cybertrol engineering: hospital utilities plant upgrades to plantpax with zero downtime
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Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Cybertrol Engineering: Hospital Utility Plant Upgrades to PlantPAx with no Downtime
Mark Visness, Engineering Manager
Michael Owczarek, Project Engineer
November 2014
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Project Successes
System Design/Implementation
Concerns/Decision Factors
End-User Overview
Cybertrol Engineering Overview
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Agenda
Project Successes
System Design/Implementation
Concerns/Decision Factors
End-User Overview
Cybertrol Engineering Overview
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
Overview
Founded 1996
50 employees, 34 engineers
Automation and IT Services
UL508 Panel Shop
Thousands of projects for over 400 clients
Rockwell Solution Partner
(Control/Process/Information)
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Project Successes
System Design/Implementation
Concerns/Decision Factors
End-User Overview
Cybertrol Engineering Overview
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
#PSUG
End-User Overview
Major hospital campus
in Minnesota
Utility plant for 8 buildings,
including administration and
patient care
Three boilers, five chillers,
and auxiliary systems
Heating and/or cooling required
24/7/365
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Project Successes
System Design/Implementation
Concerns/Decision Factors
End-User Overview
Cybertrol Engineering Overview
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Dated Legacy DCS System
Rosemount RS/3 System, vintage 1993
4 Operator Control Stations
6 Marshaling Cabinets with a total of eighteen 19” racks, 90” high
Approximately 900 I/O points (500 “loops”)
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Unit Operations Controlled
Three Boilers 80,000 pph each 250 psig steam @ 600 °F Dual fuel: oil, natural gas
Two Steam-Driven Chillers
2000 Ton each One on 250 psig steam One on 8.5 psig steam SLC 5/05 PLCs
Three Electric Chillers
2000 Ton each CompactLogix PLCs
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Unit Operations Controlled
Electric Generators
Gas Turbine Generators
RO Polisher
Cooling Towers
Weather Station
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System Concerns
Parts no longer available from distributor
Parts only available on 2nd-hand market
Risk to operations (spares not on hand)
Obsolete magnetic tape backup system
Expensive vendor support
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Decision Factors – Performance
Full ethernet connectivity
Ease of programming
Redundant processors
Redundant I/O network
Enhanced reporting
Virtualization
Remote support
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Decision Factors – Cost of Ownership
DCS System licensed by loops
Rockwell PAC – no loop licensing
FactoryTalk View SE HMI System licensed by # of displays, not loops
License for this system: 250 display
Approx. 125 displays used
Can be upgraded to unlimited
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Decision Factors – Industry Acceptance
System integrators with Rockwell experience are plentiful
Hiring Rockwell-experienced maintenance staff is easier
Rockwell Automation has 60%+ automation market share in North America
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Decision Factors – Support
Components stocked by local distributor
Other Rockwell equipment already in plant;
maintenance staff familiar, have Rockwell
Studio licensing
Local SI support or via remote connection
Plentiful support resources
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Agenda
Project Successes
System Design/Implementation
Concerns/Decision Factors
End-User Overview
Cybertrol Engineering Overview
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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System Design - Controllers
Redundant ControlLogix PACs:
Identical redundant racks Instantaneous failover to
secondary Simple check box
Device-Level I/O Ring (DLR)
Redundant pathways for I/O communications
Any one I/O cable can fail without disruption to I/O
Operator is notified of comm fault
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System Design - Network
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System Design - Servers
Process Automation System Server (PASS)
Two Hosts
Virtualized Servers
Redundant Network Switches
Thin Clients
Engineering Workstation
Network Attached Storage
Remote Access
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System Design – Software
Operating System Microsoft Windows Server
Virtualization VMWare ESXi / VSphere
Visualization: FTView SE Server with
redundancy PlantPAx
Historian & Reporting FactoryTalk Historian FactoryTalk VantagePoint
Backups VEEAM Backup & Recovery
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System Design – Virtual Machines
PASS HOST 1 Domain
Controller 1 FTView SE
Server 1 RSLinx
Enterprise 1 RDP Server 1 FactoryTalk
Directory FactoryTalk
Historian
PASS HOST 2 Domain
Controller 2 FTView SE
Server 2 RSLinx
Enterprise 2 RDP Server 2 FactoryTalk
VantagePoint Backup &
Recovery System
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System Design – PlantPAx
PlantPAx objects
Motor/VFD Valve/Analog Valve PID Loop Digital Input/Output Interlocks/Permissives
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System Design – Reports
• Trends
• Daily/Monthly Flow Totals
• Energy Usage
• Easy to develop custom reports
Develop custom reports
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System Implementation – Panels
Re-used existing field wiring
Used Point I/O chassis to fit in
same space
Every I/O point individually
fused
Clean plant – enclosures could
remain open for an extended
period
Hung new chassis on door
temporarily
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System Implementation – Cutover
All new chassis powered up on
device-level ring
I/O swapped over from existing
panel to new chassis, point-by-
point
Old modules removed and new
chassis relocated to inside of
cabinet
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Agenda
Project Successes
System Design/Implementation
Concerns/Decision Factors
End-User Overview
Cybertrol Engineering Overview
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Project Successes
Reduced Total Cost of Ownership (TCO)
Improved features and performance
No interruption to plant operations
System is easier to support and maintain
Remote support
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Project Successes
System regularly backed up
Local distributor less than 3 miles away
Standard computer hardware
Less expensive, more easily sourced
support
“This system is so much more user-
friendly and flexible. Also we are going
to save a lot in the long term in
maintenance and support costs”
Copyright © 2014 Rockwell Automation, Inc. All rights reserved.
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Learn more at www.cybertrol.com
Mark Visness, Engineering Manager
mvisness@cybertrol.com
Phone: (763) 519-7834
November 2014
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