Advanced Process Control Using Rockwell PlantPAx Processors and FactoryTalk Suite

Project Objectives 

1. Design and implement control systems to control the pressure and flowrate of process fluids used to create test conditions for devices under test.  
2. Exchange process data, test configuration, and status information with an external data acquisition system.  
3. Provide intuitive and detailed test configuration UI, allowing for wide range of test conditions and profiles.
4. Standardize programming with tested and validated control strategies to minimize operational risk and enhance troubleshooting capability.  
5. Minimize commissioning time and risk.  

Phase 1: Requirement Analysis and Planning  

• DMC conducted numerous onsite and offsite meetings with the end customer and various external stakeholders to establish design objectives and requirements.  
• From these meetings, we identified the required hardware and software features needed to meet our customer’s overall design objectives.  
• We conducted several rounds of design review with the facility end users to refine the user workflow for both operating the facility and processing test results.
• The final design of the hardware and software was translated into a Functional Specification document. All sequence steps, permissives, interlocks, alarms, and HMI wireframes were captured in this document for reference by both the DMC software development team as well as the facility end users.  

Phase 2: System Design and Development  

• PlantPAx 5.0 Selection: Given the need for highly performant process control and well-tested, robust programming blocks, DMC selected the Rockwell Automation P-Processor (1756-L83P) to control the facility. The selection of a P-processor allowed us to leverage the full PlantPAx v5.0 library, which comes built into the process controller’s firmware.  
• Application Code Manager (ACM): To allow for rapid development, consistent programming, and to minimize programming errors during implementation, DMC used Application Code Manager (ACM) to generate the base code for the project. This was especially important in the early phase of the project, where DMC aimed to prove out the user workflow for the facility even though the specifics of the facility’s field equipment were still being finalized. Even large changes to the list of field devices were easily propagated to the code throughout the development process, using ACM to quickly re-configure and push changes to the project.  
• FactoryTalk View SE: DMC selected FactoryTalk View Site Edition (SE) as the HMI platform for the facility. When used in tandem with the PlantPAx library, FactoryTalk View allows for rapid development of facility overview screens, since faceplates for each PlantPAx process object come pre-configured. The ability to quickly adapt screens and showcase the deep HMI feature set within the PlantPAx ecosystem gave our customers a high level of confidence in their new system throughout the design process.  

 Phase 3: Simulation and Testing  

• FactoryTalk Logix Echo: DMC employed FactoryTalk Logix Echo for emulating field devices and for advanced simulation of process pressures and flowrates. This allowed our development team to create a virtual environment that mimicked the real-life process behavior in the facility. Using simulation code running on Logix Echo, the team conducted extensive testing of our control strategies and sequence logic. We were even able to validate cross-platform communication to external software systems by connecting the simulated Logix Echo controller to FactoryTalk Linx Gateway’s OPC-UA driver.  
• Scenario Testing: Prior to field commissioning, DMC simulated various operational scenarios and validated system responses. This included normal operation, fault conditions, and emergency shutdown procedures. A wide range of test conditions and configurations was simulated, which helped identify the upper performance limits of the process system and decreased commissioning risk.  

Phase 4: Implementation and Commissioning  

• Staged Deployment: We coordinated with the end user team and external stakeholders to create a phased testing and acceptance plan, designed to ensure the system was functional at all levels of control—from individual devices, to process subsystems, to the entire facility.  
• Training and Support: We provided comprehensive training to the plant’s engineering and operations team on the new system, ensuring they were well-versed with the new features and functionalities. This included detailed operations and maintenance manuals on the system, a three-week structured onsite training course, and ongoing coordination meetings with the end users.  

Conclusion  

The successful implementation of the Rockwell PlantPAx P-Processors, Application Code Manager, and FactoryTalk Logix Echo for our client's flight test facility showcases DMC’s expertise in deploying advanced control systems. The project not only met the client's immediate needs but also positioned them for future growth and technological advancements. Our approach to leveraging modern tools and methodologies ensured a smooth roadmap to a fully mission-capable test facility and delivered substantial operational improvements over the legacy facility. 

Learn more about DMC’s Rockwell Programming expertise and contact us with any inquires.