T70 - Qualified Building Automation Solutions Using Logix & FactoryTalk Doug Demian Application Engineer Rockwell Automation (216) 659-2199

Rev 5058-CO900C

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

RA Life Sciences Solution Set

BAS, QBAS, EMS

Weigh & Dispense

Order Mgnt. & Scheduling

Batch Records & Mgnt.

R&D

ERP Integration

Primary Production

Equipment Control

Clinical Supply Planning

Clinical Study Combined domain expertise, industry knowledge, Mgnt. and world-class offerings create an unparalleled solution in the Life Sciences industry. Copyright © 2012 Rockwell Automation, Inc. All rights reserved. oCopyright © Rockwell Automation Inc All rights reserved Warehouse & Materials Mgt.

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Acronyms / Definitions 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.

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Impact of Manufacturing Environment What Environmental Conditions Impact Product Quality?  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.’

Direct Impact On Product Quality - Qualified / Validated

Indirect Impact On Product Quality - Validatable No Impact On Product Quality - Commercially Commissioned

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The Impact of Validation in the Manufacturing Environment User Requirements: 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 Validate the air handler control system or just Temperature, Pressure, Humidity, Particulate – direct impact parameters? Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Traditional Approach - QBAS

Non-Validated Environment Commercial Controls Commercial Control: –HVAC, –Chillers, –Boilers, –Lighting, –Security, –etc

Validated Environment Commercial Controls Validate the AHU

BAS

QBAS

Control System, Monitoring & Alarming of –Temperature –Pressure –Humidity –Particulate

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Why a Process Platform? Commercial Building Automation Systems

System Functionality

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

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Current Approach Non-Validated Environment Commercial Controls Commercial BAS Control: –HVAC, –Chillers, –Boilers, –Lighting, –Security, –etc.

Validated Environment Process Controls Validate the AHU QBAS

Control System, Monitoring & Alarming of –Temperature –Pressure –Humidity –Particulate

Migrate from commercial proprietary “black box” controllers to Process Controls in the Validated Environment - QBAS Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Risk Based Approach Non-Validated Environment Commercial Controls Commercial Control: – HVAC, – lighting, – security, – etc

BAS

Validatable Environment Process Controls AHU Control – “read only” Temperature, Control: Pressure, Humidity, Process BAS Particulate from EMS HVAC Validated Environment Process Controls EMS

Monitoring & Alarming – Temperature – Pressure – Humidity – Particulate

Validate Direct Impact Parameters – Temperature, Pressure, Humidity, Particulate, Door Status Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Common System to Learn, Validate, Operate and Maintain Commercial Building Automation Systems

Benefits

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 Copyright © 2008 Rockwell Automation Inc All rights reserved

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Common Platform Meeting Regulatory Requirements Common: • System Infrastructure • Data Management • Report Structure • Validation Methods • Data Time Stamping • Alarm Management • Operator Interface • Maintenance Strategy • Parts Inventory

•Maintenance Mgt (EAM - CMMS) •Condition Monitoring (predictive maintenance) • Metrics - OEE

• Batch •Historian, • Scheduling - ERP Integration

HMI

Data Storage

Utility Control BAS EMS Compressors Boilers Chillers

Business System

Reports

Process

Packaging

Shipping & Receiving

21 CFR 11 Enabled Functionality Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Potential Life Cycle Savings

Costs 10-15% Potential Savings Open Programming / 3rd Party Interfaces Longevity Documentation Open Training Open Support / Services / In House Maintenance Flexibility, IO, Common Platform, Spare Parts Reliability, System Availability Initial service cost + reduced annual service cost

Savings

Lower Total Cost of Ownership

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Air Handler Controllers – Constant or Variable Volume Standard Control platforms

Scalable Solutions

– ControlLogix – CompactLogix

Object-oriented, ISA S88 based code Configurable code:

CompactLogix

– HVAC parameters set via spreadsheet – No additional device operation ladder programming required

Expandable - advanced control algorithms specific to your process & facilities Compatible with Unitary and Central Plant systems

ControlLogix Re-usable Control Modules Re-usable Equipment Modules Re-usable Graphic Templates Re-usable Validation Documents Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Automation Application Design is Moving 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.

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Process BAS Software - Architecture Diagram

Unit / Scheduler Module

PID Control Module Heating/ Cooling/ Reactivation

AHU Equipment Modules

Process Xmtr Control Module (Analog In)

Exhaust Fan Equipment Modules

Press. Sw. E-Stop Freeze Alarm Control Module (Digital In)

Supply Fan Equipment Modules

Fan Control Module (VFD or Starter)

Damper Control Module (Valve or Analog Out)

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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.

Param 1 Param 2 Param 3

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ISA88 Flexibility Speeds Development Enterprise Site Area

‘Owns’ the equipment EMs Manages supervisory functions:

Process Cell

Monitoring communications Alarm records Transferring system data

Unit

Equipment Module ‘Owns’ the equipment CMs Allows alarm propagation/ management

Control Module Inputs: AI, DI Outputs: AO, DO Control: PID, PIDC

Equipment Module Control Module

Application Focus

Divide applications into logical groups Use a set of common terminology Swap modules to meet individual customer / AHU requirements Configurable modules reduces complex code changes Unit

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Automation for the Process Industry System Core

Process Information

Field Device Integration & Asset Management

Critical Control & Safety

Batch Management & Control System Tools & Utilities

Strategic Partners

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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.

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Industry Specific Modules – to support Life Science •

GAMP 5

 Library of –building – termed Promotes blocks a risk-based approach to validation (QRM – Quality Risk Management) GEMS Application Template – Promotes the leveraging of supplier activities (i.e. code,  Leverage GEMS standards documentation and testing)  Life-cycle managed library of modules which – Pre-Validated Module Set represent devices for process industry – End users benefit from reuse  Significantly reduced engineering time, with • Within a project documented pre-engineered, pre• From project to pre-built, project 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 o

Life-Cycle Managed Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Life Science PlantPAx Solution Methodology Life Science Solutions

Formulation/Filling

Cell Culture

GEMS Life Science Horizontal Applications

QBAS/BAS SIP

GEMS Life Science Design Patterns GEMS Application Template

Integrated Architecture / FactoryTalk

Flow Meter Addition CM_AIN

HMI Standards

Transfer

Level Control

Granulator Agitation

CM_PID

P_Alarm

P_Perm

Controller Standards Functional Specification FT Transaction Manager

FT View

API

Bioreactor

CM_V2S

FT Production Centre Logix

Blending

Clean In Place

P_Mode

RA/GEMS Standards / Best Practices

Oral Solid Dosage

FT Batch

PanelView

CM_M2S P_RunTime

Test Specification

FT Asset Centre Components

Integrated Solution Library Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Value Add for Life Sciences Equipment Phase

Commands

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Set points

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Status

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Acquire

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Mode

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Phase Manager

Alarms

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GAMP Compliant Documentation FS, SMFS, SDS, SMDS

Tested to LS Quality Plan Pre-Tested Modules

E-Signature Commands

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Set points

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Status

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Alarms

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Enhanced Security Audit Log/Traceability HMI Interface Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Life Science Functionality  E-Signature  Commands  Configurable  Audit Trail  Record Operator Actions  Cmds, SP Changes

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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.

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

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Integrated Solution Architecture Distributed HMI Architecture

Domain Controllers o(existing) •For the Enterprise o

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IP Printer

FT View SE and/or FT Historian oTerminal Server Clients

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Distributed Historian Architecture

FT View SE and/or o FT Historian oTerminal Server Clients o

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GEMS Managed oEthernet Switch for Enterprise Network (EN) – Business Communications

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Standard

Firewall

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VPN

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GEMS Standard

Firewall

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Domain Controllers For the Ctl Sys Domain

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Data and HMI Server

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Batch Server

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FT Historian Server

Managed Ethernet Switch for Control System Network (CSN) – HMI/Ctrl Communications oLogix Controller o

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4 Clients

Engineering Batch Highly Scalable Workstation Solutions

5 Clients

GEMS FT View SE Standard Terminal Server

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Clients

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FT Historian Clients

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FT View SE Clients

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Terminal Servers

oTight integration with Managed Ethernet Switch for Control System Network (CSN) – HMI/Ctrl Communications

GEMS Standard

Intelligent Motor Control

Media Prep

Autoclave SLC

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Control Network (FFB, DNet, ENet)

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Data and HMI Server

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UF/DF Skid

DeviceNet oFoundation Fieldbus

Data and HMI Server

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QBMS

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OEM Integration Advantage Domain Controllers (existing) •For the Enterprise o

IP Printer

FT View SE and/or FT Historian oTerminal Server Clients

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FT View SE and/or FT Historian oTerminal Server Clients o

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Firewall

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VPN

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Managed Ethernet Switch for Enterprise Network (EN) – Business Communications Firewall

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Domain Controllers For the Control System

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•

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Data and HMI Servers

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Batch Server

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FT Historian Server

Managed Ethernet Switch for Control System Network (CSN) – HMI/Ctrl Communications o

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4 Clients

FT View SE Terminal Server Clients

5 Clients

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Engineering Workstation

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FT Historian Clients

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FT View SE oThick Clients

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Terminal Servers

Managed Ethernet Switch for Control System Network (CSN) – HMI/Ctrl Communications

Media Prep

CIP

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Data and HMI Server

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Pan Coater

Data and HMI Server

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Control Network (FFB, DNet, ENet)

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OEM Utility Skid

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QBMS

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OEM Process Skid

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Building Automation System

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QBAS - Typical System Configuration Packaged Air Handlers

HMI

Fan Coil

Single Zone

FT View SE and/or FT Historian oTerminal Server Clients o o

AHU Control 0000

0000

FT View SE and/or FT Historian oTerminal Server Clients o o

Make-up Air

VAV Box

0000

Central Plant Batch Historian Scheduler Central Plant Oracle / SQL

0000

Boilers Chillers Pumping, Compressors, Cooling Towers rd 3 Party Interfaces

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3rd Party Protocol

BACNet Devices

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Third Party Protocol Interfaces BACNet N2 - (JCI) ArcNet – (JCI) FES-Frick - chillers Profibus Lonworks Trane - chillers McQuay - chillers York - chillers Modbus HART Foundation Fieldbus OPC

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Typical Redundant Controller Configuration 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.

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

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Building Automation System

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

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EMS – Environmental Monitoring System

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Integrated BAS & EMS

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Building Management System - AHU

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Project Methodology LONG TERM SUPPORT

• Parts Management • Preventive Maintenance • Training

KICK-OFF

• Functional Specification • Sequence Of Operation • Define Project Timeline • Define Project Team • Schedule Deliverables

TECHNOLOGY TRANSFER

• Detailed Project Requirements • Safety Procedure Review • Final Design Review/Approval

EXECUTE

ACCEPTANCE

COMMISSION • Pre-Startup Site-Test • Application Startup • System Integration

Copyright © 2008 Rockwell Automation Inc All rights reserved

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• System Architecture • Preliminary Design Review • Define Design Templates • OEM Coordination Procedures

REVIEW/LAUNCH

• Customized Training • Embedded Engineer

• SAT/ Customer Witness Test • System Handover

PLAN / DESIGN

• Code Development • Global OEM Coordination • Project Scope Management • Project Resource Management • FAT • Commissioning Schedule Review Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Rockwell Automation Expertise

• Project Manager – – – –

Scope Management Project Resources Risk Management Development of Project Plan & Schedule – Schedule Resources

• Technical Lead – – – – –

• Validation Lead

– Documentation development & control

• Commercial Support

• Installation

Subject Matter Expert Lead Development Operational Training Start up & Testing Documentation

Copyright © 2008 Rockwell Automation Inc All rights reserved

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– Sales – Technology Training – Technical Support – – – –

Site Project Management Schedule Network Installation/ Calibration

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Why Rockwell Automation for QBAS, BAS & EMS? Reduce Total Cost of Ownership  Modular Software – Add on instructions

Reduce Total Cost of Ownership

 Subject Matter Expertise  Global Capability & Local Support  Internal Maintainability

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Qualified Building Automation Solution Questions???

Rev 5058-CO900C

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