PR07

PR07
Sizing PlantPAx System Architectures for Optimal Performance
PUBLIC INFORMATION
Rockwell Automation TechED 2015
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Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.
Agenda
PlantPAx Process Automation System
System Architecture and Elements
PlantPAx System Characterization and Sizing Tools
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PLANT-WIDE
SCALABLE
SECURE
FLEXIBLE
Control and Optimization
and Modular
Open and Information-enabled
Delivery and Support
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Plant-wide control technologies
Standards-based architecture using Integrated ArchitectureTM
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
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Where to Get More Information?

PlantPAx Technical Documentation
Reference Manual:
Selection Guide:
How do I build a system? How do I define a system?
http://literature.rockwellautomation.comhttp://literature.rockwellautomation.com
Keyword PROCES-RM001Keyword PROCES-SG001
PlantPAx TOC on the Rockwell Automation KB: 62366

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Agenda

PlantPAx System Characterization and Sizing Tools
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PlantPAx Architecture Classes and System

Elements
System
Element
Description
Station
Process
automation
system server
(PASS)
Required system element

that may host displays,
alarms, and data
connections to controllers
Operator
workstation
(OWS)
Provides an interactive
graphical interface to
monitor and control
process
Engineering
workstation
(EWS)
Central location for

configuring the system and
maintaining operations
Single computer
serves as PASS,
EWS, and OWS
Distributed Single
Server
Distributed - Multiple Server
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)
10 OWS
1 EWS required (can

have as many as 5)
10 OWS per PASS; up to 50 per

system
1 EWS required (can have as
many as 5)
Process
Controller
Logix Based Controller
1...5 Logix
controllers
Application
Servers
Information management,
Asset management, Batch
Application Servers
as needed
Application Servers as needed
Domain
Controller
N/A
Optional
Required if there more than 10 PC
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1...8 Logix controllers
1...8 Logix controllers per PASS
PlantPAx Architecture Examples

PlantPAx System with I/O
on ControlNet Network
PlantPAx System on an
EtherNet/IP Network
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PlantPAx Simplex Controller Sizing
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PlantPAx Redundant Controller Sizing
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10
Controllers for Skid-based Equipment
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11
PlantPAx Simplex I/O
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12
PlantPAx Redundant I/O
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13
PlantPAx Process Networks I/O
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14
Agenda
PlantPAx System Characterization and Sizing
Tools
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15
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.
Distributed System (4 servers)
Controller wall (50 + PACs)
Centralized
System
(1 server)
Virtual
System
OEM (L1/L2/L3)
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Copyright 2015 Rockwell Automation,

16 Inc. All Rights Reserved.
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
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17
System Performance Criteria in

Operational Terms
1
Display 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
Display 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.
Steady 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)
Alarm 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)
System 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
Data Logging
The system will be capable of continuously data logging a minimum of 200 independent points once a second
Paint 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.
Operator Control
The operator will be able to interact with the process by changing tag values in the controller within 2 seconds.
Control 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.
10
Batch Server: Operator Action Time
An operator initiated Batch command will be responded to by the PAC with 1 second.
11
Batch Server: Server Action Time
A batch server initiated Batch command will be responded to by to the PAC with 1 second.
12
Batch Server: Controller Action Time
A batch Event in the Controller will provide the operator with feedback in 1 second .
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Measuring System Performance

The Operator Interface is the critical
element as it must meet all CSAs
Display Call-up
Data Update
Operator Command
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Copyright 2015 Rockwell Automation,

19 Inc. All Rights Reserved.
Example of PlantPAx Characterization

Iteration Report
PlantPAx
System
Tools
and Utilities
Rockwell
Automation
TechED
2015
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20
Sizing PlantPAx Systems

Selection Guide
PlantPAx Selection Guide (PROCES-SG001) provides high level
guidelines to properly size system
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21
Process Automation Tools in IAB
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22
Sizing PlantPAx Systems

PlantPAx System Estimator
PlantPAx System Estimator allows you to perform a detailed sizing estimation based on your
application requirements
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
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What is the PlantPAx System

Estimator?
Add
engineering
hours, Non RA
products
Reports
Customer Info
Proposal
Works
Proposal
Customize with IAB, including

Encompass products
PSE Wizard
IAB
PlantPAx System Estimator report must be attached to PlantPAx architecture

reviews
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System Parameters and Tree
System
Server
Subsystem
Controller
I/O
Location/Group
Workstations
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25
PASS
(Process Automation System Server)
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26
Controller Summary
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27
Configure I/O Location
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Defining Application Load Through I/O

Count and Profiles
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29
Defining Application Load Through

Control Strategies
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30
Data for PlantPAx System Estimator

Profiles
i.e. industries
These cells should not be changed
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DA and DO outputs
distribution % between
control strategies. Sum of
cells in each column should
be = 100%
Rate for
strategy (only
selectable)
Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.Copyri
PlantPAx PAC Load Estimate Tool

Reflects Recommended Task Structure
PlantPAx
System
Tools
and Utilities
Rockwell
Automation
TechED
2015
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32
PlantPAx PAC Hardware Defaults
PlantPAx
System
Tools
and Utilities
Rockwell
Automation
TechED
2015
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33
How Does PSE Show Sizing Problems?
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34

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
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35

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
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36

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
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37

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
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38

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.
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39
Whats New
Virtualization Minimum Requirements
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40
Whats New
MCC Components (Network I/O)
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41
Whats New
Local Switch (Controller Level)
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42
Whats New
Local Switch (I/O Level)
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43
Coming soon
Detailed Sizing Spreadsheet (Input Data)
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44
Coming soon
Detailed Sizing Spreadsheet (Output Data)
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45
Thank you for participating!

PUBLIC INFORMATION
www.rockwellautomationteched.com
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PR07 - Sizing PlantPAx System Architectures For Optimal Performance

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Sizing PlantPAx System Architectures for Optimal Performance

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx System Characterization and Sizing Tools

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

Control and Optimization

Open and Information-enabled

Delivery and Support

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx Process Automation System

Optimized for performance in process

Extended with tools and utilities

System definition and sizing tools

PlantPAx is our Rockwell Automation Process Automation

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

Where to Get More Information?

PlantPAx TOC on the Rockwell Automation KB: 62366

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

System Architecture and Elements

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx Architecture Classes and System

Required system element

Central location for

Distributed - Multiple Server

One PASS required

One PASS required and includes:

1 EWS required (can

10 OWS per PASS; up to 50 per

Logix Based Controller

Application Servers as needed

Required if there more than 10 PC

Rockwell Automation TechED 2015

1...8 Logix controllers

1...8 Logix controllers per PASS

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx Architecture Examples

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx Simplex Controller Sizing

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx Redundant Controller Sizing

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

Controllers for Skid-based Equipment

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx Simplex I/O

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx Redundant I/O

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx Process Networks I/O

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

Rockwell Automation TechED 2015

Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

PlantPAx System Characterization