Rockwell Automation Oil&Gas Solutions

Integrated Control and Safety System Capabilities

Nicola Iovine
Technical Consultant
FS Eng (TÜV Rheinland, #9685/14, SIS)

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Agenda

Rockwell Automation Oil & Gas

Products and Solutions for Oil&Gas Industry

Integrated Control and Safety System Capablities

References

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Our Brands

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Acquisitions Expand Domain Expertise

2013
2009

2007

2007 Deep Oil & Gas

Expertise

Advanced Process Remote Monitoring &

2007 Control Data Acquisition

Process Safety;
Deep Oil & Gas Expertise

Process Technology
& Modular Build

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Rockwell Automation in Oil & Gas
Pipeline/Transportation
Onshore

Refining and Petrochemical

Gas Processing

Offshore
Liquefied Natural Gas

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Agenda

Rockwell Automation Oil&Gas

Products and Solutions for Oil&Gas Industry

Integrated Control and Safety System Capablities

References

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved.
Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved.
 Agenda

Rockwell Automation Oil&Gas

Products and Solutions for Oil&Gas Industry

Integrated Control and Safety System Capablities

References

Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 15

PUBLIC
Rockwell ICSS Architecture
ERP
WAN Enterprise
Level 5
Enterprise Business Patch
Planning Management Remote Access Site Access
Server Terminal Server Control / Security
Asset Historian
Reporting System Management/ Server
Information
Clients Alarm
Level 3/4
Management
Site Operations

Site/Plant Network

Level 2
Operator Workstations

SIS
Supervisory Control
Engineering Workstation Domain (OWS)
(EWS) ICSS Data Server SIS SOE SIS EWS
Controller

DCS Plant Network

ESD, F&G ESD, F&G

Level 1
Process Control DCS Controller

Device Level Ring Safety Controller SIL 2

Safety Controller SIL 3 TMR Safety Controller SIL3

Ethernet Fieldbus for Remote IO / Packages Communication

Ethernet Spur

Level 0
Field Devices

Package HMI Energy

Monitoring
Local HMI

Vibration
Field Devices Monitoring
DeHydration Drives Smart Motor Builing
Field Devices PowerFlex Control Center Management
Pumps
System
Network MOV’s
HART Compression
Profibus PA
Fieldbus Foundation
Industrial Control
DeviceNet
EthernetIP
Process Packages Separation Power
ControlNet
Vibration Monitoring
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
Rockwell ICSS modular system
DCS Controller Scalability
Multi-disciplined platform
… From 10 loops to
hundreds per controller

Application examples

• Redundant PCS controller

• Can be used in smaller size in Packages (Simplex or Redundant)
• SIS Logic Solver up to SIL 2 (F&G or ESD) – Combined Process and safety Logic
Solver
• Electrical Control System (ECS) – EthernetIP integration with Rockwell Drives/MCC

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

High Performance Controller
 Control sequential, motion, safety, process, drives, and condition monitoring
within a single control platform (or single controller if desired).
 One Software Package for Structured Text, Function Block, Ladder, and SFC
 High Availability of Resources…Ocean of Talent
Conventional Approach Condition Logix
 Lowest Total Cost
Sequential of Ownership
Motion Process Drive Safety Monitoring 1 Processor
Multiple
Processors
1 Software
Multiple Package
Software
Packages
Motion Servo = Native
Different Languages
Programs and and Industry
Languages IF A>B THEN Specific
F = B * C / D;
END_IF; IF A>B THEN Instructions
F = B * C / D;
END_IF;

Multiple Fewer
Engineering & Engineering
Support & Support
Personnel Personnel

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Rockwell ICSS modular system
SIS Logic Solver Scalability
SIL 0 SIL 1 SIL 2 SIL 2 SIL 3 SIL 3
Process Fail Safe Fail Safe Fault Tolerance Fail Safe Fault Tolerance

PlantPAx
ControlLogix

AADvance
Scalable SIS

Trusted
TMR

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 20

 ControlLogix SIL2 with 1715 I/O

• For SIL1 and SIL2 SIS applications

Typical Applications
• Emergency Shutdown (ESD)
• Burner Management (BMS)
• Fire & Gas (F&G)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 21
COMPANY CONFIDENTIAL
 1715 I/O Features
Redundant Power Two Slot Adapter Three Slot I/O Redundant Termination
Supply Backplane Backplanes Assemblies

• 24VDC Discrete Input Module

• 24VDC Discrete Output Module
• 4 to 20 ma Analog Input Module
• 4 to 20 ma Analog Output Module
• Redundant 24VDC Power supply
connections
• SOE and Time stamped data
• HART

Redundant Ethernet Redundant Input Redundant Output

Adapters Modules Modules
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
COMPANY CONFIDENTIAL
 AADvance - Scalable Safety System
• Scalable for Fail Safe to TMR in the same
architectures
• OPC and Modbus comms
• CIP comms to CLX Controllers
• HART AI and AO
• Temperature range (-20 to 70°C)
• Deployed by SSB and Select SI’s

Typical Applications
• Emergency Shutdown (ESD)
• Wellhead Shutdown system (WSD)
• Fire and Gas (F&G)
• Burner Management (BMS)
• High Integrity Pressure Prevention (HIPPS)
• Blowout Preventer (BoP) – (Sub sea)

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 23

COMPANY CONFIDENTIAL
 AADvance - Scalable Safety System

 Scalable from SIL2 Simplex Fail Safe to Triple

Modular Redundant (TMR) SIL3 Fault
Tolerant for Process Safety applications
 Open communication connectivity (Modbus,
EtherNet/IP, TCP/IP)
 High level of Safety and Availability
 IEC1131-3 programming environment
 Online software modification
 Offline simulation
 Program version control and comparison
features
 IEC61508-2010 Edition Certified
 BMS, ESD, F&G, HIPPS applications

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 24

PUBLIC
 Trusted – TMR Solution

• TMR only
• High Density I/O (up to 60 channels per module)
• 120Vac and 125Vdc I/O
• Deployed by SSB

Typical Applications
• Emergency Shutdown (ESD)
• Fire and Gas (F&G)
• Burner Management (BMS)
• High Integrity Pressure Prevention (HIPPS)
• Turbo Machinery Control (TMC)

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 25

COMPANY CONFIDENTIAL
Rockwell ICSS modular system
Fully Scalable HMI system
… Same HMI software from small local
panel to DCS HMI Control Room

Machine Edition Site Edition

Package Local HMI Panel Control Room Operator workstation

PanelView™ Plus and Compact Industrial and Non-Industrial Computers and Monitors

Application Examples
• DCS OWS
• Small HMI on UCP/Package
• SOE Viewer to collect time-stamped events from SIS
• Same functionalities at all levels
 Operating parameters display, Tuning
 Trending functions
 Chronological Alarm Display
 Local data archiving
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 26
Operator Interface System
 A single database for data and
alarms.

 Data and alarms remain in their

native environment, i.e. controller

 Distributed architecture
 Larger systems management
 Easy skid integration
 Alarms & Events
 Runtime Editing
 System Redundancy
 Data logging

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Rockwell Library
Effective User Interfaces & Libraries

Global objects with telltale mode and

Supported Libraries status indicators simplify operations.
• A predefined library of controller code (add-on
instructions), display elements (global objects), and
faceplates that let you quickly assemble large applications
Add-on instruction
with proven strategies, rich functionality, and known encapsulates key data to
performance. make it available to the
Operator Interface
• Based on ISA 101.

• Standard Library Objects are fully supported by RA Tech

Support.
• A lifecycle approach will ensure a consistent look and feel
from vendors, contractor delivered systems, and acquired
facilities.
Configure, Control, Maintain and
Debug from extensive series of HMI
faceplates available for
Supervisory system and small HMI
panel.

Extract critical information from the controller and make it available to the operator. Allow the operator to become ‘the
first line of defense’ in troubleshooting. Utilize secure log ins to allow maintenance technicians and engineers to improve
performance of the system over time without modifying controller code.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Alarm Management
Effective Alarm Strategy

State of the Art Alarming

• Leverage graphics and lifecycle approach to
handling of alarm conditions.
• Based on ISA 18.2
• Templates, reports, and libraries should be
enabled to help achieve this
• EEMUA 191 Compliant

• Effectively direct the operator’s attention to the

productivity, safety, and environment of the
plant
• Operators should be controlling the plant, not
handling floods or nuisance issues.
• Critical alarms are prioritized, shelved, and
managed according to severity.

Operator response to nuisance and non-priority alarms consumes an est. 10% of our DCS interactions today. The
implementation of a strategy per ISA18.2 will satisfy EHS initiatives to ensure the highest response rates of all
operators. Advanced reporting means will drive accountability and improvement metrics as new operators are
introduced to new plant areas.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Asset Management and Device Integration
Engineering Operator Asset
Workstation Workstations Management

Ethernet (supervisory network)

Process
Controller

1756 Hart IO Flex HART Point HART

Compact FFLDC FFLD

HART Drives
FF H1 FF H1

EN2PA
CN2PA
Profi PA

Motor
Control Centers

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

30
Asset Management System
Asset Configuration and Control

Asset Management
• A tool for securing, managing, versioning, tracking, and
reporting asset information across your entire facility.
• Applicable to control software and device setup of
process instrumentation.
• Process Instrumentation on line communication from
Central Control Room AMS

• Streamlines information by user interactions for better

audit trails and root cause analysis.
• Provides change records for regulatory and quality
reporting.
• Disaster recovery of parameters to ensure faster return
to production.

By leveraging the disaster recovery features in our formulation room, we anticipate a recovery period of only 4
hours from a complete loss of data. In the past this may have taken weeks to accomplish requiring a download of all
the relevant programs, instrumentation settings, and VFD parameters manually. We can also verify who made what
changes for auditing purposes.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Rockwell Historian

 Leadership in Automation and  Real-time Performance

Information Solutions Management Software Products

 Solution Provider  Technology Provider

 Automation and Controls  Data Historian and Context

Expertise Experts

 Solution Platform  Product Platform

Market leaders joining together to provide winning solutions
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Industry Leading Data Storage and
Analytics
Integrated to deliver fast, seamless decision making information

Store Data Visualize Data

DCS Nodes

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

KPI – Asset Performance management

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

System Network Architecture
Reference Architecture

Enterprise
Enterprise Zone
WAN
Levels 4-5

Industrial
Demilitarized Zone
(IDMZ) VLANs
Physical or Virtualized Servers
• Patch Management Cisco Firewall
• Remote Gateway Services ASA 5500 (Standby)
• Application Mirror
• Anti Virus Server
Firewall
(Active)

Catalyst
Application Servers, 6500/4500
Asset Management
Historian

Remote Access Server

Catalyst 3750
StackWise
Level 3 – Site Operations Switch Stack

PlantPAx Operator
Workstations

HMI
Level 2 – Area Supervisory Control Controllers,
I/O, Drives

I/O
Drive Soft
MCC
Controller Controller Starter
Level 1 – Process Controller Level 0 – Process I/O

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 35

Defense-in-Depth
Multiple Layers to Protect the Network and Defend the Edge

 No single product, technology or

methodology can fully secure Industrial
Automation and Control System (IACS)
applications.
 Protecting IACS assets requires a
defense-in-depth security approach,
which addresses internal and external
security threats.
 This approach utilizes multiple layers of
defense (physical, procedural and
electronic) at separate IACS levels by
applying policies and procedures that
address different types of threats.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 36

Where to find more information?

PlantPAx System Selection Guide PlantPAx System Infrastructure

(proces-sg001) User Manual (proces-um001)

PlantPAx System Reference Manual PlantPAx System Application User

(proces-rm001) Manual (proces-um003)

Modern DCS White Paper Rockwell Automation Library of

(proces-wp010) Process Objects (proces-rm002)

PlantPAx Characterization Video

(YouTube)

Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved.

 Package Integration can be complicated
Traditional DCSs are proprietary platforms.

Protocol
Converter

OPC
Gateway

Protocol
Converter

 Communication Protocols and Data Mapping

 HMI Graphics and Security Protocol
Converter

 Safety Interlocks and Alarming

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 Integration Challenges

 Common Challenges Why Do These Challenges Exist?

 Communication Protocol  Few established standards for skid
 Communication Media integration standardization.
 Data Mapping
 Naming Conventions  In absence of established
standards, End Users, SIs, EPCs,
 Equipment Interfaces
OEMs create their own.
 Alarming
 Safety Interlocks
 Everyone’s “Standard” is different.
 HMI Graphics and Security

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 Package Interface Checklist

 Common Network Protocol.

 Class-based Public Interface: DCS to/from Skid
 Command, Status, Tag Naming Convention.
 Alarming
 HOW, WHAT, and WHEN to alarm, also WHAT NOT to alarm.
 HMI Standardization
 Visualization, Object Naming, Security.
 Documentation Standards.

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 PlantPAx Simplifies Package Integration

EtherNet/IP

OPC
Gateway

 Common Network Protocol – EtherNet/IP

 Common Alarm Strategy
 Common HMI Security and Visualization

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 Rockwell Automation
Typical Automation Architecture
Engineering & Operations Historian &
Maintenance Optimization Process Automation System
• Site-Wide Integrated Process Control, Motor Controls and Safety
systems based on the PlantPAx Modern DCS Platform
• Based on the ControlLogix platform, it eases integration with
modules / skid packages supplied by OEMs leveraging Ethernet
proctools
DCS
Network and Security services
SIS
• Facilitate Management of security technology, policies and
procedures
Hart FF • Manage of network convergence
Visualization Everywhere
• Effective and consistent user experiences in multiple platforms, from
local operator stations to remotely located computers leveraging
cloud based services and solutions
Full scope Engineering Services
• From concept to support
• Front End Engineering & Design (FEED)
• Main Automation Contractor (MAC)
• Global OEM Coordination
• Installation, commissioning & support
Comprehensive Support Services
• Local spare parts and repair availability
• Remote and on-site technical support
• Training
• Lifecycle management
PLC’s VFD’s MCC
Skid packages: Compressors, Pumps, Turbo Expanders, Boilers,
Heat exchangers
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Thank you

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