Technologies and Solutions for Building The Connected Enterprise

Connected Technologies and Solutions

2017 Automation Fair® Event - Technologies & Solutions Highlight

The Automation Fair® event featured the latest trends and how The Connected Enterprise is bringing the Industrial Internet of Things (IIOT) to life for companies around the world. This year, many advances, solutions and technologies were showcased at The Connected Enterprise Industries Pavilion.

OptiLift™ Intelligent Net Oil Computer

OptiLift Intelligent Net Oil Computer (iNOC) is a measurement solution for automated well testing. The iNOC system installs in the “liquid leg” of a two-phase test separator and can control the testing sequence from multiple sources. Real-time data is generated and shared for timely management of well operations and testing scenarios. Based on line pressure, line temperature and flowmeter process inputs, the iNOC system can estimate water cut online, reducing further lab tests.

The Automation Fair® event featured the latest trends and how The Connected Enterprise is bringing the Industrial Internet of Things (IIOT) to life for companies around the world.

It is designed to achieve continuous operations and helps optimize production while maximizing ROI in a well testing environment. This engineered-to-order (ETO) solution is easy to install, configure, use and maintain and features excellent reliability.

  • Enables well testing capacity optimization for up to seven wells when connected to a multi-port selector valve (MSV)
  • Improves well testing duration with oil and water volume prediction for 24 hours during any testing period
  • Supports connectivity with a ConnectedProduction™ footprint to support a remote digital oilfield environment

OptiLift Rod Pump Controller (RPC)

OptiLift Rod Pump Controller (RPC) is an advanced design on-site control solution that provides the accurate and flexible dynamometer based pump-off control necessary for sucker rod pump optimization. The solution supports pressure/temperature monitoring, natural gas flow readings, motor data, visualization, alarming functions and diagnostics customized for well operations.

The RPC provides continuous true load and position monitoring for beam pumps and belt driven linear pumping units and pump-off control with across-the-line fixed speed or VFD variable speed power packages. The dynamic surface and downhole dynamometer card display allows the operator to visualize what is occurring with the process and the four fixed speed modes and three variable speed modes provide flexibility for the operator to choose the operating mode best suited for the present conditions.

  • Provides continuous true load and position monitoring and pump off control for beam pumps and belt driven linear pumping units
  • Real-time data supports early detection and problem solving capabilities
  • Enables rapid ConnectedProduction™ SCADA integration via Asset Auto-Discovery
  • Multiple connectivity options and customization at no additional cost

OptiLift Rod Pump Controller (RPC) is an advanced design on-site control solution that provides the accurate and flexible dynamometer based pump-off control necessary for sucker rod pump optimization.

OptiLift Virtual Flowmeter

Newly added to the OptiLift line, the Virtual Flowmeter (VFM) is a software option that provides estimated flow rate measurements for the different phases (gas, oil/condensate and water) and gives the pressure, temperature, flow rate and flow rate pattern information for simulation and optimum operation of the production system. The VFM option on the high performance remote terminal unit can provide various points of data for problem detection and asset maintenance. It can be a valuable support solution for manual well test scheduling.

Computational nodes are placed along the flow regime from downhole/reservoir to surface equipment. Each node is equipped with algorithms to compute pressure, temperature and flow rate conditions. The algorithm was created with over 40 years of field data and 400 well simulations.

  • Supports operational benefits for any well type
  • Assists in inferring values between well tests, helping to optimize artificial lift operations and improve production accuracy
  • Supports a ConnectedProduction™ environment
  • Integrates with current system – whether it is a Rockwell Automation® system or other brand

New Capabilities in MES Software for Life Sciences

FactoryTalk® PharmaSuite® software comes with a fully integrated approach of modeling weighing activities, especially in the context of electronic batch recording (EBR). In addition to the rich set of different weighing modes that are already supported, PharmaSuite 8.3 offers the new quantity entry weighing mode that supports classic counting scenarios used for kitting. Especially in Biotech where certain material-based equipment components will be assembled during production, this new feature will streamline processes.

A new Enterprise Integration Hub (EIHub) application creates a common connectivity method for enterprise applications and external IT systems. It reviews incoming information from one system and transforms it into the proper format and template for the receiving system. It also verifies information receipt or sends alerts for transmission failures to streamline data translation across a Connected Enterprise.

  • Increases speed with easier process integration
  • Effectively manages inventoried equipment by including good manufacturing practice (GMP) equipment as part of a bill of material (BOM) and managing it as inventoried material
  • Runs content engine on site to stay on the latest product release with minimal risk and cost.
  • Instantiates new equipment during production and tracks its entire lifecycle within the electronic logbook.

The PlantPAx® distributed control system helps users make better, faster decisions.

New System Release and Standard Control Panel

The PlantPAx® distributed control system, a modern DCS, connects process, discrete, power, information, and safety control into one plant-wide infrastructure. It helps users make better, faster decisions by enabling them to respond more quickly to the demands of customers and fast-changing specifications.

The latest system release contains added benefits to:

  • Help ease ownership, improve delivery and drive productivity
  • Allow for a smarter, more productive and secure enterprise
  • Adopt smart system capabilities with enhanced configuration and operations

Some of the features highlighted in this release include an update of the Rockwell Automation Library of Process Objects, which includes new power & IEC61850 device libraries. Other features include enterprise-ready architectures for multi-system/multi-site, cloud-based remote access, single server for small systems, and guidance for IEC 62443 adoption.

The Standard Control Panel for the PlantPAx DCS is customizable using topologies that are recognized in the PlantPAx system selection guide and characterization lab. The resulting savings allow clients to focus their resources on core competencies related to their process expertise. It helps reduce project estimation time and project start-up and commissioning efforts, hence improves overall design phases.

Basic equipment installed includes cabinets, backplanes, power supplies, PlantPAx-ready I/O chassis and documentation.

The Standard Control Panel for the PlantPAx DCS is customizable using topologies that are recognized in the PlantPAx system selection guide and characterization lab.

Cost-Effective Gateway to A Connected Enterprise

A secure and robust network infrastructure is essential to improving overall competitiveness in a Connected Enterprise. But designing, deploying and maintaining this infrastructure can be complex and time consuming for many companies, and is often too costly for their capital budgets. Rockwell Automation has introduced its Infrastructure-as-a-Service (IaaS) offering to reduce the burden of the deployment of a properly designed industrial infrastructure.

By adopting virtual and Ethernet technologies, manufacturers can realize benefits such as:

  • Reduced server footprint
  • Improved infrastructure reliability with high availability and redundant architectures
  • Minimized mean-time-to-repair with 24x7 remote monitoring

IaaS is offered with two Rockwell Automation pre-engineered network solutions, including the Industrial Data Center (IDC) and the Industrial Network Distribution Solution (INDS). These solutions are designed for industrial use and incorporate industry-leading technologies from Rockwell Automation Strategic Alliance partners Cisco, Panduit and Microsoft.

The IDC provides all the hardware and software needed to transition to a virtualized environment, and is designed to deliver high availability and fault tolerance. The INDS is a network distribution package that helps end-users achieve secure, high-capacity connectivity between the control room and throughout the plant floor.

Companies of all sizes are eager to digitally transform their operations in a Connected Enterprise, but many are limited in their ability to connect their infrastructure. Under an IaaS contract, Rockwell Automation will size, assemble and test the infrastructure, including configuration and on-site deployment at the customer’s facility. Leveraging best-in-class technologies and architectures, companies can help optimize their network infrastructure’s performance, efficiency and uptime, as well as address security risks.

Modular and Scalable Solution Improves Well Pad Functionality

As a part of the ConnectedProduction offering from Rockwell Automation, the Well Manager solution provides oil and gas companies a single solution for all control functionality throughout a well pad, resulting in easier implementation, real-time data visibility, production efficiency and reduced costs.

The Well Manager solution is delivered pre-engineered to speed integration of a multi-well pad. It is scalable and can support up to 32 wells in one location with flow management, artificial lift control, and site-wide data visibility. Because data is pulled directly from the control system, it has higher integrity than operations that leverage manual data reporting. The solution is built with expansion in mind – ready to support wells and equipment that might be added to a site years after initial implementation.

The solution also enables self-declaring wells to be automatically discovered and integrated into the production environment. This auto-discovery feature removes human interaction, reducing risk of error and dependencies on special skill sets. It also speeds the time it takes to bring a new well online to mere minutes, allowing producers to get valuable production data out of the well more quickly.

Users can select specific solutions as needed, and monitor ROI to justify scaling up for broader usage. Each added segment of the solution is purpose-built for connectivity to help transform data into useful intelligence. The offering makes use of current investments, and does not require a complete infrastructure overhaul.

Expanding Connected Services Drive Digital Transformation

A great number of industrial companies are implementing digital technologies aimed at optimizing operations. Whether targeting point solutions or undergoing a full digital transformation, most organizations need support to plan for, deploy, and maintain new solutions, or to help them reap the most value from digitalization.

To meet the information infrastructure and security needs, Rockwell Automation employs its Connected Services offerings, and continues to expand this portfolio.

Predictive Maintenance Service is an offering that uses cloud infrastructure, machine learning and automation expertise to help predict events in an industrial asset or system that could lead to costly downtime or maintenance activities. This service offering uses process data available from an asset and, through machine learning, identifies data patterns that are indicative of issues or failures. It also provides an associated estimate of timing until the event may occur. This capability enables customers to increase their asset utilization and decrease the cost to maintain.

Remote Support, Monitoring and Response Services can prove especially valuable for critical processes through around-the-clock operations and remote operations. These services can complement on-site maintenance teams, providing everything from continuous machine monitoring and incident response to 24/7 remote support and software/firmware updates. Deployments can make use of the FactoryTalk Cloud gateway, on-premise Rockwell Automation Industrial Data Center servers, or a hybrid model that combines both options to help improve productivity and reduce downtime.

Data Integration and Contextualization Services can help capture a wealth of data and convert it into actionable information. These services can provide new opportunities to help increase productivity. Producers can reduce skills gap challenges by relying on Rockwell Automation to monitor, maintain and manage the network, equipment or entire applications. Additional digital transformation and data scientist consulting services will be available in 2018.

These software-powered services from the Connected Services portfolio build on existing application and product support services to help organizations access and use production data to improve asset utilization and productivity, while reducing risk and time-to-market.

Connected Services offerings are scalable, allowing producers to build ROI as they go, and rely more on OPEX than CAPEX funding. Rockwell Automation can deliver and execute Connected Services offerings globally, giving organizations consistent support across operations.

Allen-Bradley® Guardmaster® 442G Multifunctional Access Box is an integrated safeguarding solution is ideal for full body applications where guard doors require a higher holding force, a greater tolerance to guard door misalignment and a means for exiting the safeguarded area in an emergency.

A Combination of Guard Locking and Access Control

Allen-Bradley® Guardmaster® 442G Multifunctional Access Box is an integrated safeguarding solution is ideal for full body applications where guard doors require a higher holding force, a greater tolerance to guard door misalignment and a means for exiting the safeguarded area in an emergency. A choice of operator controls and other options offer flexibility to meet a variety of applications.

Rated PLe, Cat 4 for interlocking and guard lock monitoring, the 442G complies with the latest functional safety standards. The handle assembly has a uniquely coded bolt actuator which will only be recognized by the assigned locking module, achieving the highest level of tamper resistance in accordance with the requirements of ISO 14119.

With a high holding force 2000N, the 442G is available in two models - Power-to-Release and Power-to-Lock for personnel safety or the protection of machine production. Its features include:

  • Unique RFID coded bolt actuator achieves the highest level of tamper resistance
  • Four bright LEDs provide status and diagnostics
  • Optional escape release allows a person locked inside the safeguarded area to exit quickly and easily
  • A CIP Safety over EtherNet/IP version which enables easy integration in a networked automation control system using Studio 5000 Logix Designer® environment

The 442G is currently available with up to four controls, one of which can be an emergency stop push button. The function and the color of each push button can be assigned by the user, making it simple to customize the device for different applications.

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