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Invensys Operations Management PBPC233 - Foxboro PAC Controller and Tools

Invensys Operations Management PBPC233 - Foxboro PAC Controller and Tools. Terry Minns Director PAC Systems Portfolio November, 2011. Agenda. Introduction Where does PAC fit in the InFusion Enterprise Control System Markets and Requirements

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Invensys Operations Management PBPC233 - Foxboro PAC Controller and Tools

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  1. Invensys Operations ManagementPBPC233 - Foxboro PAC Controller and Tools Terry Minns Director PAC Systems Portfolio November, 2011

  2. Agenda • Introduction • Where does PAC fit in the InFusion Enterprise Control System • Markets and Requirements • T2750 PAC & T2550 PAC - Programmable Automation Controller and the I/O • Configuration • On line reconfiguration • Networking • Compatible with T2550

  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 Pack 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. Glass : Float, Bottling, Fibre, Solar Power : Biomass, Incinerators Small power plant < 150MW Renewable energy Metal : Heat Treatment Target Applications Target Markets • Utilities : • Burner Management • Boiler Management • Pharmaceutical : • API, • EMS/BMS • Wastewater : • Municipality, • Industrial, • Desalination • Water Treatment

  13. Wonderware PAC Software • SP • PAC 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 New At Ops Manage ‘10

  15. Range of HMI Foxboro PAC • Eycon-10 - 100mm QVGA Display • Eycon-20 - 180mm XGA Display

  16. 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

  17. T2750 PAC T2550 PAC Foxboro PAC

  18. 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

  19. 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

  20. T2750 PAC Processor • Mechanics: • Screw Fixing (not lever) for secure heat transfer • New Zero Way Redundant Base • Ethernet Bottom Entry • New Terminal Assembly • USB • PSU • Serial Communications • SRAM and RTC Battery Backup • Watchdog Hardware: • One 10/100Mb Ethernet; ELIN and Modbus TCP Master/Slave • Non-Isolated Serial Modbus RTU & RAW Communications • PSU Soft Start • Real Time Clock drift 2 mins / year - Support for SNTP • Redundant USB 2.0 and Std LEDs • Freescale Power QUICC II Pro processor, • MPC8313 – 32-bit, 333 MHz Internal

  21. T2750 Foxboro PAC • I/O density Increase: • DI16 (was 8 channel) • DO16 (was 8 channel) • RLY8 (was 4 channel) • CPU Upgrade: • 8 time faster than T2550 • 2000 Blocks (was 400) • Logging capacity 32MB (was 7) • USB port on the CPU (Up load UHH files) • Modbus TCP & RTU • Raw Communications

  22. User Interface Foxboro PAC

  23. Cold start Primary Cold start Secondary T2750 PAC - Panel Layout • Status • On - IOC hardware good and is running. • Off - No power or IOC failed • Fault • On - Module missing / faulty / incorrect type or base size / any H/W fault. • Off - All OK • Battery • On - Battery is OK • Flashing - Battery failed or not fitted • Off - Deliberately not fitted • Communications • On - T2750 is transmitting field communications • Off - T2750 is not transmitting • IP resolution • On - IP address fully resolved • Flashing - IP address being resolved • Off - IP address cannot be resolved or DHCP failure • Duplex • On – Inter-processor communications functioning correctly. • Flashing – Inter-processor communications failed • Off – Not operating in redundant mode • Watchdog - Switch • T2750 has watch-dogged - this switch causes the IOC to reset & attempt re-boot. • T2750 is running - Switch has no affect.

  24. Cold start Primary Cold start Secondary T2750 PAC - Panel Layout Primary • On – This processor is the Primary and is running a strategy • Flashing - Strategy being loaded or unit is idle. • Off – This processor is not the primary Standby • On – This processor is the secondary • Flashing – Processors are being synchronised • Off - This processor is not the active secondary Sync - Switch • Primary and Secondary are unsynchronised, • Operation of this switch on the Primary causes the T2750 to start the synchronisation process. • Primary and Secondary are synchronised, • operation of this switch on the Secondary causes Primary / Secondary changeover. De-Sync - Switch • Primary and Secondary are synchronised • operation of this switch on the Primary causes the T2750 to desynchronise. • Operation of this switch on the Secondary has no affect. USB v2 (activity) Ethernet (activity) • On - connected to live Ethernet network • Flashing – Ethernet traffic detected • Off - no valid Ethernet connection • Ethernet (speed) • On – 100 MB • Off – 10 MB

  25. Cold start Primary Cold start Secondary T2750 IOC - Connections Ethernet connection • 10/100Mb • Auto sensing Serial Communications • RJ45 (field communications) connector located below each IOC, wired together such that either IOC can drive both connectors. • RS485/422 jumper selection • Redundant power connectors (24Vdc), • Diode protection for reverse polarity supply USB v2 connection Real time clock and Hot start memory support • Battery Connection Watchdog connection

  26. T2750 Terminal Assembly Double width IOC TU assembly Capable of supporting operation in Duplex and Simplex modes. In Simplex mode, an ‘empty’ IOC case is used to blank off the second IOC slot. IOC cases cover • Heat transfer area • Hot/Cold start switches • LIN node address

  27. 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

  28. 2500 I/O Modules Foxboro PAC

  29. I/O Modules AI2 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 AI4 AO2 AI3

  30. I/O Modules DI8 DI16 RLY4 DO8 DI6 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 DO16 RLY8

  31. 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

  32. Configuration Foxboro PAC

  33. 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)

  34. Online Reconfiguration Foxboro PAC

  35. Online Reconfiguration • Reconfiguration -modes • Edit • Trying • Indication. • Online reconfiguration, • Using LINtools - Simplex and desynchronised Duplex nodes. • Online reconfiguration limited to FBD and I/O only. • Tentative Delete • Wire. • Block • Tentative Addition • Block • Wire • Unlink • Reconfiguration - Actions • Mixed connection • Wire • Try • Un-Try • Apply

  36. Networking Foxboro PAC

  37. Network Switch Network SwitchRapid Spanning Tree Protocol (RSTP) Network SwitchRapid Spanning Tree Protocol (RSTP) T2750 peer to peer Communications • Simple installation • Standard Ethernet cables • ‘Industrial off the shelf’ network components • Protocol support • Foxboro PAC ELIN • Modbus-TCP Master and Slave Network Switch Network Hub Redundant Ethernet

  38. T2550 Foxboro PAC

  39. T2550 PAC – Q4 (Oct) 2010 • T2550 I/O: • Identical to existing system • Without support for DI16, DO16 & RLY8 • CPU: • Identical to original T2550 PAC • Mechanics: • A facelift • Invensys Colours • Processor Case ‘Darker’ than I/O • T2550 Backplane, • Updated Terminal units • new colour connectors • Existing I/O PCBs, New Cases • No Terminal units cover • Vents in cases, temp 0->55degC • Also applies to 2500

  40. T2550 to T2750 PAC Processor Upgrade Hardware Required: • New Processors • New Terminal Unit • Same Base • Same I/O (only V2 modules) • Same I/O Terminal units • No wiring Change • Not Possible on-line. Turn off and swap-over Software: • Copy Application Files – No edit required RESULT -> Faster/More Power/Digital I/O

  41. T2550 & T2750 – Mix Old & New Parts • New Processors: • T2550 & T2750 CPU Wont Synch and Different Terminal units • T2750 & New Terminal Unit with existing I/O: works but looks … Ok? • Mix & Match mechanics: • Same I/O Card Electronics & PCBs in new cases • New I/O Modules on old TAs • Old I/O Modules on new TAs • i.e. Any TA, Any I/O Module, in Any Combination on T2550/T2750 base • Old Style Mechanics (CPU and I/O Module Cases): • Available on special order • NOT Terminal Units • NOT Base/Chassis • NOT Complete (composite) Base, Processor and I/O Modules

  42. Questions Foxboro PAC

  43. Thank You Hardware and Software Solutions for Real Time Success

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