Implementation of a Central Process Utility Plant controls upgrade for Compressed Air systems; architecture consists of four standalone 300 HP air compressors, and a Refrigerated Water system composed of five chillers and six cooling towers. The major challenge for this upgrade was the requirement for 100% uptime on all utilities throughout the entire project. The upgraded control system was based on an Rockwell Automation process solution utilizing a PlantPAx for Life Sciences architecture along with a virtualized server infrastructure. Review of business drivers behind the investment and desired return is also reviewed.

1. Utility Plant Upgrade
with Redundant, PlantPAx Platform
Tom Brown – Program Manager, Banks Integration Group, Inc.
June 8, 2016

2. Agenda
Lessons Learned
System Design
System Selection Process
Project Overview

3. 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

4. Project Overview
 Central Process Utility Plant – CPUP
Refrigerated Water
(5) Chillers
(6) Cooling Towers
Compressed Air
(4) 300 HP Compressors

5. 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

6. 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

7. 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

8. 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

9. Agenda
Lessons Learned
System Design
System Selection Process
Project Overview

10. 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

11. 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

12. PlantPax for Life Science
Rockwell Automation Library – “Out of the Box”

13. 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

14. Process Objects for Life Science
Benefits
 Pre-programmed modules

15. Process Objects for Life Science
Benefits
 Pre-validated following GAMP Life Cycle Model

16. Process Objects for Life Science
Benefits
 Increased visibility

17. Process Objects for Life Science
Benefits
 Reusable Global Object Library

18. Process Objects for Life Science
Benefits

19. 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

20. 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

21. Network Calculations – ControlNet
 Network Bandwidth Calculation – 16.5% Utilization

22. Network Calculations – EtherNet/IP
 Network Bridge Module is the bottleneck – 17.9% Utilization

23. 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.

24. DLR Design

25. DLR Diagnostics
 Status screen created for each network

26. Agenda
Lessons Learned
System Design
System Selection Process
Project Overview

27. System Design

28. System Design

29. SCADA Architecture

30. SCADA Components
 Virtual servers hosted on an HP
blade server system
 Wyse Thin Clients
 Wyse ThinOS, based on Linux
platform
 Touch screen OIT’s

31. 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

32. 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

33. 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

34. Agenda
Lessons Learned
System Design
System Selection Process
Project Overview

35. 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

36. Lessons Learned
 Executing a DLR Hardware FAT reduced startup time

37. Questions
Tom Brown – Program Manager, Banks Integration Group, Inc.
June 8, 2016