Selection Guide: ” “How do I define a system?” Keyword PROCES-SG001 Reference Manual: “How do I build a system?” Keyword PROCES-RM001 PlantPAx TOC on the Rockwell Automation KB: 62366

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Architecture and Elements

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx Architecture Classes and System Elements System ElementDescriptionStationDistributed – 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 OWS 10 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) Process Controller Logix Based Controller Logix controllers Logix controllers Logix controllers per PASS Application Servers Information management, Asset management, Batch Application Servers as needed Domain Controller N/AOptionalRequired if there more than 10 PC 8

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. PlantPAx Architecture Examples 9 PlantPAx System on an EtherNet/IP Network PlantPAx System with I/O on ControlNet Network

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. PlantPAx Simplex Controller Sizing 10

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. PlantPAx Redundant Controller Sizing 11

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Controllers for Skid-based Equipment 12

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx Simplex I/O 13

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx Redundant I/O 14

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx Process Networks I/O 15

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Characterization and Sizing Tools

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Characterization Main goal of PlantPAx System Characterization is to provide a recommended architecture and information (boundaries) concerning a system operation / performance early in the sales cycle to reduce / eliminate perceived risk of the system being able to provide the needed performance. 17 Controller wall (50 + PACs) Distributed System (4 servers) Centralized System (1 server) OEM (L1/L2/L3) Virtual System

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Characterizing the System Loading by Using “Control Strategies”  A control strategy identifies the relationship between the loop control code and its data requirements. A control strategy can represent any control code, such as process control, I/O, data flow, and visualization for a control entity. A control strategy can be a 2- state device, a PID loop, a sequencing block:  Controller code  IO data  Controller data  HMI Server data  HMI Client data  HMI DL data  Batch data  Historian data  Using the control strategy model, we are able to estimate these system parameters:  HMI server tags on scan (alarm tags, display tags, data log tags, event detector tags, and derived tags)  Controller memory usage  Controller execution time 18

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG System Performance Criteria in “Operational” Terms 1Display Call up A HMI Display “Paint Time” is the time it takes to call up a new screen (not cached) and must be operational in less than 2 seconds 2Display Data Update A change in a active value within any controller is displayed on a graphic screen on the OWS (HMI client) in less than 1 second. 3Steady State Alarms The System must support a Steady State alarm condition, consisting of twenty new alarms being generated every second, with the difference between the time an alarm is triggered and its timestamp not exceeding one (1) second (cannot miss any alarm) 4Alarm Burst The System must support an Alarm Burst condition, consisting of one thousand (1000) new alarms generated all at once, with the difference between the time any alarm is triggered and its alarm timestamp not exceeding three (3) seconds (cannot miss any alarms) 5System Recovery Within five (5) minutes after a failed System Element is restored, the system should recover and perform as it did before the system element failure 6Data Logging The system will be capable of continuously data logging a minimum of 200 independent points once a second 7Paint Time for Datalog Trend A datalog trend display will present 12 hours of historical data of any data logged point on the OWS within 30 seconds of the operators display request. 8Operator Control The operator will be able to interact with the process by changing tag values in the controller within 2 seconds. 9Control Loop Update Time The system will be capable of supporting 125 Complex Regulatory Control Loops (cascaded) within a 250ms periodic task. This time is from instrument to actuator. 10Batch Server: Operator Action Time An operator initiated Batch command will be responded to by the PAC with 1 second. 11Batch Server: Server Action Time A batch server initiated Batch command will be responded to by to the PAC with 1 second. 12Batch Server: Controller Action Time A batch Event in the Controller will provide the operator with feedback in 1 second.

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Measuring System Performance 20 The Operator Interface is the critical element as it must meet all CSAs Display Call up Data Update Operator Command The Operator Interface is the critical element as it must meet all CSAs Display Call up Data Update Operator Command

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Tools and Utilities 21 Example of PlantPAx Characterization Iteration Report

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Sizing PlantPAx Systems Selection Guide 22 PlantPAx Selection Guide (PROCES-SG001) provides high level guidelines to properly size system

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG 23 Process Automation Tools in IAB

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Sizing PlantPAx Systems PlantPAx System Estimator  Wizard in Integrated Architecture Builder (free download)  Define, size, and generate BOM for your system  Performs the loading calculations for you  Customize sizing rules based on your application PlantPAx System Estimator allows you to perform a detailed sizing estimation based on your application requirements

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Add engineering hours, Non RA products Customize with IAB, including Encompass products PlantPAx System Estimator report must be attached to PlantPAx architecture reviews What is the PlantPAx System Estimator? Customer Info PSE Wizard IAB Reports Proposal Works

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Estimator (New) System Parameters and Tree 26 System Subsystem Server Controller I/O Location/Group Workstations

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PASS (Process Automation System Server) Summary 27

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Controller Summary 28

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Configure I/O Location 29

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Defining Application Load Through I/O Count and Profiles 30

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Defining Application Load Through Control Strategies 31

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG Data for PlantPAx System Estimator C o p y ri g h t © R o c k w el l A u t o m a ti o n, I n c. A ll ri g h ts r e s e r v e d. These cells should not be changed DA and DO outputs distribution % between control strategies. Sum of cells in each column should be = 100% Rate for strategy (only selectable) Profiles i.e. industries

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Tools and Utilities 33 PlantPAx PAC Load Estimate Tool Reflects Recommended Task Structure

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Tools and Utilities 34 PlantPAx PAC Hardware Defaults

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG How Does PSE Show Sizing Problems? 35

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Estimator Server Tags on Scan / Second Server Tags on Scan / Second What Is It? Communication rate through data server What does it do? Limits the controller per server ratio by limiting communication load What is the impact? Recovery from abnormal conditions, performance How to address? Add PASS, move controllers into new server 36

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Estimator Server Tags in Memory Server Tags in Memory What Is It? Memory on data server used to manage controller connections What does it do? Limits the OWS per server ratio by limiting server memory utilization What is the impact? System stability How to address? Add PASS, move controllers into new server 37

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Estimator Alarms Configured on Server Alarms Configured on Server What Is It? Number of alarms hosted by server What does it do? Limits the alarms per server ratio What is the impact? Recovery from abnormal conditions, performance How to address? Add PASS, move controllers into new server 38

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Estimator Controller Memory Controller Memory What Is It? Memory on controller used What does it do? Limits the how much logic can be put in the controller What is the impact? Everything How to address? Change controller type, or add controller and move I/O to new controller 39

Copyright © 2014 Rockwell Automation, Inc. All rights reserved. #PSUG PlantPAx System Estimator Controller CPU % Controller CPU % What Is It? CPU utilization of controller What does it do? Restricts how much code can run in controller at specified rate What is the impact? System stability How to address? Review and adjust control strategy execution rates or add controller, move I/O into new controller. 40

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. Rev 5058-CO900D Questions? 41