PlantPAx Process Automation System

Delivering Plant-Wide Optimization

Utilize Your Process Automation System to Address Key Market Challenges

As technology continues to drive innovations, the production enterprise must keep step to remain competitive. Companies must converge their production disciplines into an integrated plant-wide architecture that better addresses their key market challenges. Cultivate INNOVATION with increased visibility and knowledge capture Support SUSTAINABILITY with extended product lifecycles, safer environments, and reduced energy usage Improve PRODUCTIVITY with continuous improvements that provide better asset utilization and system performance Facilitate GLOBALIZATION with extensive global support capabilities that meet local standards requirements

PlantPAx provides a range of integrated solutions delivered through: Control and I/O Operator Eectiveness Engineering and Configuration Tools Asset Management Safety and Critical Control Batch Management and Control Advanced Process Control Operations Productivity Industrial Security

Drive Plant-wide Optimization Across Multiple Enterprises

By converging your plant oor with your enterprise IT systems, your people, processes and technology, are transformed into assets that help you achieve higher levels of business performance. The Rockwell Automation PlantPAx process automation system helps you do just that. PlantPAx combines the plant-wide control technologies and unmatched scalability of Integrated Architecture with all the core capabilities expected in a world-class distributed control system (DCS). Based on open communication standards and leveraging EtherNet/IP as its backbone, PlantPAx makes real-time information readily available throughout the organization for better business decisions.

Gain a Competitive Advantage

The PlantPAx process automation system provides the technology and solutions to help you achieve a competitive advantage. In addition to delivering multi-disciplined functionality for maximum reach, PlantPAx also delivers adaptability to changing requirements. It offers you easy design, deployment and improved visibility.

We had a very clear view of what we wanteda distributed control system which runs o a set of servers integrated into our general IT infrastructure.
Andy Ellams, Process Development Manager, PZ Cussons

Plant and Production Operators True plant-wide control for reduced total cost of ownership Increased availability for greater production performance Real-time intelligence for better business decisions Skid and Process Equipment Builders Right-sized designs to save costs Easy integration to existing plant control systems Eciency tools for faster time to market Solution Providers / System Integrators Comprehensive suite of design and development tools to increase engineering eciencies Increased technical competency through training, events, and support access Greater customer satisfaction
We have been very successful in applying PlantPAx to numerous applications, including Advanced Process Control. As a member of the Process Systems Integrator Program we distinguish ourselves from non-members because Rockwell Automation endorses our ability to deliver quality PlantPAx systems to mutual clients. This gives our clients the assurance and comfort of working with technically competent and experienced solution providers and has increased our client satisfaction throughout the project and system lifecycles
Steve Malyszko, President Malisko Engineering, Inc.

A Wealth of Capabilities in an Integrated Solution

PlantPAx is the only process automation system capable of managing the entire range of automation applications, including motion, safety and drive systems. The scalability of the PlantPAx system, combined with the domain expertise of Rockwell Automation, enables you to address production issues with real-time plant-wide intelligence, helping you respond quickly and cost-effectively to market demands.

Engineering and Configuration

Helps shorten development time and minimize human error

Consolidated Engineering Environment

Single starting point for system configuration and tools for library management and bulk system engineering save time

Modular Object Library

Logic and HMI objects co-developed and co-deployed shorten development time

Defined System Architectures

Minimizes risk of incorrectly sized systems and ensures system performance
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Control and I/O

Offers the most modern infrastructure for the most cost effective design Scalable Controller Portfolio
Align process areas from 10 points to thousands across the platform

Safety and Critical Control

Reduces your economic risk by protecting only critical assets High Availability Process Control
High availability solutions from redundant I/O to redundant controllers, resilient networks to redundant HMI servers

Robust Network Infrastructure

Demonstrated performance leveraging CISCO technology and EtherNet/IP with redundancy options at every level

Scalable Process Safety

Integrated basic process control system (BPCS) and scalable SIS solutions, including Triple Modular Redundancy (TMR) for the highest availability

Comprehensive Connectivity
The broadest range of traditional I/O and intelligent devices

Operator Eectiveness
Helps facilitate operator performance with easy-to-interpret process information Integrated Visualization
Intuitive displays, objects, and faceplates with integrated diagnostics streamline operator response

Alarm and Event Management

Provides a single, integrated set of alarm information

Decision Support Tools

Dashboards help identify opportunities for continuous improvement

Scalable Architecture
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DIAGNOSTIC

DIAGNOSTIC

Solutions for on-process, mobile, and stand-alone applications up to large distributed systems deployed traditionally or virtualized

Asset Management and System Maintenance

Helps ensure process uptime through improved asset performance management and predictive maintenance Instrumentation
Comprehensive device management enabled by industry standards

Devices
Variable frequency drives and intelligent motor control devices as native components

Batch Management and Control

Offers the flexibility to respond to external pressures such as regulatory compliance, yield optimization and production agility Scalable Platform
From unit scale to highly complex integrated batch solutions

Native ISA-88 Structure

Simplify change management and regulatory compliance

Integrated Analysis Tools

Batch reports, material usage, genealogy, and solutions to optimize batch production

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ETHERNET
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Operations Productivity

POWER

RUN

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FORCE BAT

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NODE:

RUN

REM

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RXD

TXD

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DIAGNOSTIC

DIAGNOSTIC

DeviceBus Status

Relay Output
1734-ADNX

120 VAC Input

220 VAC Input

24VDC Sink Input

24VDC Source Output

120V 220 VAC Output

220VAC Input

4 0

1
2 3
1734 OW4

5 6 7

1 2 3
1734 IA4

1 2 3
1734 IM4

1 2 3
1734 IB8

5 1 6 2 7 3
1734 OB8E

5 6 7

1 2 3
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1 2 3
1734 IM4

Puts actionable information into the hands of decision makers quickly Scalable Data Collection
Chassis-based, plant-wide or enterprise-wide historian for collecting real-time data at the source

Decision Support Portal

Track production KPIs to manage cost, quality, and resources to help optimize operations

Advanced Process Control

Broadest Solution Portfolio

Delivers proven economic gains through increased production, reduced costs, improved product quality and reduced environmental risks
From basic regulatory control to fuzzy logic and soft sensors to model predictive control

Scalable Optimization
From single loop in the controller to plant-wide optimization at the supervisory layer

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Industrial Security

Addresses risks to help protect people, assets and information from accidental and malicious threats Safe and Reliable Operations
Control system architecture with layered security to help maintain operational integrity under threat

Assets and Information Protection

Product and system features to help control access and limit information exposure

Government and Standards Alignment

Responsible disclosure with control system solutions that follow global standards

Consumer Industries
One plant-wide control architecture enables plant-wide optimization from raw materials, primary processing, packaging and warehousing.

Plant-Wide Control

Drives Total Cost of Ownership (TCO) savings

One platform, one system with common configuration Multi-disciplined control process, discrete, motion, safety and power Leverages EtherNet/ IP from the plant oor to the enterprise linking production information to business systems

Manufacturing Intelligence

Enables continuous process improvement

Information-enabled DCS supports lean Six Sigma programs Real time intelligence enables faster decision making

Batch Management

Allows for modular designs providing savings on engineering and maintenance costs
Enables control strategies that support exible production capabilities Enhanced material tracking and tracing for regulation and standards requirements Defined repeatability to achieve golden batch

OEM Scalable

Provides cost-effective skid design, development and deployment

Easy integration of skids to DCS Rapid field device integration Supports multi-vendor integration Reduced training requirements

Rockwell Automations batch solution is giving us the ability and exibility to meet our very aggressive schedules.
Jim Hasler, Silica Treatment Development Centre Leader, Cabot Corporation

Resource Industries
Premier integration of power control components on industrial EtherNet/IP network, which includes variable frequency drives and motor control centers, provides reduced system lifecycle costs. Additionally, real-time access to device information improves maintenance and troubleshooting capabilities and helps lower energy consumption.

Operational Excellence

Provides critical asset health and performance information for optimization

Integrating control, power, and safety enables asset performance management Diagnostic data can trigger manual or automatic intervention before any unplanned shutdown Immediate access to information enables quicker troubleshooting and response times World leading advance process control and condition monitoring drive energy eciencies and reduced variability for cost savings

Security

Protects people, assets, and information from accidental or malicious threats

Intellectual property protection through standard system capabilities Government and standards alignment to fulfill independent requirements Control system architecture with layered security to help maintain operational integrity under threat

High Availability and Safety

Provides protection for personnel, equipment, production and the environment

High availability and redundancy throughout the architecture for demanding 24 x 7 critical applications Scalable safety solutions from SIL1 to SIL3, including TMR Focused on availability, uptime, maintainability and repeatability

Sustainability

Provides cleaner, safer and more energy ecient operations to help you achieve your business goals
Easy integration of PlantPAx, with energy monitoring control and reporting tools Vital data helps maximize asset availability, utilization and eciency, which means more production uptime, reduced raw material use and optimized, ecient energy use Continuous emission monitoring to help ensure active compliance

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Skid and Process Equipment Solutions

Scalable, Cost-Eective and Easily Integrated Rockwell Automation and its partners help lower your Total Cost to Design, Develop and DeliverSM equipment. Our PlantPAx libraries and productivity toolkits provide the technology and economic advantages required. We can help you assess and quantify the value realized by choosing us as your preferred process automation partner. Reduce Short-Term Costs System resides on the skid and ships fully tested and operational Interfaces exist to other supplier systems Speed design and integration through robust process library Simplify remote monitoring and support through use of unmodified Ethernet Maximize uptime and customer satisfaction Protect Intellectual Property Because of its scalability and designed openness, our OEM solutions can be connected to other systems without exposing your intellectual property Deal directly with the end user no need to share your proprietary control algorithms with other suppliers or their integrators Create long term support contracts with end users instead of relinquishing support to other suppliers Reduce Your Total Cost to Design, Develop and Deliver By taking advantage of our systems, products and services you will be better equipped to react quickly to change while continuously improving profitability. We can help reduce the cost of: 12 Quotation Engineering Commissioning Installation Purchase Training Warranty Service Design Updates

The ability to go from discrete wiring to a network implementation has not only helped achieve signi cant savings in wiring, but also has helped reduce installation costs. In one recent project, we were able to eliminate more than 600,000 feet of wiring while cutting our installation time in half.
Mike Hilton, Director of Electrical Instrumentation and Controls, Industrial Furnace Company

Migration Solutions
Migration services from Rockwell Automation help you expertly and quickly migrate to newer technologies while minimizing downtime and maximizing operational success. They help you achieve productivity gains, lessen the risk of maintaining legacy equipment, and allow you to migrate at a pace that is comfortable for you. And most importantly, they are instrumental in driving system lifecycle cost savings. We have expert migration solutions for many legacy DCS systems. This includes ease-of-migration tools such as scanners, cables, wiring harnesses, database conversion tools, and more.

WE CAN HELP YOU GO FROM HERE . . . Lack of visibility to production data Uncertain parts and service sourcing Limited network options Weakening technical service and high repair costs

TO HERE . . . Easy access to plant and production data for better decision making Quickest response to market demands Open, integrated architecture for increased flexibility Product backed by the outstanding support services of Rockwell Automation Re-use of engineering practices to reduce development time and costs associated with startups Maximizing returns from existing assets through improved control and monitoring Single environment for integrated motion, process, and safety for plant-wide optimization 13

Unscheduled downtime risks and lengthy startups

Questionable reliability of older electronics

Old equipment that lacks production eciency and flexibility

Solutions & Services

Bringing You a World of Experience Across industries and processes, you can leverage our global experience and partner resources to tailor solutions and services capabilities to meet your needs. Rockwell Automation understands that a profitable, safe and sustainable operation is your goal. As your partner, we offer industry and technology-specific expertise to address your unique challenges and meet your goals. Our services include: - 80 countries Asset Management Consulting & Assessment Engineered Packages & Panels Integration & Turnkey Services Main Automation Contractor (MAC) Maintenance & Repair Migration Services Online & Phone Support On-Site Services Systems Design Training Our commitment to you is to help reduce project risk and provide solutions specific to your needs executed globally and supported locally. - 20 languages - 18 ISO-certified repair centers - 9 exchange hubs - 6 remote support centers - Single site or multi-site delivery - Average 13+ years industry experience

Reduce your project risk

Originate
Pre-project planning

Initiate
Develop project charter Identify stakeholders

Plan
Collect requirements Define activities Develop project management plan
(cost, quality, risk, communication, schedule, scope and change control, procurement and stang)

Customer

Front End Engineering & Design (FEED)

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Optimize Your Operation As your partner, we start with an important step often overlooked in todays competitive business world: we listen, to learn about your company, your issues and your goals for today, tomorrow and the future. After we understand your unique situation, we draw on our global pool of in-house experience and partner resources to deliver tailored, repeatable, scalable and maintainable solutions. Protect Your Investment By leveraging our global infrastructure of support centers and subject matter experts, were here to help you protect your automation investment. Beyond providing you peace of mind, as we help you keep your plant running, well assess your entire operation and recommend the right mix of services to help maximize productivity, optimize plant assets and improve your overall financial performance.

Solutions & Services for any stage of your automation lifecycle

Execution & Control
Quality assurance Manage resources Communicate and report Monitor and control risks Manage and control
(resources, scope, schedule and costs)

Close
Close project activities Capture lessons learned Survey customer satisfaction Transfer to operations / support teams

Operate & Improve

Parts management Preventive maintenance Training Embedded engineer

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The Power of Collaboration

When you choose Rockwell Automation, you also tap into the power of our PartnerNetwork program a framework of well-managed relationships based on your needs. Our program provides you with access to a local, regional and global network of best-in-class companies including distributors, system integrators, machine builders, alliances and complementary product providers. The keystone of our PartnerNetwork is collaboration that allows a seamless relationship with you, built on mutual trust and shared business values.
PartnerNetwork
Business Enterprise
Strateg Strategic ic Alliances Enterprise Solution Partners

Sales & Solutions

Distributors Solution Providers Machine Builders

Products & Technologies

Produc Product t Refe Refe f renc rence e Technology Licensing T echnology Licensing

For more information about our process automation solutions, please visit: http://www.rockwellautomation.com/solutions/process/

Rockwell Automation, Inc. (NYSE:ROK), the worlds largest company dedicated to industrial automation, makes its customers more productive and the world more sustainable. Throughout the world, our agship Allen-Bradley and Rockwell Software product brands are recognized for innovation and excellence.

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PlantPAx, Integrated Architecture, Listen. Think. Solve, Total Cost to Design, Develop and Deliver, and PartnerNetwork are trademarks of Rockwell Automation, Inc..

Publication PROCES-BROO1D-EN-P August 2011

Supersedes Publication XXXX-BR00XX-XX-P Month 20XX

Copyright 2011 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.