Presentation Transcript

1. Invensys Operations ManagementPBPC131Foxboro PAC System introduction

   Terry Minns Director PAC Systems Portfolio November, 2011
2. Agenda Introduction Where does PAC fit in the InFusion Enterprise Control System? Markets and Requirements Wonderware Pac Software Eycon Panel Displays T2750 PAC & T2550 PAC Programmable Automation Controller and the I/O Store and Forward - Data Recording at source Redundancy and the PLC Case Study overview
3. Introduction Foxboro PAC
4. Invensys Enterprise Control Offerings Corporate Systems Industry Solutions Services: Consulting, Project Execution, Learning, Operational Improvement, Maintenance & Support Partner Ecosystem Corporate Software Applications Invensys and Third Party Manufacturing / Production Operations Automation Invensys and Third Party Enterprise Control System IT Platform Integration and Collaboration Platform
5. PAC, SCADA and Enterprise Control Execution Integration & Collaboration Platform Enterprise Asset Management Mobile Workforce Management Manufacturing Execution Systems Batch Performance Software Applications Enterprise Manufacturing Intelligence Performance Measurement and Reporting Asset Performance Enterprise Integration Visualization Quality Optimization Workflow Advanced Process Control Simulation / Optimization Design Operator Training Third-Party Offerings Open Device Integration Web Portal Control DCS PAC SCADA HMI Automation Software Applications Application Toolkit Safety Turbomachinery Control Safety Instrumented Systems General Purpose Safety Historian Measurement & Instrumentation Recorders Instrumentation Controllers
6. It’s more than “just the hardware” Although the focus of this presentation is primarily about the Foxboro PAC product, it is important to keep in mind that it is the plant floor to top floor integration capabilities that can maximize the value that we can bring to a customer. From standalone control, to fully integrated systems, it’s more than just the hardware.
7. Foxboro PAC System - Overview Wonderware PAC Software – Enterprise-wide visualization Proven Scalable Architecture with Wonderware System platform inside Versatile scalable suite of software tools to ease the configuration workload, with extensive object symbol libraries Store and Forward, Historian ERP and MES connectivity Eycon - Visual Supervisor Panel Mounting, Touch screen, Display and Control Alarm Management, Batch, Recipe, Setpoint programming Open communications Auditor software - 21CFR part11 compliant access control T2750 PAC & T2550 PAC - Programmable Automation Controller Maximises Process up time - High Availability Processor and I/O Redundant Continuous & Sequential control and Data Recording Signal conditioning and Direct field connection of universal I/O Start Small - Grow Big: Ideal for New and Retrofit Applications
8. A2 Scalable System solutions we have today Foxboro PAC Solutions Eycon10/20 HMI Visualiser Historian HMI- Visualizer HMI- Visualizer Server T2750 (PAC) T2750 (PAC) T2750 (PAC) Control & I/O Small Systems <1000 I/O Unit Systems <250 I/O Large System & Cluster >3000 I/O
9. Markets and Requirements Foxboro PAC
10. Vertical Markets – Market Positioning High L E V E L O F A U T O M A T I O N Classic DCS PLC + HMI Refining Automotive Oil Chemicals Aerospace Gas Power Hybrid Markets -PAC Machine Parts Pulp & Paper Beverage Semiconductor Metals Fine Chemicals Food Water Pharmaceutical Glass Biotechnology Mining Low Scientifically-Oriented (Process) Craft-Oriented (Batch) Mechanically-Oriented (Discrete)
11. PAC System Requirements Hybrid Markets PAC Single vendor Tightly integrated Upward scalability Downward scalability Built-in Redundancy High Availability Flexible architecture Low Entry - scalable Central Configuration Prebuilt interface Lifetime support Local SI support Classic DCS Single vendor Tightly integrated components and common platform Good upward scalability Poor downward scalability Built-in Redundancy High Availability >99.999% Moderately flexible architecture High Entry Cost Central Configuration Prebuilt Operator interface Lifetime support PLC + HMI Multi vendor Loosely integrated components , many platforms Poor upward scalability Good downward scalability Custom Engineering Normal Availability Highly flexible architecture Low Entry Cost Many config environments Custom operator displays Local SI support
12. Utilities : Burner Management Boiler Management Pharmaceutical : API, EMS/BMS Waste Water : Municipality, Industrial, Desalination Water Treatment Glass : Float, Bottling, Fibre, Solar Power : Biomass, Incinerators Small power plant < 150MW Renewable energy Metal : Heat Treatment Target Applications Target Markets
13. Wonderware PAC Software Foxboro PAC
14. Foxboro PAC–Wonderware PAC Software ArchestrA MES LINTools IEC 1131 configuration-SFC/FBD/ST Distributed Database Online Reconfiguration Galaxy System Platform T2750 PAC Redundant CPU Competitive High Density I/O Distributed Data Logging Peer to Peer Communications
15. SP Wonderware PAC Software PAC What is Wonderware PAC software? Full DA server support DA Server deployment & Browser extensions Device Integration objects with diagnostic symbols PAC toolscomplete integration to Integrated Development Environment PAC application repository in the Galaxy Application objects Base objects (Alarm “Ack in” field functionality) I/O reference binding Process application objects Binding tool Store and Forward extension ArchestrA MES LINTools Galaxy System Platform
16. Equipment-Centric Objects: Graphic symbols Inputs/Outputs Logic/Scripting Faceplates Historical Information Alarms (Ack in field) and events Object Security
17. Range of HMI Foxboro PAC Eycon-10 - 100mm QVGA Display Eycon-20 - 180mm XGA Display
18. Eycon Series – Visual Supervisors Embedded SCADA Combination Logic Setpoint Programmer Recorder Operator Panel PID and SequenceControl Eycon – More than a Display
19. Advanced HMI Products. Store and Forward Up to 99 User definable Screens User definable Off Screen Function keys USB Port for removable data archive 45Mb Internal NV Flash for Archiving Removable Personality Flash Card Serial Communications Modbus-RTU Master or Slave Two serial ports (422/485) Ethernet Connection 10/100BaseT ELIN and Modbus-TCP Master and/or Slave FTP for transferring Archive Data to Server Profibus DPv1 Master .Eycon 10 / Eycon 20
20. T2750 PAC and T2550 PAC Foxboro PAC
21. What can the T2750/T2550 PAC Do? Advanced PID Control with optional Autotune Single Loop, Cascade Control, Ratio Control, Override Control Continuous and Sequential Control Function Block Diagram (FBD) Sequence Function Chart (SFC) Structured Text (ST) Ladder Signal Conditioning Alarm Monitoring Data Acquisition Store and Forward Online Reconfiguration Available in 0, 8 & 16 module base sizes
22. T2750 IOC (Input Output Controller) Simplex or Redundant Processors The IOC is the ‘Brain’ of the T2750 PAC System Can be used in Simplex or Duplex Mode Easy Synchronisation of Duplex Processors Bumpless Processor Changeover Hot Swap Processors Simple Licence Upgrade Path Try before you buy’ mode Auto/Man Licence Upgrade Wizard Auto responder available to Group Pay only for what you need SDHC Card contains licensing and configuration data base
23. Simplicity = Efficiency Reduced Service and Maintenance; Low MTTR (Mean Time To Repair) Hot Swap failed I/O modules Fit failed Processor Personality flash card to replacement Hot Fit New Processor to Base
24. Simplicity = Lower Engineering costs Toolset SAME SOFTWARE for EYCON Visual Supervisor T2750 PAC and T2550 PAC ONLY LEARN ONE SET OF TOOLS Context Sensitive Help 4 User Tasks Auto I/O generation of database Integrated Custom Screen Builder Multiple Application Programming Languages to IEC 61131 part 3 FBD (Function Block Diagram) SFC (Sequential Flow Chart) Ladder ST (Structured Text)
25. I/O modules Foxboro PAC
26. Analogue I/O AI2 2 Channel Analogue Input TC, RTD(2,3,4 Wire), Volts, mA, mV, Pot, Pyrometer AI3 3 Channel Analogue Input mA, 24V TX Supply on each Ch AI4 4 Channel Analogue Input TC, mV, mA, Pyro AO2 2 Channel Analogue Output mA with 10V compliance (500R max) Volts with 20mA max compliance I/O Modules AI2 AI4 AO2 AI3
27. Digital I/O DI6 6 Channel Digital Input High voltage(110 / 240Vac) DI8 8 Channel Digital Input Voltage Input, Contact Closure DO8 8 Channel Digital Output Logic Output DI16 16 Channel Digital Input DO16 16 Channel Digital Output RLY4 4 Channel Relay Output 3 NO + 1 CO Relay RLY8 8 Channel Relay Output 8 NO Relay I/O Modules DI8 DI16 RLY4 DO8 DI6 DO16 RLY8
28. I/O Modules Specialist I/O FI2 2 Channel Frequency Input 0.01Hz – 40KHz Magnetic - 10Hz – 40KHz Contact 115V ac, 230V ac ZI Zirconia (Hi Z) FI2 ZI
29. Store and Forward Foxboro PAC
30. D_es m_s_ing dat_ cost yo_r company mon_y? Foxboro PAC can help Secure acquisition of business critical data s u e a o i
31. Store and Forward extension Foxboro PAC, Eurotherm Recording and Wonderware devices resolve the data loss issue. T2750 & T2550 Historian tags and Area/Alarm groups Mapping to hardware recoded tags Eycon 6000 recorders FTP / Ethernet Store and Forward extension service Wonderware Databases nanodac FTP Server
32. When you lose communications anything can happen… You could guess?... BUTYou don’t need tolose information Store and FORWARD ?
33. PLC Vs PAC Comparative price Analysis Foxboro PAC
34. Allen Bradley ControlLogix PLC PSU£405 Comms Module£1764 CPU £1764 Redundancy Module£1995 Control Net module£735 Base£178 £15,514 + I/O £15,514 + I/O Redundant PSU£427 Redundant PSU£427 Adapter£65 Control Net module£735 Base£178 PLUS I/O CPU£1764 Redundancy Module£1995 Control Net module£735 Comms Module£1764 PSU£405 Base£178 £6,841 £1,671+I/O £6,841 Based on : 2 X T2750 L60 1 X Redundant TU 1 X Base 2 X T2500P/1A3 + I/O as needed
35. Case Studies Foxboro PAC
36. Power Foxboro PAC
37. Invensys proprietary & confidential Boiler control Combustion boilers use Embedded Function Blocks Drum Level, Feed-water, Degassing, Blow Down, Turbine Monitoring.
38. Experiences in Power Generation Industrial Plants Blue Star, France – upgraded high pressure gas boilers Steam monitoring – many examples of distributed consumption Skid Mounted CHP plants in Spain Fossil Fuel China – 30 coal fired installations using T2550 DCS via SI Other fossil fuel boiler applications such as gas and oil Nuclear Structural Temperature Monitoring and reporting Emergency Incident Control monitoring and reporting Biomass 10 to 20MW complete Foxboro PAC with System Platform
39. Pharmaceutical Foxboro PAC
40. Large-scale Pilot plant - $700K
41. Vent Storage Speciality Chemical – Pharmaceutical – Food Process Purification ofImmunoglobulin Ethanol Filtration Centrifugation Anion exchanger Vent Harvest Separation Plasma Cryo-Poor Plasma Factor VIII, iX, AT III, C1 Suspension and Precipitation Suspension and Precipitation Storage Buffer Cryo-Precipitation Factor VIII, Fibrogen Vent Ultrafiltration Precipitate Harvest Filter Modules Formulation and Filling Buffer Chromatography Suspension Virus Inactivation Buffer Clarification & Color removal Fraction I Vent ImmunoaffinityChromatography Fraction II+III Air Filter Buffer Purification ofCryo-Factors Fraction III Purification ofAlbumin Filtration Fraction IV Formulation and Filling Pasteurization Formulation and Filling Fraction V Storage Diafiltration
42. Complete Solution Life Science Fermenter Maximise Production; Load is High Value Affordable Redundancy Devolved Sequence & Control Loss of HMI – T2550 continues to control Easy Periodic Calibration Multi-tasking facilitates Fast Interlocks
43. Redundant Modular controller Accurate control & data acquisition Phase Control Alarms Peer-to-peer Communication Hot Swap Processor & I/O Warm start capability Local Operator Panel Easy to use & navigate Secure, access controlled Local & Plant wide control & monitor Load, run & control batches locally & plant wide Local & plant wide Alarms & events management 21 CFR Part 11 Validateable Scalability : $30K job Biotech
44. Water Foxboro PAC
45. Industrial Wastewater plant $ 950K WaterPlant (BUSAN_JOONGANG) KOREA DLP Projector 100” 100” KT Logging Printer Alarm Printer Hard Copier TM/TC#S1 CCTV CCTV POS POS PES TM/TC#S2 TM/TC#S3    TM/TC#S9 통합컨트롤 시스템 TM/TC#M HUB HUB Fiber Optic Cable (Ethernet) TM/TC #M TM/TC #M T103 Unit Controller T940 Unit Supervisor KT KT 2500 Remote I/O    RIM MLS#1 MSBR#A MSBR#B MLS#2 MLS#3 MLS#4 TM/TC#S1 TM/TC#S9
46. Industrial Waste water plant : 120 wells local control panel
47. Wastewater Purification Aeration & Blower control Wet well level pump control Chemical feed, pH, Chlorine control Engine generation control Digester control Rotating biological contractor control Sequential batch reactor control Laboratory reporting Water Treatment and WastewaterAutomation & Control Water Treatment Plants Filter backwash control Clear-well level control Chemical feed, pH, Chlorine control Laboratory reporting Dynamic maintenance management
48. Glass Foxboro PAC
49. Glass production process > $1M Typical project Motors £1,000K Drives £500K Control £500K £200K £300K 20% of glass process Stocking silos Production machine Packaging Final heat treat Batch prep Furnace Inspection Feeder Mixer Customers 25% (top 5) Tier 1 Leverage “main player” positioning among Tier 1 customers to expand vertically to Tiers 2 and 3 50% (10 to 20) Tier 2 5% (300 to 400) Tier 3 = Present
50. Complete Solution GLASS Glass Furnace Distributed functionality High Availability Scalable Redundancy On-line Reconfiguration Low MTTR facilitated by CF Personality Card Direct Plant connection to I/O Disconnect Facility for commissioning/maintenance Hi Insulation protection on TCs Secure Furnace Reversal Management Synchronised to Real Time Clock
51. Heat Treatment Foxboro PAC
52. Heaters Chamber Low Vacuum Gauges Cooling Coils Back Fill Chamber High Vacuum Gauges Gas 1 High Vacuum Valve Air Admit Roughing Valve Gas 2 Partial Pressure Backing Line Valve Control Over Temp and Record Thermocouples Backing Line Low Vacuum Gauge Booster Pump Hearth No.2 Hearth No.1 Heat Shields Work Thermocouples Rotary Pump Holding Pump and Valve Diffusion Pump and Heater Port Seals Highly Accurate Heat Treatment Solutions Cooling Fan Cooling Door Shop Floor Automation Integrated Solutions
53. Multi-Tasking Control Environment Primary Task (Analog) Temperature >110ms Primary Task (Digital) Door Status >110ms Rapid Digital Tasks >10ms Shut Door
54. Metals and Mining Foxboro PAC
55. Steel production process Posco, Korea - 5 off Anshan Iron & Steel, China Tula Chermet, Russia BS Port Talbot - 2 off BS Redcar BS Port Talbot BS Llanwern BS Redcar BS South Bank BS Port Talbot BS Scunthorpe Pont A Mousson, France BS Port Talbot BS Lackenby Cogne Italia BS Port Talbot BS Llanwern BS Scunthorpe AST Terni Italia BS Redcar BS Lackenby Gruppo Riva Taranto United Engineering Steels Caparo Merchant Bar Rotherham Engineering Steels Stockbridge Engineering Steels Shanghai Iron & Steel, China Swedish Steel BS Ebbw Vale Stockbridge Engineering Steels U.N.S.C.O. Stainless Steels Orb Electrical Steels Ltd Dalmine Italia Avesta, Sheffield BS Port Talbot Acciaierie Bolzano Italia BS Trostre Sollac, France BS Llanwern BS Ebbw Vale BS Port Talbot BS Shotton Marcegaglia Italia Sollac, France
56. Questions and Answers Foxboro PAC
57. Thank You Hardware and Software Solutions for Real-Time Success