Discovering the Functionality of the PlantPAx Library of Process Objects

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The PlantPAx Libraries are key ingredients to providing rich functionality with known performance. Each library object will be presented for its capabilities and typical application. Common library features such as modes and alarms is explained. Walk away with the knowledge to more efficiently develop and operate process systems and OEM skids.

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Discovering the Functionality of the PlantPAx Library of Process Objects

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Discovering the Functionality of the PlantPAx® Library of Process Objects
  2. 2. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2 Agenda Demos, Discussion, Questions What’s Coming? What’s New Since 3.0? What’s in the PlantPAx Libraries? Overview
  3. 3. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 3 PlantPAx System Modern DCS using Plant-Wide Technology 3 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. 4. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Overview
  5. 5. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Reusable Library for Design Productivity  Suite of control and HMI objects to accelerate project engineering  Role-based feature set for  Operation  Maintenance  Engineering 5 PlantPAx Standard Library – “Out of the Box”
  6. 6. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Library Philosophy 6 Standard Applications Control Strategies (Control Modules) Library Hierarchy  Devices (valves, motors / drives, control algorithms, transmitters, etc.)  Logix5000 function blocks, faceplates and graphic objects  Level control, temperature control, etc.  Mixer/Reactor, etc. Example Included in base system System Add-On Custom Purchase Logix Programming and Visualization Tools Devices (Process Objects)
  7. 7. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Key Benefits 7  Improvements in:  System “out-of-the-box” experience  Engineering efficiency, plus tools, for solution providers  Focus on application engineering rather than building base blocks  Consistency of application solutions from multiple delivery partners  Predictability of system behavior  Library managed by Rockwell Automation  Consistent engineering library framework  In line with customer expectations  TechConnectSM support Ask for “PlantPAx Support”
  8. 8. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Demonstration 8  Over the next few slides, your host will present and demonstrate how to:  Add a P_Motor instance in Logix, connect its I/O  Add a motor graphic symbol to a display  Link the HMI to Logix via Global Object Parameter  Start and stop the motor  Add blocks to build up functionality  Add related devices  Items marked (like below) can be demonstrated on the PlantPAx Trainer equipment at the end of the session  But there’s not enough time to show all of them
  9. 9. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Installing the Library: Logix Components 9  For Add-On Instructions (AOIs), import only the ones you need.
  10. 10. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. All Dependencies Are Imported 10  IMPORTANT: All dependencies are included in the AOI import file  Embedded AOIs and all required data types (UDTs, STRINGs)  Example: the P_Motor instruction uses P_Alarm and P_Mode
  11. 11. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Use RUNG Imports if Available 11  Some instructions provided with both AOI import and RUNG import files  A RUNG import includes all the associated Tags and UDTs for In/Out Parameters  Example: Fault Codes  Import the RUNG (to a Ladder Diagram routine)  Do this once, even if you are implementing in Function Block Diagram  Then simply delete the rung of logic  All the other stuff you need stays
  12. 12. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Installing the Library: HMI Components 12  First, add the library components to your HMI application (FactoryTalk® View Site Edition or FactoryTalk® View Machine Edition) 1. Import the Images – all the .PNG files 2. Import the Global Objects – all the .GGFX files 3. Import the Displays – only the GFX files you need  The order is important: each item depends on the previous items  Add any platform-required items (Tags, Macros,etc.) See Release Notes.
  13. 13. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Displays: Just the Ones You Need  Each Faceplate, Quick or Help popup counts as only one Display  … even though the Faceplate has multiple tabbed views.  Many instructions use P_Mode, P_Alarm, P_Gate  ...so don’t forget to include their Help and Configuration Displays.  Include “Common” displays 13
  14. 14. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Create an Instance: Logix 14  Add the instruction: in Ladder (LD), Function Block Diagram (FBD), or Structured Text (ST)  Create its backing tag  Controller or Program scope  You can do this online  Actually, you can do all of this, including importing AOIs, online
  15. 15. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Connect Its I/O 15
  16. 16. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.  Open your Display  Drag and drop the graphic symbol  From the appropriate “… Graphics Library” GGFX file  3.0: Note the updated graphics, with .PNG images, throughout the library Create an Instance: FactoryTalk® View 16
  17. 17. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Create an Instance: Link It Up 17 Just one global object parameter
  18. 18. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Default Configuration  IMPORTANT: Every instruction defaults to the simplest, basic device configuration.  Motors: outputs only with no run feedback  Valves: outputs only with no limit switch feedback  Additional features are used if you configure / enable them  Defaults are listed in the Reference Manual for each instruction 18
  19. 19. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Add Run Feedback  Link the run feedback input in the code  Open the faceplate and enable Run Feedback checking  Engineering tab: Has Run Feedback; Maintenance tab: Use Run Feedback 19
  20. 20. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. “HAS” and “USE” 20  Has: the function exists, is coded  Under control of Engineering  If an AOI does not have a function, it is not visible to operators or maintenance  Use: the function should be used as intended  Under control of maintenance  Allows bypassing or disabling a function temporarily  Maintenance Bypass Indicator  Has but not Used
  21. 21. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Designed Around User Roles 21  Operation, maintenance, engineering tabs  Pre-defined security model  User profiles for operator, operating supervisor, maintenance, maintenance supervisor, manager, engineer, administrator
  22. 22. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Operation: What Shut Us Down? 22  Interlocks with first-out  Access to logic for complex interlocks  Snapshot when logic triggers shutdown
  23. 23. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Operation: Where Am I Right Now? 23  Quick access to detail displays  Highlight of current state  Available commands and data entries are obvious  Tooltips  Help displays
  24. 24. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Operation and Maintenance: What keeps us from running? 24  Several object faceplates have a Diagnostics Tab  In 3.0:  PowerFlex® 755, 753  In 3.1:  Any device with “Sts_NotRdy”  New “Nrdy_xxxx” bits highlight individual causes  More about Library 3.1 shortly!
  25. 25. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Maintenance: Find and Work Around Problems 25  Goal: no need to force I/O or change code to bypass typical issues  Bypass run feedback, position feedbacks  Substitute PV (discrete or analog input)  Maintenance bypass indicators  Follow the trail of breadcrumbs
  26. 26. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Maintenance: Tools to Maintain Equipment 26  Bypass Interlocks / Permissives (as allowed by engineering)  Maintenance data collection  Motor run times and start counts  Valve stroke times and counts
  27. 27. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Engineering: Tools to Manage Configuration 27  Instantiation tools to speed development and roll-out  Restricted HMI configuration access for changes
  28. 28. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. What’s in the PlantPAx Libraries?
  29. 29. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Library of Process Objects 3.0 29  Add-On Instructions for Logix V18 or later  Graphic Symbols and Faceplates for FactoryTalk View SE and FactoryTalk View ME V7.0 or later  Manuals • Motors: Single speed, two speed, reversing, hand-operated (monitor) • Variable Speed Drives: PowerFlex 753, 755 (PowerFlex 523, 525 in Library 3.1) Generic VSD for PF4 / 40 / 70 / 700 / DC / 7000 • Valves: Solenoid-operated, motor-operated, mix-proof, hand-operated (monitor) • Analog inputs with scaling and threshold alarms: single, dual, multiple; input channel diagnostics • Advanced analog input adds rate of change, square root extraction, and deviation alarms • Analog output (manual loading station) • Control valve (analog or pulse, with feedback) • Flowmeter or weigh scale dosing, with dribble and self-tuning preact • Simple sequencer, manual prompt • Continuous Control: PIDE (wrapper AOI), Hi/Low Select, Fanout
  30. 30. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Library of Process Objects 3.0 30 • Updated graphics: Softer images Even grayer when normal • Enhanced navigation Both upstream and downstream • Permissives with bypass • Interlocks with First-Out indication and Bypass • Motor Run Time, Starts, Restart Inhibit • 2-state Valve Statistics • Discrete Logic with snapshot • Discrete Input with alarm • Discrete 2-, 3- or 4-State Device • n-Position Device (up to 8) • Discrete Output (with Pulsing) • Tank Strapping Table • Logix Diagnostics • CPU Utilization Monitor • Task Monitor • Controller Redundancy Monitor • Change Detector • Faceplates for built-in instructions: • PIDE RMPS TOT • IMC CC MMC • Standard Modes and Alarms (updated) Better alignment with ANSI/ISA-18.2-2009 and FactoryTalk View 7.0, including Operator Shelving
  31. 31. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. P_Seq 31  Simple Sequencer – a single Add-On Instruction  Boolean Inputs (32) for transition condition checking  Boolean (32) and Real (32) Outputs for actuation and setpoints  Number of steps limited only by memory  Operator and maintenance features for ease of use  Standard PlantPAx library features (mode model, breadcrumbs, etc.)  Visual and named references for all “waiting” conditions  Forcing of input conditions or steps (with appropriate access)  Configure, edit and monitor via supplied PlantPAx graphics and faceplates  Embedded fixed state machine with Pause, Branch, Hold capabilities  Supplemental AOI provided for manual prompt steps added  P_Seq Backported to Release 2.0-10
  32. 32. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. P_Seq: Operating and Detail Displays 32  Detail – scrolls steps  Shows Input, Output states, Real Out values  Manual Prompt capability  Shows “Waiting For” conditions
  33. 33. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. P_Prompt 33  Multiple capabilities  Message to operator  Data to operator  Operator selection  Data from operator  Text from operator
  34. 34. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. P_PIDE 34  “Wrapper” for PIDE  PlantPAx Modes, Alarms  Hi-Hi deviation, Hi deviation, Lo deviation, Lo-Lo deviation, Interlock Trip, Fail  PlantPAx parameter naming  All PIDE capabilities  Latest release: end user can enable Autotune  Plus:  Powerup Loop Mode, CV, SP  Interlock with CV and trip alarm  Override Mode is a “full” owner
  35. 35. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. P_HiLoSel 35  For CV High-Select or Low-Select (CV Override) applications  Up to 6 primaries (upstream CV sources – PIDE, P_PIDE)  Kp * E offset calculation for each primary  Avoids winding up due to noise on PVs  Highest or Lowest CV is selected, others biased so error must change sign on another loop before it can become selected.  Uses “CVPrevious” input to PIDE / P_PIDE for feedback
  36. 36. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Graphics for APC Instructions 36  Symbols and Faceplates for Advanced Process Control (APC) built-in instructions  IMC (Internal Model Control) – 1 PV, 1 SP, 1 CV  CC (Coordinated Control) – 1 PV, 1 SP, 3 CVs  MMC (Modular Multivariable Control) – 2 PVs, 2 SPs, 3 CVs
  37. 37. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Operator “Quicks” 37  Simple operator-only faceplates for devices  Call-up options:  Always shows Quick; always shows full Faceplate  Or set by login privileges: Quick for Operator, Faceplate for Maintenance
  38. 38. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Enhanced Navigation 38  Enhanced navigation in Faceplates  Motor, Valve, etc.: to Interlocks, to Interlock logic, to logic inputs  P_PIDE: back to PV source, forward to CV destination  Analog Inputs: to source input channel for diagnostics
  39. 39. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Drives: Fault Code Lookup 39  Fault Code  Description lookup in all Drives AOIs  Read fault code from drive  Datalink from PF70 / PF700 / PF753 / PF755 / PFDC / PF525 / PF523  MSG get from PF4 / PF40  Fault code / description tables in Controller Tag  Linked to AOI instance via In/Out Parameter  Populated by configuration spreadsheet tool  Codes and descriptions for all PowerFlex Drive Families
  40. 40. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Enhanced Alarms 40  Release 3.0 of Library requires FTView 7.0 or later  FactoryTalk Alarms and Events support for ANSI/ISA 18.2-2009:  Suppression by Design (Program Suppress in P_Alarm)  Out of Service (Maintenance Disable)  Shelving (Operator Shelve) with Shelf Time  All with handshaking between P_Alarm in Logix and FTAE Server  New Alarm Configuration popup  Shelf Timer, Auto Unshelve  Program Unshelve  e.g., shift change  Custom Alarm text
  41. 41. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Premier Integration – Instrumentation  Objects for:  HART  1756, 1794 inputs  Others to follow  Foundation Fieldbus  EN2FFR  Profibus PA  EN2PAR  Endress + Hauser  Promag 53E  Promass 83E  Promass 100E  on EtherNet/IP  With Library Rel. 3.0-04 41
  42. 42. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Color Change Tool  Export displays and global objects from FactoryTalk® View Studio  Modify using the color change tool  One color palette  Save yours  By function  e.g., “Running”, “Energized”, “Fault”  Apply to all exported displays and global objects at once  Import modified displays and global objects into FactoryTalk View Studio 42
  43. 43. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PlantPAx Instance Configuration Tool  Microsoft Excel workbook  Uses RSLinx® Classic to configure controller online  Requires RSLinx activation (Gateway, OEM); cannot use RSLinx Lite  Preconfigured sheets (tabs) for PlantPAx AOIs  All configuration parameters, including local tags  Read configuration from controller  Store as archive for disaster recovery  Modify configuration using Excel  Tab for each AOI (class)  Write configuration to controller 43
  44. 44. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Alarms Builder and Tag Data Editing Tool  Alarms builder  Creates alarm XML import files:  for FactoryTalk Alarms and Events polling-based tags  for FactoryTalk View ME  Preconfigured definitions for PlantPAx Process Library V3.0 AOIs  Alarm tag parameters use underlying Logix tag parameter values  Tag data editing tool:  Edit multiple tag data values  Including AOI Local Tags (strings)  In spreadsheet-like table  Copy / paste / import / export / filter functions  Use with any Logix data types: UDTs, AOIs, etc.  Alarms builder and tag data editing tool can be used independently 44
  45. 45. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Alarms Builder: QuickBuild  QuickBuild creates an XML alarm import file using these settings:  Creates FactoryTalk Alarms and Events discrete alarms  Creates alarm only if P_Alarm “Cfg_Exists” = 1  AckRequired is set to true (AckRequired handled by P_Alarm AOI)  Latched is set to false (ResetRequired handled by P_Alarm AOI)  P_Alarm priority (1, 2, 3, 4) is mapped to FactoryTalk Alarms and Events severity (1, 251, 501, 751)  P_Alarm Cfg_Desc (description) text added to FactoryTalk Alarms and Events alarm message  FactoryTalk Alarms and Events alarm name set to object’s tag name + alarm name (‘TI101_Alm_HiHi’)  FactoryTalk Alarms and Events alarm view command set to call up object’s faceplate  FactoryTalk Alarms and Events alarm class set to controller name, program name, tag name, tag type  FactoryTalk Alarms and Events alarm status and control handshake tags automatically populated to link to P_Alarm for acknowledge, suppress/unsuppress, disable/enable, shelve/unshelve  TIP Set up alarms using configuration spreadsheet, then QuickBuild FactoryTalk Alarms and Events database 45
  46. 46. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. LogixView Utility (LVU) 46 LogixView Utility Logix Library Builder Build Library Controller Configuration Builder Drag & Drop Instances HMI Display Template Builder HMI Configuration Builder Build Application
  47. 47. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Additional Libraries 47  PlantPAx Library of Steam Table Objects  Given T(sat) find P(sat)  Given P(sat) find T(sat)  Given P,T find Enthalpy, Entropy, Specific Volume  PlantPAx Library of Logix Diagnostic Objects  Logix CPU Utilization  Logix Task Monitor  Logix Redundancy Monitor  Logix Change Detector  64-bit Integer Math, Time and Date Math Libraries  Added in 3.0: T_Sync – gets controller time from an NTP Server
  48. 48. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. How Do I Get These Tools?  PlantPAx Library of Process Objects and Tools  Preferred: Software Downloads  http://download.rockwellautomation.com/ webupdates/enter.aspx  Search “PlantPAx Library”  RSLogix™ 5000 / Studio 5000 DVD  You already have it  Knowledgebase AID #62682  Library, tools, plus 3 sample projects  Templates  Samples App  Pipeline Pump Station  LogixView Utility  Talk to your session host or local GPTC  We can guide your ramp-up and provide support 48
  49. 49. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Where to Find More Information  Online Literature Library  PlantPAx Library Product Profile Pub. PROCES-PP008  PlantPAx Library of Process Objects Reference Manual Pub. PROCES-RM002)  PlantPAx Library of Logix Diagnostic Objects Reference Manual Pub. PROCES-RM003)  AOI Reference Manuals Pub. SYSLIB-RMnnn 49
  50. 50. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. What’s Coming?
  51. 51. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Library 3.1: IMC Integration  Add-On Instructions for Overload Relays  P_E3Ovld  E3 and E3 Plus Overloads, DeviceNet or EtherNet/IP (via 2100-ENET)  P_E1PlusE  E1Plus Overload communication module on EtherNet/IP (193-ETN)  P_E300  E300 Overload on EtherNet/IP  Current, Voltage, Ground Fault sensing 51
  52. 52. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Library 3.1: IMC Integration  P_SMC50  P_SMCFlex  P_PF52x  PowerFlex 523  PowerFlex 525  NOT PowerFlex 527  (Motion drive) 52
  53. 53. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Library 3.1: Features 53  Faceplate for P_HiLoSel  Interlocks and Permissives: Individual Condition Bypassing
  54. 54. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Library 3.1: More Features 54  Not Ready reasons (Nrdy)  Page on Diagnostics Tab  Comm Status / Simulation  Indicator for Source & Quality
  55. 55. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Library 3.1: Even More Features 55  Alarm Test  Trend Display Improvements
  56. 56. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Post-3.1: Instructions 56  Remaining HART I/O  1734(sc), 1769(sc), 1797  Outputs for 1756, 1794  E+H Integration: Promag 100, Liquiline CM44  Lead / Lag / Spare Selector  Up to 32 pumps / motors in a group  You provide the demand  Number of pumps to run  We select the pumps  Hand vs. Auto vs. Off  User-defined priority  Rotate list
  57. 57. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Post-3.1: State Machine Builder 57  User defined State Machine  PC based application  Enforce user standard state machines  Built-in simulator for testing  User settable priorities on commands  Up to 32 states, 32 commands  User definable groups and contexts  Compiles encrypted AOI for import to Logix
  58. 58. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Demos, Discussion, Questions 58 DEMO
  59. 59. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. About the Demo Hardware 59  Used with PlantPAx curriculum (PRS013, PRS015, PRS018)  Configuration Fundamentals, Troubleshooting, System Integration  Common PlantPAx configuration  Redundant controllers, Distributed View SE image  Device Level Ring (DLR) Ethernet  Drive, starters, overloads  HART Analog I/O  HW/SW for maintenance scenarios  Switches create opens, shorts  Software scenarios to debug  Trainer Hardware: ABT-TDPAX
  60. 60. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank you! Questions? Answers!!!
  61. 61. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 61 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!

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