t30 new connectivity and reporting client for...
TRANSCRIPT
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
T30
New connectivity and
reporting client for
FactoryTalk Historian
Jan Pingel
Product Manager, FactoryTalk Historian
Rockwell Automation
Automation Fair 2011
November 16-17, 2011
Chicago, IL – McCormick Place
FactoryTalk Historian
Announcement with OSIsoft
FactoryTalk Historian
Site Edition
Released
2006
2007
2008
2009
2010
2011
2012
FactoryTalk Historian
Site Edition 2.1
Update
FactoryTalk Historian
Machine Edition
Released
FactoryTalk Historian
Site Edition 2.2
Update
FactoryTalk Historian
Machine Edition 2.2
Update
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Soon Launching
updated version of
Historian SE with latest
version of
PI Server 2010
New
version 3.0
2006
2007
2008
2009
2010
2011
2012
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And launching
FactoryTalk Historian
Enterprise Edition
New
version 3.0
2006
2007
2008
2009
2010
2011
2012
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Agenda
2. Typical Challenges for Historian systems
5. Wrap-up
1. Introduction
4. New solutions for Information Software
3. Information solutions with Historian today
INTRODUCTION FactoryTalk Historian
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Turning Process Data into Manufacturing Intelligence
• A single, information management application server is the central data
point for process information. The information management server
application offers these features:
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Control Systems
HMIs
Production
Scheduling Alarms/Events
Other Database
Systems
Computerized
Maintenance
Management
Systems
Performance
Quality
Systems
Data Historians
Laboratory
Information
Management
Systems
• Supports both data
management and
decision support
• Manages several
different data sets flows
into the server
• Supports data analysis
from the server.
Decision Support Data Management
Data Management
• A distributed, data management strategy enables different focuses of
data by various users.
– Operator viewing data from the machine directly in the HMI
– Supervisor viewing data to make plant-wide decisions
– Manager viewing key KPIs from each plant and evaluating plant performance
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Excel Dashboards
Trend Reports
Portal
KPIs
Data Collection
Data Storage Process Book
Batch Analysis
DataLink
SQC
Decision Support
Decision Support
• A decision support strategy addresses the need to rapidly capture and
evaluate information to make
– business decisions. This starts by efficiently and reliably collecting data and integrates
the support
– tools necessary to analyze, view, and summarize that data. Portals and dashboards
are key to presenting users the information they need, when they need it.
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Decision Support Data Management
Excel Dashboards
Trend Reports
Portal
KPIs
Data Collection
Data Storage Process Book
Batch Analysis
DataLink
SQC
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What is a Historian?
• Time Series Data collection
– Data Historian
– Plant Historian
– Process Historian
– All different names for the same function
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Process Historian
• Traditional Historians for Continuous Process
– Collection continuous process data from the equipment
• Temperatures
• Pressures
• Speed
• Etc.
– Trending process data over time
used by in industrial and manufacturing environments to record and report on historical data over time, which
can include process and product information, as well as network performance and IT monitoring. Automated
Results provides historian application and database consulting, support, integration, user and administrator
training, custom application development, and reporting services.
Process Trend View
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What is NOT a Historian(s task)
• Not trending the data
– Probably not going to use a Historian !!
• Collecting records of data
– Data should be stored outside a time series data store
– i.e. Batch Records, Production lots, Orders, Shipments, etc.
– Records with multiple columns (elements)
• Should be stored in a relational database
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The Hybrid Model
• The Data Model in a comprehensive plant data base Incorporates:
– Real Time Data
– Relational Production Data
– Time Series Data
• A Data Historian can’t replace a
complete plant database, and
• A Relational Database is not a
replacement for a good Historian
• There will always be room for both technologies in a good plant data
model.
Production Data
Process Data
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The Hybrid Model
• Merging both Technologies
– Adding Context / Model
• Moving away from a flat data structure
to an organizational structure
• Link time series data to assets
– Adding: asset properties, events, analytics etc.
– Event Framing
• Store events like: Batches (full S88 model),
shifts, material flow, alarm and events etc,
• Visualize the process data within those
events (fence posting)
• Use analytics: Totalize data over the event
/ time box
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The Hybrid Model
• The connected Historian
• Connecting:
– The traditional Time Series Data with
– Event data (Event Framing / Fence Posting)
– Asset Data (Context / Properties / Analysis )
– Production Data
– Manufacturing Data
– ERP Data
– Etc.
Time Series
Data
Event Data
Asset Data
Analysis
Production Data
Manufacturing Data
ERP Data
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TYPICAL CHALLENGES FOR HISTORIAN SYSTEMS
FactoryTalk Historian
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Historian Challenge
• Collecting the data
– Identifying what to collect
– Configure the data collection
• Visualizing the data
– Navigating the data structure
– Correlated Historical data with other data types
– Finding the right way to present the information
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Data Historian Users
• Complex configuration
• Many different interfaces
• Many potential architectures
• Time consuming
• Hard to make repeatable
• With multiple layers of
Historians makes it more
complex.
• Flat data structure
• Complex tag names
• Often times 1000’s of tags
• Not easy for all levels of user
in an enterprise
• Require lots of pre-
configured content
• Not easy to run quick Ad hoc
analysis from the data
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INFORMATION SOLUTIONS WITH HISTORIAN TODAY
FactoryTalk Historian Data Collection
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Deployment and Configuration made easier
• Premier Integration to FactoryTalk
– Pre configured: Users, Data sources, databases, systems
• Auto Discovery / Auto Configuration
– Standardization of code and data structures can get systems up and running quicker
• Configuration Rules
– Can make deployment repeatable
– When a similar skid, system, line is deployed the data collection can be configured
by repeating the previous configuration.
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MOTOR1.SPEED TANK1.TEMP
TANK1.PRESSURE
TANK1.TEMP
TANK1.SIZE
TANK1.PRESSURE TANK1.VOL
TANK2.SIZE
TANK2.VOL
MOTOR1.ACC
MOTOR1.SPEED MOTOR1. PRE
MOTOR1.PID.SP
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Auto Discovery and Configuration based on rules defined in included rule tool
• Auto Configuration based on:
– Easy to configure rules
– Based on consistent naming
convention at customers
– Allows to discover individual tags
and structures
– Multiple rule files can be defined
for different purposes
• Types of machines
• Areas in customer plant
• From different vendors
• Etc.
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Tags discovery are also automatically configured
• For each discovery rule:
• A configuration can be defined
– That defines the way the tags
discovered by the rule will be
configured.
– Which means that no fine tuning
of the tags will be needed after
the configuration wizard is done.
– Configuration includes:
• Description, units
• Range, typical value
• Exception and Compression
• Etc.
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Calculation Engine and Analytics
• Internal calculation engine
– Performance equations
– Totalizers
– ACE – Advanced Computing Engine
• Real-time SPC alarming on server
– Including SQC client to display SQC charts
• Development tools
• Open data access methods
– OPC
– OLEDB
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System
Management
Tools
Thin Clients: VantagePoint, Portals,
Rich Clients: View, ProcessBook, DataLink, FactoryTalk
Applications, Custom Application…
PI SDK
Secondary
Historian
Configuration
Changes
Redundancy and High Availability
Data Buffering
Services
Historian Interfaces
Data Buffering
Services
Historian Interfaces
Secondary
Historian(s)
Primary
Historian
If your customer wants high availability,
then you need to specify redundant
historian servers
If your customer wants redundancy,
then you need to specify redundant
interface nodes
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How about distribution of data collection?
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Multi tiered
Architecture
High Speed at
machine level with
local trending
Plant Historian with
Analysis, Calculation
and Consolidation
Enterprise Historian with multi
site aggregation capability and
enterprise visibility
With integration into Universal
Production Model – You don’t
need to know where the data
physically resides – system
finds data on request
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• New Embedded Historian Module for ControlLogix
• Capability for High Speed data collection in the backplane
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Where traditional data
collection is done
through interfaces and
data servers
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Where traditional data
collection is done
through interfaces and
data servers
Data Transfer –
transfer's archive
data directly from the
ME module to Plant
Historian
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• Enterprise Historian for large scale data aggregation
• Capability for collection millions of tags
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FactoryTalk Historian Enterprise Edition 3.0
• Final piece to the Distributed Historian strategy now being released
• Completing the architecture with the Enterprise level data aggregation
• Based on latest PI Server 2010
• Will be commercialized in partnership with OSIsoft
– EE Customer will have access to both vendors support teams
• Target Release Date: January 2012
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FactoryTalk Historian EE Positioning
FactoryTalk Historian ME
• Machine / Line Historian
• Temporary Storage – Limited to circular buffer in Flash memory
– Requires Plant Historian for long term storage
• Reliable data collection – If the machine and chassis is powered and the
controller is running the machine, the data gets
collected
• Backplane data collection – Scan rates down to 10 msec
• Embedded Historian Module – No OS or patches to maintain
• Full Historian Capability – Built-in Basic Calculation Engine for
• Performance Equations and
• Statistical Totalizers
• Low Deployment cost – Easy to buy, Easy to own
– Up and running in less than an hour
FactoryTalk Historian SE
• Plant / Site Historian
• Persistent Storage – As much as Drive space allows
– Archive / backup strategy can be put in place for
long term storage
• Redundancy required for reliability – If minimal data loss is required, redundant
architectures has to be applied from the
controller and up.
• Data collection based on Network – Scan rates down to 100-250 msec max
– Significant 3rd party connectivity
– DA Component (OPC, OLE DB)
• Windows Server Based Historian – Maintaining a Windows Server OS
• World Class Historian – Added Advanced Calculations
• VB.Net Adv. Calculation Engine
• Analysis Framework
• Easy to deploy – Up and running in less than a day
FactoryTalk Historian EE
• Enterprise Historian
• Persistent Storage – As much as Drive space allows
– Archive / backup strategy can be put in place for
long term storage
• Redundancy required for reliability – If minimal data loss is required, redundant
architectures has to be applied from the controller
and up.
• Data collection based on Network – Scan rates down to 100-250 msec max
– Significant 3rd party connectivity
– DA Component (OPC, OLE DB)
– Supports data aggregation over WAN
• Windows Server Based Historian – Maintaining a Windows Server OS
• World Class Historian – Added Advanced Calculations
• VB.Net Adv. Calculation Engine
• Analysis Framework
• Typically requires services – Complex Architectures
– Multiple server connection setups etc.
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NEW SOLUTIONS FOR INFORMATION SOFTWARE
FactoryTalk Historian Data Visualization
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Talk about getting data to users
• How to visualize data
– So it make sense to the users
– Brings valuable insight about the process and production
– In formats appropriate for the solution
• FactoryTalk VantagePoint !!!
– Advanced trend tool
– XY Plotter
– Excel Add-in
– Advanced Dashboards
– Portal for thin client access
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Trending Made Easy
• Compare data over different
time periods including
historical, pre-set and real time
• Analyze and display multiple
tags/items from the model
concurrently
• Powerful trend functionality -
drag and drop, pan, zoom,
stack and synchronize
• Publish and share trends with
others through the portal
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FactoryTalk VantagePoint XY Plotter
• Analyze one value with respect
to another over time periods
including- historical, pre-
defined or real-time
• Display and compare multiple
tag pairs concurrently
• Powerful functionality including-
drag & drop, pan, zoom and
scale
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Excel Reports Available to Everyone
• Easily retrieve data from
Historian to use in Excel
• Calculate, analyze and
format reports using Excel
functionality
• Only “one version of the
truth” because Excel reports
are built within VantagePoint
and are saved in the model
• Published reports can be
viewed by anyone with
access to a browser
Retrieve
Data From Any
Source
Calculate,
Analyze
and Format
Publish to the
VantagePoint
Portal
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Powerful Easy-to-read Dashboards
• Create powerful dashboards
that monitor key
manufacturing KPIs
• Dashboards can update
dynamically and on demand
• Published dashboards can
be viewed by anyone with
access to a browser
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All You Need is a Browser
• No client install is needed to
view trends, reports and
dashboards
• Simply publish reports in the
portal to allow access
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Composite Reports for Greater Visibility
Reusable
Components
Dashboard
Builder Trend
Excel
Plot
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Access From All Systems and Context Based on User Roles
• Access to ALL plant floor, production and business systems
• Integrate and organize time series and transactional data
• Users at all levels of enterprise can view role-based KPIs, reports
and dashboards
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Manufacturing Intelligence via VantagePoint
• The Unified Production Model is:
– Logical layer of organized information created by instances of types & their
properties
– Examples of Types include:
– It can also be collections / hierarchies of types
– Standard set of types provided
– Ability to create custom types to represent your business / manufacturing process
– Reports / visualization are built on the UPM, not the source data
Assets Pump
Extruder
Tank
Filler
Welding Cell
Utility Meter
Structures Production Line
Production Area
Plant
Enterprise
Production Schedule
Operator
Process Quality Audit
Repairs
Test / Inspection
Batch
Product Parameters
Shift
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Type Example: A Pump
Process Control Engineer
• Pressure
• Flow
• Speed
Production Manager
• Volume pumped
• Product throughput
• Operation history
• Power consumed
Maintenance Manager
• Running hours
• Performance spec
• Manufacturer data
• Spares on hand
• Maintenance date
Process Engineer
• Related equipment
• Rating
• Vibration data
Asset Manager
• Purchase date
• Cost
• Warranty
• Manufacturer
• Engineering specs Quality Assurance
• Batch record
• Leak test data
• Lab sample
Live Data: Control System/HMI
Historian
Asset
Database
ERP, LMS, SQL
Database
Maintenance
Management
System
Scalability via the Unified Production Model
Logical
Model
(UPM)
Physical
Data
Sources
Site 1
Plant/Area 1 Data Sources Plant/Area2 Data Sources
VantagePoint Unified Production Model
Site 2
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Plant Model enhancement for Historian
VantagePoint Historian Connector functionality:
• Context Enhancement to replace the flat name structure in Historian
– Logical model of the data points
– Instances of types – allows for quick deployment of new Historian tags to report on
• Inter correlation of real time tags and historical tags
– Real time tags that are historized are automatically detected
– User can drag a real time tag onto a trend and automatically the system will show
historical data
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Functionality of VantagePoint since version 3.0
Plant Model enhancement for Historian (cont.)
• Inter correlation of historical tags
– When tags are historized in multiple historians the system can find the best source
of information needed for a report / trend.
– Makes reporting completely transparent to the end user
• they only need to know one reference point (logical) for a data value
• Aggregations of data are automatically handled in Historian
– When users request aggregated results in VantagePoint
• Requests that can be handled faster and more efficient by Historian, are
automatically forwarded to Historian for processing.
– Significantly reduces the calculation loads on the VantagePoint Server
– Allows for processing of aggregations at the best performing server.
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Historian to Historian tag correlation
• System selects the correct Historian tag when:
– A real time tag is pulled into a trend
• Best historian tags is selected
– A high speed historian tags is pulled into a trend
• But data is no longer stored locally
• Data is aggregated to Plant Historian
– A plant historian tags is pulled into a trend
• But newer data is available elsewhere
– Etc.
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Historian to Historian tag correlation
• What does it really mean?
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Correlating live data tag to best match Historian tag
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Inter correlating Historian tags based on time window
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Adding the Logical model (UPM)
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SoCAL
Area 1
Tank 1
Temperature Temperature
Data aggregation handled by Historian
• System diverts aggregations and calculations to Historian where
appropriate:
– Interpolated values instead of raw values
– Summarizations
– Statistical Analysis
– Etc.
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Data aggregation handled by Historian
• What is the significance?
• … Performance improvements !!!
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Data aggregation handled by Historian
• Allows us to add more clients to VantagePoint without adding significant
to the overall performance requirements !!
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WRAP UP FactoryTalk Historian
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Summary: Scalable, performance Historian
• Scalable data collection
– From in-chassis high speed to
– Advanced Plant Historian to
– Enterprise level aggregation
• Easiest Historian to deploy
– especially on a Logix platform
• High Availability
• Extensive calculations and aggregations included
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Summary: Informed Decision making
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• Comprehensive Historian client
– Excel reports, Advanced trends, dashboards, composite reports
– All available from a think client portal – all you need is a browser
• Brings context to Historian data
– From complex flat data model to logical, easy to navigate Universal Production Model
• Connect disparate data sources to live and historical data
– Makes the information valuable and relevant
• And now …
• Seamless correlation of data points collected in various data sources
• Executing presentation layer aggregations in the Historian
Summary: What results can you expect?
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Decreased overhead costs
– Reduction in data collection and information
transformation (data prep)
– Increased utilization of fixed assets
Information rather than data
– Advanced portal, reporting, and analytical
capability
– Increased productivity, revenue, and profit
Decrease in manufacturing costs
– Better understand your process, then optimize it
– Reduced materials, labor, and energy
Decrease in cost of quality
– Higher accuracy and agility via process control
– Less scrap and material losses
Increased productivity by 10 percent
in less than one year, allowing the
company to get more product to the
market at a lower price point and be
more competitive - CPG
With premier integration to our controls,
and auto configuration and tag
browsing, we can get a system up and
running in about an hour
– Pipeline company
720 man-hours saved annually in
generation of regulatory and ad hoc
reports, estimated savings of one
man-year in automation of billing
process - Water Wastewater
For more information on VantagePoint
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Thank You
For more information:
Jan Pingel
Product Manager, FactoryTalk Historian
+1 704 665-6026
http://discover.rockwellautomation.com/<product>
Brian Porter
Product Manager, Information Software
+1 440 646-6508
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