The Digital Sugar Mill

1. The Digital Sugar Mill
Seminar on Sugar & Ethanol Automation

2. PlantPAx Capabilities &
Functional Overview
M. Ali Omer
Technical Project Manager

3. PlantPAx
Process
Agenda
What is PlantPAx
System Sizing and Characterization
PlantPAx Logic Add-Ons
PlantPAx HMI Functionality
PlantPAx Components
Process Safety
Batch Management
3

4. It’s a process automation system that
gives you everything you want in a
world-class, contemporary DCS and way
more.
PlantPAx – It’s More
Than a Distributed
Control System (DCS)
PlantPAx
 Plant Process Automation
Excellence
Word Class DCS
 Plant-wide control capabilities
 Open, flexible, scalable,
modular architecture
 Integrated control (process
and machine), power, safety,
and information
 24/7 local support available
through Avanceon
4

5. PlantPAx
Capabilities
5
Capability PlantPAx
Plant wide Control Disciplines
Discrete 
Motion 
Process & Machine Safety 
Continuous Process 
Batch 
Drives 

6. 6
PlantPAx
Capabilities
Capability PlantPAx
Control System Features
Controller Redundancy 
Remote I/0 
System Scalability with Single
Platform/Control Engine(Single Machine
to Large Plant

Hot swappable I/0 
Broad I/0 capability (Rack mounted, field
based distributed I/0 and hazardous form
factors

Full digital integration with drivers 

7. 7
PlantPAx
Capabilities
Capability PlantPAx
Configuration and Programming
Object Oriented 
All IEC 61131-3 Programming Languages 
Online Editing/Configuration 
Tag Based Addressing & Programming 

8. 8
PlantPAx
Capabilities
Capability PlantPAx
Visualization
Fully Integrated Client/ Server HMI with
Redundancy

Panel Based HMI 
Web based HMI Interface 
Historical Data Collection (SOE, EVENTS,
TRENDING, REPORTS)

Alarms and Events 

9. 9
PlantPAx
Capabilities
Capability PlantPAx
System Communication and Field Buses
Ethernet (I/P) 
Standard Ethernet Infrastructure (Cisco
Alliance)

Control Net 
Device Net 
MODBUS RTU/TCP/IP 
AS/I (Actuator Sensor Interface) 

10. 10
PlantPAx
Capabilities
Capability PlantPAx
Process Control
Regulatory 
Logic Function Block 
Sequence 
Batch 
Controller based ISA-S88 phase support 

11. 11
PlantPAx
Capabilities
Capability PlantPAx
Advanced Control
Fuzzy Logic 
Auto tune technology 
Model predictive control 

12. 12
PlantPAx
Capabilities
Capability PlantPAx
Process Fieldbuses
Foundation fieldbus 
Profibus PA 
HART 

13. 13
PlantPAx
Capabilities
Capability PlantPAx
Process Safety
Scalable Process Safety 
Integrated Process Safety 

14. 14
PlantPAx
Capabilities
Capability PlantPAx
Service and Support
Project Engineering and Solution provider
Network

24 x 7 Technical support 
Configuration Services 
Hardware Maintenance Services 
Installation Services 
Software Support and Upgrade Support 
Training 
Single Source Supplier 

15. PlantPAx – Distributed Architecture
15

16. Al Moiz PlantPAx System Architecture

17. PlantPAx System
Characterization
PlantPAx supports all widely
spread Process Networks I/O
17

18. PlantPAx Process
Networks I/O
Main goal of PlantPAx System
Characterization is:
 To provide a recommended
architecture and information
[boundaries] regarding a system
operation and/or performance
early in the sales cycle to reduce
 To eliminate perceived risk of the
system being able to provide the
needed performance.
PlantPAx system is carefully tested
and designed to ensure best
possible performance.
Controller Wall
50 + PACs
Distributed System
4 servers
Virtual
System
Centralized
System 1 server
18

19. 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.
19

20. Characterizing the
System Loading by
Using “Control
Strategies”
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
20

21. 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
2
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.
3
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)
4
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)
5
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
System Performance Criteria in “Operational” Terms
21

22. 22
6
Data Logging The system will be capable of continuously data logging a minimum of
200 independent points once a second
7
Paint Time for Datalog Trend A data log 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.
8
Operator Control The operator will be able to interact with the process by changing tag
values in the controller within 2 seconds.
9
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 .

23. Measuring System
Performance
The Operator Interface is the
Critical Element and has three
main features:
Display Call Up Time
Data Update Rate
Operator Command
The Operator Interface is the
critical element
 Display Call up
 Data Update
 Operator Command
23

24. Example of PlantPAx Characterization Report
24

25. PlantPAx Interface

26. PlantPAx – Harmony between Logic and HMI
26

27. PlantPAx
Available
Instructions
27

28. PlantPAx Library of
Logix Diagnostic
Objects L-CPU:
Controller Usage
Monitor
PlantPAx offers extensive CPU
Diagnostics and all
information is available from
within the HMI interface
28

29. PlantPAx EtherNet/IP
Network Monitoring
• Complete
Information of
Stratix Switches
• Complete
Information of DLR
Network
• Complete
Information of
EtherNet/IP Nodes
29

30. PlantPAx Process
Ad-Ons
PlantPAx has extensive built
in Add-Ons for all Process
Devices.
Add-Ons significantly
reduces Engineering time
and Maintenance activities
30

31. PlantPAx Process
Faceplates
 PlantPAx has detailed
Faceplates corresponding to
Logic Add-Ons.
 Complete Information
available from within
Faceplates.
 Setting Alarms, Bypassing
Interlocks, Simulating devices,
enabling/disabling alarms,
detailed Help.
31

32. PlantPAx Modes &
Security
 Operator: .Commanded from the HMI
 Program: Commanded by the application logic
 Override: Commanded by application logic for
abnormal operation, supersedes Program and
Operator modes.
 Maintenance: Commanded from the HMI for
maintenance, bypassable interlocks and
permissive and feedback checks can by bypassed.
 Hand: Tracks controlled by hardwired local
station..
32

33. Operations Layer
33

34. Operations: Maintenance
and Troubleshooting
Made Easy!
34

35. New shelve alarm
capability per
ISA 18.2
Enter shelve time
duration and
comments
Better integration
with PlantPAx Library
Operations: Standards-based alarming
35

36. Operations: Standards-
based alarming
Provides method for gating threshold
alarms or indications includes:
Gate Input
Gate Delay
On-Delay
Off-Delay
36

37. Operations:
Standards-based
alarming
Easily navigate from motor
to interlock to cause
Interlocks with first-out
Access to logic for complex
interlocks
Quick Troubleshooting for
improved MTTR
37

38. Operations:
Automation of
Operator
Procedures
PlantPAx sequencer object:
Easily configurable to
capture critical sequences
Rich visualization provided
to the operator
Built-in Exception Handling
38

39. Asset Management
&
System Maintenance
Extensive Asset Management
and System Maintenance Tools
Instrument
Diagnostics
Instrument
Management
Instrument Health
Instrumentation
Device Diagnostics Device
Management
Device HealthPowerControl
Operator: “Is it OK?”
Maint: “How bad is it?”
Tech: “How do I fix it?”
39

40. Batch
Management
 Provides Scalable Platform From
simple, single unit scale to highly
complex, integrated batch
solutions.
 Integrated Analysis Tools Batch
reports, material usage, genealogy,
and solutions to optimize batch
production
 Native ISA-88 Structure Simplify
change management and
regulatory compliance
40

41. Operations
Productivity
 Scalable Data Collection Chassis-
based, plant-wide or
enterprise-wide historian
 Decision Support Tools Trends,
dashboards, and reports
 Users Collaboration to make
actionable decisions
41

42. Process
Optimization
 Broad Advanced Control Portfolio
From advanced regulatory to simple
model-based control, soft sensors to
complex model predictive control
 Flexible Deployment From loop and
unit-level optimization in the
controller
to plant-wide economic optimization
at the supervisory layer
IMC_01
IMC ...
Internal Model Control
0.0
PV
0.0
SPProg
0.0
SPCascade
0.0
RatioProg
0.0
CVProg
0.0
HandFB
0
ProgProgReq
0
ProgOperReq
0
ProgCasRatReq
0
ProgAutoReq
0
ProgManualReq
0
ProgOverrideReq
0
ProgHandReq
CVEU
0.0
SP
0.0
ProgOper
0
CasRat
0
Auto
0
Manual
0
Override
0
Hand
0
MMC_01
MMC ...
Modular Multivariable Control
0.0
PV1
0.0
PV2
0.0
SP1Prog
0.0
SP2Prog
0.0
CV1Prog
0.0
CV2Prog
0
CV3Prog
0
ProgProgReq
0
ProgOperReq
0
ProgCV1AutoReq
0
ProgCV2AutoReq
0
ProgCV3AutoReq
0
ProgCV1ManualReq
0
ProgCV2ManualReq
0
ProgCV3ManualReq
0
ProgCV1OverrideReq
0
ProgCV2OverrideReq
0
ProgCV3OverrideReq
CV1EU
0.0
CV2EU
0.0
CV3EU
0.0
SP1
0.0
SP2
0.0
ProgOper
0
CV1Auto
0
CV2Auto
0
CV3Auto
0
CV1Manual
0
CV2Manual
0
CV3Manual
0
CV1Override
0
CV2Override
0
CV3Override
0
CC_01
CC ...
Coordinated Control
0.0
PV
0.0
SPProg
0.0
CV1Prog
0.0
CV2Prog
0
CV3Prog
0
ProgProgReq
0
ProgOperReq
0
ProgCV1AutoReq
0
ProgCV2AutoReq
0
ProgCV3AutoReq
0
ProgCV1ManualReq
0
ProgCV2ManualReq
0
ProgCV3ManualReq
0
ProgCV1OverrideReq
0
ProgCV2OverrideReq
0
ProgCV3OverrideReq
CV1EU
0.0
CV2EU
0.0
CV3EU
0.0
SP
0.0
ProgOper
0
CV1Auto
0
CV2Auto
0
CV3Auto
0
CV1Manual
0
CV2Manual
0
CV3Manual
0
CV1Override
0
CV2Override
0
CV3Override
0
42

43. Skid & Process
Equipment
Solutions
Overall System Performance
 Proven, tested architectures for not
only DCS
applications, but skid-sized solutions
as well
to ensure total system performance.
 Machine Automation functionality and
full support built in
43

44. SIL 0
Process
SIL 1
Fail Safe
SIL 2
Fail Safe
SIL 2
Fault Tolerant
SIL 3
Fail Safe
SIL 3
Fault Tolerant
Basic Process Control
System
SafetyInstrumented Systems
(SIS)
PlantPAx
(Logix)
EtherNet/IP communication:
AADvance™ & PlantPAx™ Trusted
TMR
AADvance
Scalable
Safety
Process Safety
 Provides Integrated and scalable
SIS Solutions, including TMR for
the highest availability.
 PlantPAx based on Logix Platform
 Redundant Logix Platform
 Redundant Logix Platform with
Redundant I/Os
 GuardLogix SIL3 Fail Safe
 Aadvance
 Aadvance Trusted TMR
44

45. Question & Answers
Thank You for Your Valuable Time
45

46. Lahore, Pakistan
Headquarters South East Asia
19 Km Main Multan Road
Lahore, Punjab 54660
Pakistan
Phone : + 92 42 111 940 940
Dubai, UAE
Headquarters Middle East And Asia
Office FZS1 BD04, Jebel Ali Free Zone
PO Box 18590, Dubai
United Arab Emirates
Phone: +971 4 88 60 277
Exton, USA
Headquarters Americas
180 Sheree Boulevard, Suite 1400
Exton, PA 19341
United States of America
Phone +1 610 458 8700
Regional Offices and Global Headquarters