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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Rev 5058-CO900C
T70 - Qualified Building Automation SolutionsUsing Logix & FactoryTalk
Doug DemianApplication EngineerRockwell Automation(216) 659-2199
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
RA Life Sciences Solution Set
o2oCopyright © Rockwell Automation Inc All rights reserved
R&D ERP IntegrationPrimary
Production
Clinical Study Mgnt.
Clinical Supply Planning
EquipmentControl
Warehouse & Materials Mgt.
Batch Records & Mgnt.
Order Mgnt. & Scheduling
Weigh &Dispense
Combined domain expertise, industry knowledge, and world-class offerings create an unparalleled
solution in the Life Sciences industry.
BAS, QBAS, EMS
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Acronyms / Definitions
o3
BAS / BMS / HVAC: Building Automation System– Description: Controlling & monitoring of HVAC, lighting, security,
etc. systems.– Compliance: Not required – Commercially Commissioned
QBAS: Qualified Building Automation System– Description: Closed loop control & monitoring of Temperature,
Pressure, Humidity, Door Status and maybe Particulate – the “ENTIRE” HVAC System – typically 20 to 30 hardwired points per AHU”. Monitoring, Reporting, Historian
– Compliance: Validation / 21 CFR part 11 requirements.EMS: Environmental Monitoring System
– Description: Monitoring Temperature, Pressure, Humidity, Door Status and maybe Particulate – “Direct Impact” parameters - typically 5 to 10 points per room”. Monitoring, Reporting, Historian
– Compliance: Validation / 21 CFR part 11 requirements.PAS / PlantPAx: Process Automation System
– Description: Process Control, Monitoring, Reporting, Historian– Compliance: Validation / 21 CFR part 11 ready
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Impact of Manufacturing Environment
Federal Regulation 21 CFR 211.68 states: ‘...if a computer (or controller) can affect
product quality, it must be “Validated”.
ISPE Baseline Guide on Commissioning & Qualification states: ‘...if something can directly affect product quality, it is classified as “Direct Impact”, and therefore, it should be commissioned, qualified, and have enhanced documentation.’
o4
What Environmental Conditions Impact Product Quality?
Indirect Impact On Product Quality
- Validatable
No Impact On Product Quality- CommerciallyCommissioned
Direct Impact On Product Quality
- Qualified / Validated
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
The Impact of Validation in the Manufacturing Environment
o5
Identify, capture and manage critical environmental data -“Direct Impact”Effectively meet regulatory requirements for: documentation, data collection, security, storage and reporting.Increase overall operational excellence
User Requirements:
Validate the air handler control system or just Temperature, Pressure, Humidity, Particulate – direct impact parameters?
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Traditional Approach - QBAS
o6
Non-Validated Environment
Commercial ControlsValidated EnvironmentCommercial Controls
Commercial Control:
–HVAC, –Chillers,–Boilers,–Lighting, –Security, –etc
BAS QBASValidate the AHUControl System, Monitoring & Alarming of
–Temperature –Pressure –Humidity –Particulate
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Why a Process Platform?
o7
Process Automation System
System / Data Security
Alarming / Reporting
Time-stamped Audit Trails
Standard Reports
Traceable Electronic Records
Data Visualization
Validation Documentation
Fast Data Collection Speed
Data Storage
Event Handing
System FunctionalityCommercial Building Automation Systems
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Current Approach
o8
BAS
Non-Validated Environment
Commercial ControlsValidated Environment
Process Controls
QBAS
Migrate from commercial proprietary “black box” controllers to Process Controls in the Validated Environment - QBAS
Validate the AHU Control System, Monitoring & Alarming of
–Temperature –Pressure –Humidity –Particulate
Commercial Control:
–HVAC, –Chillers,–Boilers,–Lighting, –Security, –etc.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Risk Based Approach
Control:HVAC
o9
BAS
Non-Validated EnvironmentCommercial Controls
Validated EnvironmentProcess Controls
Monitoring & Alarming
– Temperature – Pressure – Humidity – Particulate
Commercial Control:
– HVAC, – lighting, – security, – etc
ProcessBAS
EMS
Validatable EnvironmentProcess Controls
Validate Direct Impact Parameters –Temperature, Pressure, Humidity, Particulate, Door Status
AHU Control – “read only” Temperature, Pressure, Humidity, Particulate from EMS
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Common System to Learn, Validate, Operate and Maintain
o10oCopyright © 2008 Rockwell Automation Inc All rights reserved
Process Automation Systems
Flexible Service Support
Single System Validation
Common System Support
Common Data Storage
Open Network Protocol
Common Maintenance
Approach
Common Training
Common Audit Trail
BenefitsCommercial Building Automation Systems
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Common Platform Meeting Regulatory Requirements
o11
ReportsData
Storage
Common:• System Infrastructure• Data Management• Report Structure• Validation Methods• Data Time Stamping• Alarm Management• Operator Interface• Maintenance Strategy• Parts Inventory
BusinessSystem
Shipping & ReceivingPackaging
21 CFR 11 Enabled Functionality
HMI
Utility Control
BASEMS
Compressors BoilersChillers
• Batch•Historian,• Scheduling - ERP Integration
•Maintenance Mgt (EAM - CMMS)•Condition Monitoring (predictive maintenance)• Metrics - OEE
Process
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Potential Life Cycle Savings
o12
10-15% Potential SavingsOpen Programming / 3rd Party InterfacesLongevityDocumentationOpen TrainingOpen Support / Services / In House MaintenanceFlexibility, IO, Common Platform, Spare PartsReliability, System AvailabilityInitial service cost + reduced annual service cost
Lower Total Cost of Ownership
Costs Savings
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Air Handler Controllers –Constant or Variable Volume
o13
Standard Control platforms– ControlLogix– CompactLogix
Object-oriented, ISA S88 based codeConfigurable code:
– HVAC parameters set via spreadsheet– No additional device operation ladder
programming requiredExpandable - advanced control algorithms specific to your process & facilitiesCompatible with Unitary and Central Plant systems
Re-usable Control ModulesRe-usable Equipment Modules Re-usable Graphic TemplatesRe-usable Validation Documents
ControlLogix
CompactLogix
Scalable Solutions
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Automation Application Design is Moving
o14
From To
The Paradigm Shift:• Understanding the process as a grouping of modules• Thinking in terms of function instead of hardware and software• STOP designing and constructing custom solutions• START using modules to assemble and configure your solutions
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Process BAS Software - Architecture Diagram
o15
FanControlModule
(VFD orStarter)
PIDControlModule
Heating/Cooling/
Reactivation
ProcessXmtr
ControlModule
(Analog In)
Damper ControlModule
(Valve orAnalog
Out)
Press. Sw.E-Stop
Freeze AlarmControlModule
(Digital In)
AHUEquipmentModules
ExhaustFan
EquipmentModules
SupplyFan
EquipmentModules
Unit /Scheduler
Module
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Flexibility and Module Independence Speeds Meeting Customer Requirements
Modular ISA88 design allows swapping of modules in and out to meet differing user requirements by individual customers
Highly configurable modules enable simple configuration changes versus complex code changes.
o16
Param 1Param 2Param 3
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
ISA88 Flexibility Speeds Development
o17
Control Module
Equipment Module
Unit
Process Cell
Area
Site
EnterpriseDivide applications into logical groupsUse a set of common terminologySwap modules to meet individual
customer / AHU requirementsConfigurable modules reduces complex
code changesUnit
‘Owns’ the equipment EMsManages supervisory functions:
Monitoring communicationsAlarm recordsTransferring system data
Equipment Module‘Owns’ the equipment CMsAllows alarm propagation/ management
Control ModuleInputs: AI, DIOutputs: AO, DOControl: PID, PIDC
Appl
icatio
n Fo
cus
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. o18
Automation for the Process Industry
Process Information
System CoreField Device
Integration & Asset Management
Batch Management& Control
Critical Control & Safety
Strategic PartnersSystem Tools& Utilities
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
PlantPAx, the next step - GEMS (Global Engineering Modularity Standards) Industry specific framework of control and equipment
modules (i.e. Life Sciences) For use by Rockwell Solutions delivery. Built on programming standards and the Rockwell
Automation Foundations of Modular Programming. Identical interface to Process Modules Provides End Users a consistent industry specific
starting point with the flexibility to add your Intellectual Property.
Being used today by multiple industries since 2005.
o19
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Industry Specific Modules – to support Life Science
Library of building blocks – termed GEMS Application Template
Leverage GEMS standards Life-cycle managed library of modules which
represent devices for process industry Significantly reduced engineering time, with
documented pre-engineered, pre-built, pre-tested modules
Engineering provided for each module: Functional Specification (SMFS) Component Design Specification (SMDS) Component Code Object (AOI) HMI Faceplate(s) Test Specification (SMTS) Component Certified Test Results Programmers Reference Manual
o20
oLife-Cycle Managed
• GAMP 5– Promotes a risk-based approach to validation (QRM – Quality
Risk Management)– Promotes the leveraging of supplier activities (i.e. code,
documentation and testing)– Pre-Validated Module Set– End users benefit from reuse
• Within a project• From project to project
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Life Science PlantPAx Solution Methodology
o21
Logix FT View PanelView Components
FT Asset Centre
FT Batch
FT Transaction Manager
FTProduction Centre
Test SpecificationFunctional SpecificationController StandardsHMI Standards
Integrated Solution Library
RA/GEMS Standards / Best PracticesIntegrated Architecture / FactoryTalk
GEMS Application Template
GEMS Life Science Design Patterns
GEMS Life Science Horizontal Applications
Life Science Solutions
CM_AIN CM_V2S CM_PID CM_M2S
Flow Meter Addition Level Control Agitation
Clean In Place Bioreactor
QBAS/BAS
GranulatorSIP
Cell Culture
Blending Transfer
Formulation/Filling Oral Solid Dosage API
P_Mode P_Alarm P_Perm P_RunTime
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
E-SignatureEnhanced SecurityAudit Log/Traceability
HMI Interface
Value Add for Life Sciences
o22
oCommandsoSet pointsoStatusoAcquireoModeoAlarms
oCommandsoSet pointsoStatusoAlarms
GAMP CompliantDocumentationFS, SMFS, SDS, SMDS
Tested to LS Quality PlanPre-Tested Modules
Equipment Phase
Phase Manager
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Life Science Functionality
E-Signature Commands Configurable
Audit Trail Record Operator
Actions Cmds, SP Changes
o23
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
OEM Skid Coordination
Skid Network Connectivity Network Design Specification (addressing and isolation) Data and Alarm Collection Security Integration
Interfacing to an OEM Skid Skid request for WFI Status and Interlocking between skids. Supervisory SCADA for monitoring of Skids
Integrating Skids Sequencing of Equipment Operation (Formulation CIP Skid) Create Interface layer for sequencing of Unit Operations. Use Phase Manager as Interface from Batch Server to Vendor Supplied Code. Batch Server is used as the engine to Start/Stop, Download Parameters and Upload Reports
for Unit Operations. Full Integration
OEM only supplies the equipment, Rockwell does all the automation design and code. Fully integrated systems for long term lower cost of ownership. Common operator,
maintenance and validation interfaces and documentation.
o24
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. o25
oDomain Controllers (existing)•For the Enterprise
oFT Historian Clients
o Engineering Workstation
o FT Historian Server
oAutoclaveoSLC
oFT View SE oTerminal Server Clients
o 4 Clients
oFirewall
oFirewall
oIP Printer
o 5 Clients
oFT View SE Clients
oFT View SE and/oroFT Historian oTerminal Server Clients
oManaged Ethernet Switch for Enterprise Network (EN) – Business Communications
o Terminal Servers
oDomain Controllers•For the Ctl Sys Domain
oManaged Ethernet Switch for Control System Network (CSN) – HMI/Ctrl Communications
oFT View SE and/oroFT Historian oTerminal Server Clients
o Data and o HMI Server
o Batch Server
Integrated Solution Architecture
oManaged Ethernet Switch for Control System Network (CSN) – HMI/Ctrl Communications
o Data and o HMI Server
oControl Network (FFB, DNet, ENet) oUF/DF Skid
oMedia Prep
o Data and o HMI Server
oQBMSoDeviceNetoFoundation Fieldbus
oTight integration with Intelligent Motor Control
oLogix Controller
oDistributed HMI Architecture
oDistributed Historian Architecture
oHighly Scalable Batch Solutions
oVPN
o GEMS Standard
o GEMS Standard
o GEMS Standard
o GEMS Standard
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. o26
oDomain Controllers (existing)•For the Enterprise
oFT Historian Clients
o Engineering Workstation
o FT Historian Server
oCIP
oFT View SE oTerminal Server Clients
o 4 Clients
oFirewall
oFirewall
oIP Printer
o 5 Clients
oFT View SE oThick Clients
oFT View SE and/oroFT Historian oTerminal Server Clients
oManaged Ethernet Switch for Enterprise Network (EN) – Business Communications
o Terminal Servers
oDomain Controllers•For the Control System
oManaged Ethernet Switch for Control System Network (CSN) – HMI/Ctrl Communications
oFT View SE and/oroFT Historian oTerminal Server Clients
o Data and o HMI Servers
o Batch Server
OEM Integration Advantage
oManaged Ethernet Switch for Control System Network (CSN) – HMI/Ctrl Communications
o Data and o HMI Server
oControl Network (FFB, DNet, ENet) oPan Coater
oMedia Prep
o Data and o HMI Server
oQBMS
oVPN
oOEM Process Skid
oOEM Utility Skid
oBuilding Automation System
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
QBAS - Typical System Configuration
o27oCopyright © 2008 Rockwell Automation Inc All rights reserved
Boilers ChillersPumping, Compressors,
Cooling Towers3rd Party Interfaces
3rd Party Protocol BACNet Devices
Make-up Air VAV Box
Fan CoilSingle Zone
Packaged Air HandlersAHU Control
0000
00000000
HMI
0000
Batch HistorianScheduler
Central PlantOracle / SQL
Central Plant
oFT View SE and/oroFT Historian oTerminal Server Clients
oFT View SE and/oroFT Historian oTerminal Server Clients
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. o28
Third Party Protocol Interfaces
BACNetN2 - (JCI)ArcNet – (JCI)FES-Frick - chillersProfibusLonworksTrane - chillersMcQuay - chillersYork - chillersModbusHARTFoundation FieldbusOPC
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Typical Redundant ControllerConfiguration
Redundancy- Operator Stations (HMI) HMI Servers Data Servers Historians Redundant Controllers -
ControlLogix Networks I/O - Rack, Flex or Point I/O:
temp, press, humidity, particulate Networked AC Drive and Motor
Overload interface for diagnostic and data collection.
o29
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Typical Project Overview
Operator Work Stations Air Handler Units
ControlLogix / CompactLogix Distributed I/O Intelligent Motor Control Variable Speed Drive Field Instrument Devices
Make Up air Recirculation Fans Exhaust Fans Central Plant Control Air Flow Stations
o30
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EMS – Environmental Monitoring System
o32oCopyright © 2008 Rockwell Automation Inc All rights reserved
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Integrated BAS & EMS
o33oCopyright © 2008 Rockwell Automation Inc All rights reserved
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Building Management System - AHU
o34
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Project Methodology
o35oCopyright © 2008 Rockwell Automation Inc All rights reserved
KICK-OFFLONG TERM SUPPORT
• Parts Management• Preventive Maintenance• Training
• Functional Specification • Sequence Of Operation• Define Project Timeline • Define Project Team• Schedule Deliverables
PLAN / DESIGN• System Architecture• Preliminary Design Review• Define Design Templates• OEM Coordination Procedures
REVIEW/LAUNCH
EXECUTE• Code Development• Global OEM Coordination• Project Scope Management• Project Resource Management• FAT• Commissioning Schedule Review
COMMISSION
ACCEPTANCE• SAT/ Customer Witness
Test• System Handover
TECHNOLOGY TRANSFER
• Customized Training• Embedded Engineer
• Detailed Project Requirements• Safety Procedure Review• Final Design Review/Approval
• Pre-Startup Site-Test• Application Startup• System Integration
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Rockwell Automation Expertise
o36oCopyright © 2008 Rockwell Automation Inc All rights reserved
• Validation Lead– Documentation development & control
• Commercial Support – Sales– Technology Training– Technical Support
• Installation– Site Project Management– Schedule– Network – Installation/ Calibration
• Project Manager– Scope Management– Project Resources – Risk Management– Development of Project Plan &
Schedule– Schedule Resources
• Technical Lead– Subject Matter Expert– Lead Development – Operational Training– Start up & Testing– Documentation
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Why Rockwell Automation for QBAS, BAS & EMS?
Modular Software – Add on instructions
Subject Matter Expertise
Global Capability & Local Support
Internal Maintainability
o37
Reduce Total Cost of
Ownership
Reduce Total Cost of
Ownership
Reduce Total Cost of Ownership