Oil and Gas

Industry PlantPAx
5.0 Demo
onCourse FY23
Table of Contents
Purpose ................................................................................................................................................................................................ 3
Overview .............................................................................................................................................................................................. 3
Gas Processing .................................................................................................................................................................................... 5
Introduction ..................................................................................................................................................................... 5
Key Values ...................................................................................................................................................................... 5
Demonstrated Key Values .............................................................................................................................................. 6
Cause & Effect ................................................................................................................................................................................... 11
Compressor........................................................................................................................................................................................ 12
Additional Features and Capabilities within Fiix ................................................................................................................................. 16
Fiix – Main Dashboard..................................................................................................................................................17
Fiix – Work Order Details .............................................................................................................................................18
Fiix – User Groups ........................................................................................................................................................19
Fiix - Assets ..................................................................................................................................................................19
Operator Training................................................................................................................................................................................ 22
PlantPAx Value - Summary ................................................................................................................................................................ 22

Rockwell Automation 2 Oil and Gas Demo

Purpose
This demo was built to demonstrate our relevance in the Oil and Gas (ONG) Industry. It can be
used for sales pursuits, customer visits at the Experience Centers, Process Training Unit
(PTU) and for industry events and tradeshows such as Automation Fair. The key takeaway
for customers is that our modern distributed control system (DCS) is not just for skids or
certain applications- it is built for plant wide control and forms the basis for digital
transformation. Our DCS enables customers to be more productive and profitable while
reducing operational risk. This drives efficiency, increased asset utilization, and improved
environment, health and safety performance.

The Oil and Gas demo is built using the latest version of PlantPAx 5.0 and the process object
library. It shows a comprehensive overview of a simulated base process of oil and gas
production. The oil and gas customers know RA as a PLC provider whose technology runs
utilities, compressors, MCC, Drive, and other sub-system or. This demo allows us to bring a
complete single-vendor control system solution case to extend the application into whole
process, safety, utilities and gas processing, and power.

It is important to utilize and familiarize yourself with the demo and this script to gain a better
understanding of the features and key messages. Every customer is motivated a little
differently, so customize your delivery using your sales skills. You have exciting products that
can make your clients more productive, so keep that in mind as you find a path forward with
your customer.

Overview
The ONG demo contains 2 major areas of operation: Gas processing and Utilities.
Throughout the script, each area of the demo will highlight specific features tied to desired
business outcomes, while providing a better understanding of the areas and how to support
the customer with a DCS in the oil and gas industry. The higher-level theme in the demo is to
optimize control of assets and improved operation safety and situational awareness.
The themes are shown over common oil and gas unit operations (both PLC and DCS use
cases) which can relate to our oil and gas customers’ facilities. All these themes are seen
within an ISA-101 style centralized control system. The flow of the demo follows the typical
layout of oil and gas production facilities – gas processing and auxiliary facilities. This
illustrates what an operator would see on the HMI, as shown below of this section.

Situational awareness and standardized ISA guidelines improve the safety of the customer
and facility with features such by opening faceplates, an operator has easy access to details
of information on interlocks/permissive, device/instruments and control performance.
There’s access to diagnostics, helping investigate operational incidents.

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Operation Graphics (HMI) have been organized by Framework hierarchical way to provide
users with a logic progress of complexity from main areas down into detailed process flow
diagram level.

Logix Echo: Double click the icon from the Desktop to make all demo controllers

running . If it failed with red cross and error message like “ not responding” ,
please do the following steps to recreate the controller:
1) Write the ACD file address, IO address and Slot number

2) Delete the failed controller from the dialog window.

3) Recreate the controller by replicating the device information of Step 1 and 2. Then
download and remote run the project ACD file

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HMI access: Find and Double click icon ONGClient from the Desktop to
open the HMI client (make sure the login account is PLANTPAX-V4\Rockwell)

Gas Processing

Introduction
If an ONG customer is looking for the gas process solution, take the customer to the
Debutanizer. This section will demonstrate a distillation column to rectify the butane out of
the basic gas liquid stream. This continuous process is the most common processing unit at
the oil and gas facilities. Some customers may have already deployed it with RA PLC system,
from this section it will demonstrate that the RA has abilities to control entire plant from the
control platform to process visualization, as well as able to be integrated with third-party
PLC system.

Key Values
▪ The modern DCS PlantPAx Provides plantwide control and integrated safety into the
gas process unit, we will go through them with and examples how to showcase them.
• By following ISA guidelines, we provide improved situational awareness for the
process area. By having the ISA 18.2 alarming with breadcrumbs allows for
quicker trouble shooting and response time.
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 • Graphic objects are providing uses with the built-in faceplates to easily access
plant assets for maintenance and tuning.
• Maintenance has configured information like the motor’s running mode ( Auto,
Program or Manual) , how many times a motor has been started, how long it’s
running, or how many times a block valve has been stroked. Alerts can be
configured based on Preventive-Maintenance analytics to help plan
turnaround rather than abrupt abnormal malfunction which causes unplanned
downtime.
• Fault Detection, the machine learning will help detect the instrument failure
and issue an alert whenever it occurs.
• Sequencing Operation is to demonstrate the functionality of Equipment
Management from recent release PlantPAx 5.0 Library. It will automatically
help manage the procedures of plant shut-off/down to mitigate human
mistakes
• Advanced Analytics: Model Predictive Control application was applied to
optimize the column operation. This showcase will demonstrate that PlantPAx
MPC is able to effectively improves the product qualities (or push the
throughout) against the process constraints. In this part you will expect to
observe when the product quality is purified from 95 to 97% and 99%, the MPC
drives the relevant manipulated variables (MVs) approaching the optimal
operation condition until the reboiler (or other process variables) hits the
operation constraints.

Demonstrated Key Values

• By following ISA guidelines, we provide improved situational awareness for

operational technician. By having the ISA 18.2 alarming with breadcrumbs
allows for quicker trouble shooting and response time.
• Process KPI overview. Click on the Tab of Debutanizer MPC to lead to
the process overview. this graphic list the simplified process flow
diagram, key process variables and performance index. As listed
below.

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 • If the black question mark (?) is observed, click it to dig into the
diagnostic faceplate to troubleshoot the cause, which is the faulty
channel.

• To Trigger sequencing start-up/stop : Going to the page C2000 Dist

Column for the column operation , then click the button of
startup/shutdown to pop up Sequence faceplate, this sequencing
operation is based on the library object of Equipment Management
from this faceplate you can demonstrate:

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 •

Resetting system: to settle down the whole process to the ready status.
Fill Column: Cold-start the operation with feeding the column from the
start-up tank then ramp up to the normal loads along with boosting up
Reboiler and condenser.
Run: To initiate the start-up process from the front to the end with raw
material.
Stop_Feed: To shut off the operation step by step.
• Analytics Demo1, In the Box of Demo Control, Click the simulate bad
impeller to trigger the scenario of the impeller malfunction, after it is
active the pump will indicate the Maint Req (highlighted with
yellow/black box) from the Model Ok, see the demo below.

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 •

•
• Analytics Demo2, Click the simulate bad input to trigger the fault of the
flow rate instrument (FT-2000) , after it is active the black question
mark will indicate the service attention, see the demo below.

• Alarm setting overview, Click Display Alm Display to pop up the

summary of the configured alarms. From this window not only does it
display each single alarm threshold but also the status of the operation
mode of the PID loops ( AUTO,MAN,PRO). This can improve the
operational awareness and reduce the respond time. As demonstrated
below.

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 • Turn on PlantPAx MPC, Click Enable MPC button of Demo Controls to set
MPC application ready. Open up the faceplate of Purity_CV, then click
the “ Display faceplate for this object”, the standard faceplate for MPC
is displayed: HomePage is to access single controller variables, CV,MV
and DV by clicking on variable tab ( to change the tuning parameters,
cost functions and turn it on/off.) Maintenance (wrench) includes the
details of controller parameters: Cost Move (economic factor), moving
suppression, significance scale.

Improving Purities, When MPC enables, click the button of Set MPC
Purities 97%, the MPC will simultaneously increase the reflux flow and

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 reboiler steam flow to maintain the bottom temperature and the top
purities. It turns out that purity will reach the target 97%.
MPC Constraints Demo, Click the button of Set MPC Purity 99%, the
purity target was set as 99%, then MPC will continue to increase the
reflux flow, meanwhile more steam will be demanded for the bottom
temperature. But the steam increment was constrained by the limit of 8
MBPD, which indicates the MPC hits the constraint(s).

Cause & Effect

• Built-in standard Cause & Effect chart allows for the customer to have
quick access to diagnose abnormal events: what causes the system or
device contingent shutoff.

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 •

Compressor
• The compressor is monitored by key operation variables like vibration
measurements, loads and mechanical status.
• Fiix Maintenance request demonstration: this showcase applies Fiix to help
manage the service request from the operation board. The below shows the
workflow of how the system Click the button of Maintenance Request, the
request will be sent to Fiix platform and delivered to the designated
maintenance team via emails or instant message (installed Fiix Apps).

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 • ThingWorx configuration: Open Edge Browser to click the Compose (see below) to
enter the login page by the username: Administrator; Password: Rockwell@12345

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 ThingWorx helps to transfer the command bit from the HMI (Maintenance Request) into the Fiix
tenant to create a work order task for the relevant personnel.

- Fiix URL log in

Click the bookmark or type the following address in your own PC or

mobile device: https://raoilandgas.macmms.com/
- Username: manager
- Password: cmms12345

From the Dashboard page, the work order was created and notified to the designated the
maintenance team via emails or instant message.

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To view the work order, click on the “Work Requests” widget on the dashboard.

Once the work order requests displays, filter the work orders by clicking on the drop-down triangle to the
right of the search area.

A pop-up menu will appear. Select to filter by all work orders.

Once viewing all work orders, see the ones recently created through PlantPAx:

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Next, let’s view the scheduled work order creation. On the menu bar at the right-hand side of the screen,
select ‘Maintenance,’ followed by ‘Scheduled Maintenance.’

View the created scheduled maintenance to inspect the compressor daily, and to replace the bearing when
the inspection fails.

An email can be set up to be sent when there is a corrective action on the inspection. Here you can see
that the email was sent to replace the bearing on the compressor (Note: you will not be able to see this
part during the demo; this is for informational purposes only):

Additional Features and Capabilities within Fiix

The previous section showed a demonstration of automatic work order capabilities and
notifications using Fiix. However, Fiix is a cloud-based CMMS. That means the only thing necessary
to begin using Fiix is an internet connection and a browser. Browsers supported include IE11+,
Mozilla Firefox, Google Chrome, and Safari. Fiix also has a mobile application for technicians to
utilize on the job or field to immediately view work orders, work instructions, take meter readings,
and create orders based on inspections.

Fiix CMMS is easy to use, gives access to critical information, and helps visualize key maintenance
and operational KPI’s crucial for each level of user, from the technician to the plant manager.

Rockwell Automation 16 Oil and Gas Demo

For an interactive demonstration of how to use Fiix in the Oil & Gas industry, please go to the
following location: https://rockwellautomation.storylane.io/share/jy09eexujeyk

Let’s go through these features to see how easy Fiix is to use and configure for the industry. Some
of the features we’ll go through include:

• Configurable and easy to read user dashboards

• Work Order Priority
• Work Order Details
• Role-Based Access Control within User Groups
• Assets and the Asset Tree
• Work Orders associated with an asset
• Important and key information stored within an asset
• Asset History

In case the window was closed previously, let’s open the Fiix CMMS that we’ve been using and
enter the credentials necessary.

Click the bookmark or type the following address in your own PC or

mobile device: https://raoilandgas.macmms.com/
- Username: manager
- Password: cmms12345

Fiix – Main Dashboard

If the Fiix tenant was still open, then click on the dashboard icon to get to the main Oil & Gas
dashboard:

The main dashboard is configurable, and can be used for technicians, managers, purchasing, and
administration. Each dashboard can be configured for importance to each user (KPI’s, scheduled
maintenance, work orders assigned, etc.).

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Fiix – Work Order Details
First, let’s explore High Priority Work Orders.

This shows a high-priority work order on the CAT G3520J compressor. Additional details include:
• Work order status
• Who the work order was assigned to
• Work order type
• additional details

Go back to the main dashboard by selecting Back .

Next, let’s view all of the Open Work Orders.

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The following screen will appear:

Information given in the Open Work Orders page includes:

• Work order number
• Work order description
• Work order priority
• Assigned asset of work order
• User or User Group assigned
• Work order status
• Work order type (preventive/predictive (planned) vs. corrective or breakdown (reactionary))

Fiix – User Groups

Let’s explore a user group. Select the Technicians user group:

The Technicians user group is an example of how to set up role-based access control within Fiix
CMMS. This is where different users can be assigned to and removed from a group. The group is
used to ensure that only the proper personnel have access to the areas they need. Click OK once
you’ve viewed the different tabs within the user group.

Fiix - Assets
Next, let’s view what assets are available in the Oil and Gas area within Fiix. Select ‘Assets’ on the
menu on the left-hand side of the screen.

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Fiix employs a multi-asset and multi-hierarchy layout for assets. This means that you’re able to
have as many assets as you need within the system (multi-asset), and that you can stack the
assets for a parent/child relationship with no limit to the hierarchy levels (multi-hierarchy).
An asset hierarchy has a typical asset classification as follows: region, site, location, asset, tool.

Once at the Asset Tree, keep hitting the to expand the Oil and Gas asset tree until you reach
the Compressor CAT G3520J1 asset. Click on the compressor name to open the asset.

Let’s explore the various aspects of the asset.

In the header of the compressor asset, one can mark whether the compressor is online or offline.
This helps to track uptime, meantime between failures (MTBF), and meantime to repair (MTTR).
There is also a QR code. This is created within Fiix CMMS. However, if your asset already has a QR
code associated with it, it can replace this code within the system.

As you can see below the header, there are multiple tabs within the compressor asset. We’re not
going to go into every detail on this particular asset, but we will highlight what each tab does.
• General: Make/Model/Serial #, location of asset, charge department
• Parts/BOM: This gives the ability to associate parts or a Bill of Materials that are specific to
this asset. These parts will be highlighted so the technician knows they’re specific to that
asset when work on a work order within that asset.
• Personnel: any assigned users or user groups to this asset.
• Warranties
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 • Businesses: If the compressor is serviced by a 3rd party, the party could be listed here
• Purchasing (original purchase)
• Custom fields
• Financials: tracking cost on the asset (labor, parts, misc. expenses from work orders)

Let’s go through a couple more of the tabs. Click on ‘Metering/Events.’ Near the bottom of the
screen, you should see “AE1 – Replace Bearing.” Click on the event.

This keeps the event history of the compressor asset when a bearing was replaced. When finished
reviewing, click X to close.

Next, click on the ‘Files’ tab. This area is useful to store manuals, drawings, useful pictures, work
instructions, links to websites, and potential maintenance procedures and best practices. The
example in the compressor is an image of the compressor itself.

Finally, select the ‘Log’ tab. This section will show scheduled maintenance, open work orders, work
order history, parts consumed, and when the compressor was offline.

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This concludes the Fiix portion of the lab.

Operator Training
This whole process is simulated on the recent release P-Controller and PlantPAx module. It is
alternatively able to run on the FactoryTalk Logix Echo as well if MPC demo is not needed.
Therefore, it can be used to train operators or plant personnel; it’s an operator training
system.

PlantPAx Value - Summary

PlantPAx, provides the user a standardized look and feel that follows ISA guidelines. By
having the standardized look, it provides the personal, operator and engineer an easier, more
effective way to troubleshoot an alarm or an issue that occurred in any area of the plant
itself. PlantPAx can control the entire plant, allowing personnel to make continuous
improvements to processes and provide additional data to achieve a connected chemical
plant. This demo allows us to bring a complete single-vendor control system solution story
for the main process, safety, utilities and BOP, and power - essentially our Integrated
Architecture play of one set of rules and tools specifically to a chemical facility. Throughout
this demo, key features were shown for Batch, separations, and utilities of a chemical plant.

Note:

1) Demo files are located: C:\Demo Files

2) Fiix CMMS address: https://raoilandgas.macmms.com/
Username: manager
Password: cmms12345
3) Recipient Notification
[email protected]
password: Rockwell@12345

Rockwell Automation 22 Oil and Gas Demo