DM08 – FactoryTalk Historian Site Edition

Advanced Lab 2

Advanced use of ProcessBook

Presenter: Stephen Anderson

Rockwell Software
DM08 – Lab2 — Historian SE Advanced Lab -
Advanced use of ProcessBook

Contents

About This Lab ............................................................................................................................................ 4

What You Will Accomplish In This Lab ......................................................................................................... 4

Who Should Complete This Lab ................................................................................................................... 5

Lab Format.................................................................................................................................................... 5

Lab Materials................................................................................................................................................. 6

Software ........................................................................................................................................................ 6

Tools and prerequisites................................................................................................................................. 7

Communications Overview: .......................................................................................................................... 7

Document Conventions................................................................................................................................. 8

Before You Begin .......................................................................................................................................... 8

Section 1: Using ProcessBook Datasets.................................................................................................. 9

About This Section ........................................................................................................................................ 9

Exercise...................................................................................................................................................... 10

Section 2: ProcessBook Relative Displays ............................................................................................ 23

About This Section ...................................................................................................................................... 23

Exercise...................................................................................................................................................... 24

Section 3: SQC Charting in ProcessBook .............................................................................................. 37

About This Section ...................................................................................................................................... 37

Exercise...................................................................................................................................................... 38

This concludes the lab ............................................................................................................................. 55

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Welcome to FactoryTalk Historian Advanced Lab

About This Lab

Welcome to the FactoryTalk Historian Advanced Lab! This session provides you with an opportunity to
explore more advanced features of the new FactoryTalk Historian Site Edition. The following sections explain
what you’ll be doing in this lab session, and what you will need to do to complete the hands-on exercises.

FactoryTalk Historian Site Edition is a solution for optimizing your manufacturing process through the analysis
of historical data. Historian provides the capability to collect, store, analyze, and visualize data using a
powerful capturing engine and a powerful set of reporting tools (such as time-series trends, bar chart, pie
chart, and tabular) and easily generate reports using Microsoft Excel.

What You Will Accomplish In This Lab

As you complete the exercises in this hands-on session, you will:

• understand Historian’s capabilities for Analysis and Reporting

o Including extensive use of Historian clients: ProcessBook and DataLink
• understand the System Management functions of the system
• be introduced to Event Framing and Batch anaysis
• be familiar with Historian’s Data Access Components and how to use those for reporting with
Microsoft Reporting Services

When using Historian you will see references to OSIsoft PI. FactoryTalk Historian is built on OSIsoft PI
technology, based on a joint development and licensing relationship between Rockwell Automation and
OSIsoft. Some of the more advanced tasks in FactoryTalk Historian will have to be performed using the
OSIsoft PI tools such as SMT (PI System Management Tool), ICU (PI Interface Configuration Utility) etc.

This lab uses a combined FactoryTalk View SE and FactoryTalk Batch project called Instant Soap which
simulates a Soap manufacturing process. The plant has several work cells generating data that will be
collected by Historian for use in your production reports.

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Who Should Complete This Lab

This hands-on lab is intended for individuals who:

ƒ controls engineers who want to understand how to configure Historians and Time series data collection.
ƒ system integrators who need to learn about the new Historian and how to apply it to an integrated
offering including Data Management.

Lab Format

This lab is a “pick and choose” lab, with six (6) different lab to choose from. Each lab will take about 30 min to
one hour, so it is not the expectation that you will finish all six labs. You will be able to take these labs material
with you after the lab, for further learning later.

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Lab Materials
For this Hands-On lab, we have provided you with the following materials that will allow you to complete
the labs in this workbook.

Software
This hands-on lab uses the following software:
ƒ Microsoft Windows Server 2003 SP2
ƒ Microsoft Internet Explorer 7.0
ƒ FactoryTalk Historian Site Edition 2.1
ƒ FactoryTalk Historian ProcessBook.
ƒ FactoryTalk Historian DataLink
ƒ FactoryTalk Historian BatchView Add-in
ƒ FactoryTalk Historian SQC Add-in
ƒ FactoryTalk Historian ActiveView
ƒ FactoryTalk Administration Console 2.10 (CPR9)
ƒ A modified InstantSoap Logix 5000 project.
ƒ FactoryTalk View Site Edition 5.0 (CPR9)
ƒ Microsoft Office 2003 (Excel 2003)
ƒ Activation licenses for appropriate software
ƒ SoftLogix v16

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Tools and prerequisites

ƒ One (1) “host” computer with VMware virtualization software will host 2 “guest” operating systems for a
total of 2 virtual computers in a workgroup named “FTHDEMO”. The VMware images are named as
follows:
1. “VM-DATA”: A Windows 2003 Server computer to act as a FactoryTalk Directory and
FactoryTalk View Site Edition HMI Server and Client. Internet Information Server (IIS) and the
necessary Rockwell Software has been pre-installed (and activated) for you.
2. “VM-HIST”: A Windows 2003 Server computer to act as the server for FactoryTalk Historian SE,
and to host the clients: Configuration Clietns, ProcessBook, and DataLink clients.

Learning Point: We are not participating in the RSTechEd Windows Domain during this lab. While a
Windows Domain is recommended for use with FactoryTalk View SE, it is not required for 10 computers or
less. A Windows Domain is also not required to use Terminal Services. We are using VMware’s “Host Only”
networking environment to create a virtual Ethernet limited to your PC.

Communications Overview:
Host PC

Virtual Ethernet

TCP/IP Protocols
(numerous ports)

VM-DATA VM-HIST
(FTSP & View SE Server) (FT Historian SE and Clients)

The 2 VMware guest images use the following pre-existing user account:
o Administrative User:
o Username: Administrator Password: rockwell
o Desktop Background: RSTechEd08

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Document Conventions
Throughout this workbook, we have used the following conventions to help guide you through the lab
materials.
This style or symbol: Indicates:
Words shown in bold italics (e.g., Any item or button that you must click on, or a menu name from
RSLogix 5000 or OK) which you must choose an option or command. This will be an
actual name of an item that you see on your screen or in an
example.
Words shown in bold italics, An item that you must type in the specified field. This is information
enclosed in single quotes (e.g., that you must supply based on your application (e.g., a variable).
'Controller1')
Note: When you type the text in the field, remember that you do
not need to type the quotes; simply type the words that are
contained within them (e.g., Controller1).
The text that appears inside of a gray box is supplemental
“Learning Point”. The text is intended to emphasize certain key
concepts about using the product.

Note: If the mouse button is not specified in the text, you should click on the left mouse button.

Before You Begin

The following steps must be completed before starting the lab exercise:

1. Start the VMWare image(s) for the Lab 5.

2. At the login screen, log on with the following credentials:

a. Username: Administrator

b. Password: rockwell

Password all lowercase

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Section 1: Using ProcessBook Datasets

About This Section

FactroyTalk Historian ProcessBook data sets provide a means of producing locally calculated data. Data sets
can perform flexible calculations on dynamic data which can be trended or displayed like any other historian
data point. The calculations are local to the ProcessBook workbook and provide an ideal place to prototype
calculations which once finalized can later be moved to server side calculation mechanisms like performance
equations.

In this section you will:

ƒ How to use ProcessBook’s data sets to produce values and trends based on locally calculated data.

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Exercise

1. Verify that you are on the VM-HIST image by checking the hostname on the background image:

2. Launch ProcessBook:

3. Click on the “New” toolbar button:

4. Select new “ProcessBook Display (.pdi) File”, set the “Display Name” to “Test”, and click
the “OK” button:

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5. Select the “Data Sets…” command on the “Tools” menu:

6. In the “Data Sets” dialog, click on the “New” button and choose the “PI Calculation” sub-type:

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7. Set the data set “Name” to “LEVEL” and the “Description” to “Tank Level”. Set the “Tag or
Expression” to the tag “SINUSOID” and the “Interval” to “1h” then click the “OK” button:

8. Close the “Data Sets” dialog by clicking the “Close” button:

9. Change to build mode by selecting the “Build” button on the toolbar:

10. Select the “Trend” button on the toolbar:

11. Drag a box in some empty space to create a trend:

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12. Use the drop-down to the right of the “Tag Search…” button to select a “PI Calculation”:

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13. First, select “LEVEL” from the “Datasets” list. Next, select from the “Columns” the “Average”, “Minimum”,
and “Maximum” columns. Finally, click the “OK” button:

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14. Change the “Start Time” to “*-12 Hour” and then click the “OK” button:

15. Examine the effect of the data set calculations on the SINUSOID tag. Notice how the summary
calculations that we selected are performed on an hourly basis as configured by the “Interval” setting:

16. We will now explore using Data Sets to perform custom calculations. Use the “Open” icon on the toolbar
to open the file “Ex12 – Data Sets.PDI” located in the class files folder:

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17. Again, select the “Data Sets…” entry on the “Tools” menu:

18. Notice that the “Data Sets” dialog is again empty. This is because the data sets we previously created
are local to the file in which they were created. Click on the “New” button and choose the “PI
Calculation” sub-type:

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19. On the “PI Calculation Data” dialog, set the following values:
o Name: PRODUCTA
o Description: % Product A
o Tag or Expression: ‘CDT158’ * 100 / (‘CDT158’ + ‘BA:TEMP.1’)
o Column Label: % Product A

20. Back in the “Data Sets” dialog, click on the “Close” button:

21. Change to build mode by selecting the “Build” button on the toolbar:

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22. Click on the “Value” toolbar button:

23. Use the “Value” tool and click on the area beneath the “% Product A” label:

24. Select “PI Calculation” from the drop-down to the right of the “Tag Search…” button:

25. Select “PRODUCTA” from the “Datasets” list. Next select “% Product A” from the “Columns” list.
Finally, click the “OK” button:

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26. Click the “OK” button:

27. Notice that the tank outlet now displays the current percentage of “Product A”:

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28. With the “Build” cursor selected, double-click on the empty “Plot-0”:

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29. Select “PI Calculation” from the drop-down to the right of the “Tag Search…” button:

30. Select “PRODUCTA” from the “Datasets” list. Next select “% Product A” from the “Columns” list.
Finally, click the “OK” button:

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31. Click the “OK” button:

32. Now you can enjoy a live updating trend of the calculated product A percentage:

33. Close ProcessBook. This exercise has been completed.

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Section 2: ProcessBook Relative Displays

About This Section

Using Module Contexts from the Module Database we are able configure ProcessBook displays against
properties and aliases of units. Once these displays are associated with one or more module units, the
display will automatically populate with data from the chosen context.

In this section you will:

ƒ How to use contexts from the Module Database to build single ProcessBook displays which can apply to
multiple units..

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Exercise

1. Verify that you are on the VM-HIST image by checking the hostname on the background image:

2. Launch Excel 2003:

3. Click the “Open” toolbar button and open the file “Ex15 - PB Rel Display Setup.xls” located in
the class files folder (ask instructor for exact location):

4. If you are presented with a macro security warning, simply click the “OK” button:

5. Verify that you are on “Sheet2” of the workbook:

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6. Select the “Export Items…” entry on the “Module Database Builder” sub-menu of the “PI-SMT”
menu. Be careful to not use the “Export Tags…” entry on the “PI-SMT” menu.

7. First expand the tree and click on the “Modules” entry to select it. Next, change the “Mode” to “Create”.
Finally, click the “OK” button:

8. Verify that the only errors produced are “-12001”. These can be ignored for this exercise. Click the “OK”
button:

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9. Close Excel and launch the System Management Tools (SMT):

10. Under the “Operation” category, select the “Module Database” plug-in:

11. Expand the “Modules” tree and verify that the “Aliases” and “Properties” for “Reactor 1” and
“Reactor 2” were properly created:

12. Close the SMT and launch ProcessBook:

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13. Click on the “New” toolbar button:

14. Select a “Type” of “ProcessBook Display (.pdi) File”, set the “Display Name” to “Test”
and click the “OK” button:

15. Make sure that you are in “Build” mode and select the “Symbol Library” toolbar button:

16. Drag a box in some empty space and then select a tank from the symbol library:

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17. On the “Tools” menu, select the “Add Module…” entry on the “Module Context” sub-menu:

18. Use ctrl-clicks to select both “Reactor 1” and “Reactor 2”. Next click the “>” button to add them both
to the “Selected Modules” list. Finally click the “OK” button:

19. Click the “Value” toolbar button:

20. Click on the background to the right of the tank to initiate the dynamic value dialog:

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21. In the “Format” options, select a display location of “Top” for the “Tag” attribute. Next, select the
“Module Context” entry from the drop-down to the right of the “Tag Search…” button:

22. From the “Properties” category, select the “Height” entry. Next, click the “>” button. Finally, click
the “OK” button:

23. Click the “OK” button:

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24. Repeat steps 19 through 23 to add the “Radius” property and the “Level”, “Concentration”, and
“Temperature” aliases:

25. Click the “Bar” toolbar button and then drag a rectangle over the tank:

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26. Select “Module Context” from the drop-down to the right of the “Tag Search…” button:

27. Click on the “Level” alias, then the “>” button, and finally the “OK” button:

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28. Click the “OK” button:

29. Click on the “Value” toolbar button and then click on the background below the tank:

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30. In the “Format” options, select a display location of “(None)” for the “Tag” attribute. Next, select the
“Module Context” entry from the drop-down to the right of the “Tag Search…” button:

31. Select the “Current Context” checkbox and then click the “OK” button:

32. Click the “OK” button:

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33. Select the “Trend” toolbar button and drag a rectangle on the background below the tank:

34. Select the “Module Context” entry from the drop-down to the right of the “Tag Search…” button:

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35. Click on the “Teperature” alias, then the “>” button, and finally the “OK” button:

36. Change the “Start” time to “*-1 Hour” and then click the “OK” button:

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37. Change back to “Run” mode and try changing the active context to “Reactor 2”:

38. After you have finished exploring your module relative display, close ProcessBook. This exercise has
been completed.

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Section 3: SQC Charting in ProcessBook

About This Section

The PI SQC add-in for ProcessBook provides a client side SQC mechanism for FactoryTalk Historian. With
the add-in, users can flexibly configure SQC control charts. These charts can have advanced filtering,
perform SQC statistical calculations, and even check data points against SQC alarm conditions. A similar
add-on module, RtSQC, performs the same functionality server side and will be covered in the advanced
class.

In this section you will:

ƒ How to use the PI SQC add-in to configure control charts in ProcessBook and perform common SQC
calculations.

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Exercise

1. Verify that you are on the VM-HIST image by checking the hostname on the background image:

2. Launch Excel 2003:

3. Click the “Open” toolbar button and open the file “Ex16 - ProcessBook SQC Setup.xls” located in
the class files folder (ask instructor for exact location):

4. Choose the “Export Tags…” entry on the “PI-SMT” menu:

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5. On the “Export PI Tags” dialog, verify that the “Mode” is set to “Create” and then click the “OK”
button:

6. Acknowledge the results dialog by clicking the “OK” button:

7. Close Excel

8. Launch ProcessBook:

9. Use the “Open” icon on the toolbar to open the file “Ex16a – SQC.PDI” located in the class files folder:

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10. Verify that you are in “Run” mode and then explore the interactive SQC chart:

11. Drag a rectangle on the data plot to zoom in to the selected area:

12. Click the “Revert Time Ranges” toolbar button to undo the zoom:

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13. Double-click on the chart control to maximize it. Double-click on it again to return it to its original size and
location:

14. Use the “One Time Period Back” and “One Time Period Forward” toolbar buttons to scroll
through the data:

15. Use the “Scroll Time” bar to free scroll through the data:

16. Use the set time range button to look at a specific period of data:

17. Set the time span from “*-4 Hour” to “*” and click the “OK” button:

18. Use the “Trend Cursor” to explore the data values:

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19. Double-click on the “Exercise 1: [Individuals]” title bar to bring up the “Statistics Window”:

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20. Examine the various statistics and information available, eventually selecting the “Plot Data” option
and click on the “Save Data To File” button:

21. Save the data as “sqcdata.txt” in the “My Documents” folder:

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22. Close the “Statistics Window” and open the “sqcdata.txt” file in Notepad:

23. When you are done examining the available statistics, close Notepad and close the ProcessBook display
file.

24. Click on the “New” toolbar button:

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25. Select new “ProcessBook Display (.pdi) File”, set the “Display Name” to “Ex16 - XBar”,
and click the “OK” button:

26. Switch to “Build” mode and then click on the “SQC Chart” toolbar button:

27. Drag a rectangle on the background to create an “SQC Chart”:

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28. On the “General” tab, set the following fields (and click “OK”):
o Chart Title: X-Bar Control Chart
o Chart Type: X - Bar
o Chart Tag: stationary1

29. Click the “Save” toolbar button:

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30. Click the “Save” button:

31. Take some time to explore your recently created SQC chart. When you are ready, use the “Save As…”
command on the “File” menu:

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32. Set the new name to “Ex16 – Moving Avg.PDI” and then click the “Save” button:

33. Double-click the chart to return to the configuration dialog:

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34. On the “General” tab, set the “Chart Title” to “Moving Avg Control Chart”. Next change the
“Chart Type” to “Moving Average”. Finally click on the “Sample” tab:

35. On the “Sample” tab, set the “Sample Size” to “5” and then click “OK” button:

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36. Click the “Save” toolbar button:

37. Take some time to play with the SQC chart. When you are done, close the current PDI and then reopen
the “Ex16 – XBar.PDI” file:

38. Use the “Save As…” command on the “File” menu:

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39. Set the new name to “Ex16 – XBar Time Sampled.PDI” and then click the “Save” button:

40. Double-click the chart to return to the configuration dialog:

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41. We want to change the sampling algorithm. We want to take two samples every ten minutes starting on 5
and 6 minutes after the hour. On the “Sample” tab, change the “Calculation Basis” to “Time”. Set
the “Calculation Period” to “00:10:00”. Set the “Sample Period” to “00:01:00”. Set the
“Start Time of Sample” to “00:05:00”. Finally click the “OK” button:

42. Click the “Save” button on the toolbar:

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43. Take some time to play with the SQC chart. When you are done, close the current PDI and then open
the file “Ex16b – SQC.PDI” located in the class files folder:

44. Double-click the chart to return to the configuration dialog:

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45. On the “Sample” tab, use the “Tag Search…” button to select the “stationary3_filter” tag and set
the “Filter Equation” to : ‘stationary3_filter’ = 1

Then click the “Check Syntax” button:

46. Click “OK” to acknowledge that the filter equation is correct. Then, click “OK” to close the “PI-SQC Chart
Definition” dialog:

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47. Change to “Run” mode and use a “Trend Cursor” to verify that now values greater than 31.9 or less
than 29.1 appear in the SQC Chart anymore:

48. Save the file and then close ProcessBook. This short exercise has been completed.

This concludes the lab

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