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Reduce Cost, Size, and Weight

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1 Reduce Cost, Size, and Weight
Programmable Automation Controllers (PAC) Reduce Cost, Size, and Weight July 21, 2005 © 2005 Fairmount Automation, Inc. All Rights Reserved.

2 About Fairmount Automation
Founded in 1996 Located in Suburban Philadelphia, PA OEM of Programmable Automation Controllers Products Installed on Over 30% of U.S. Navy Fleet Leadership Role in Design and Development of Automated Damage Control Systems for DD(X) Product Development Engineering Services Andres and Gary founded the company in 1996 to respond to a U.S. Navy need to modernize aging pneumatic control systems. The NAVY knew that they needed to make the leap to microprocessor based controllers but had special requirements that could not be met by commercial device. Andres and Gary took on the challenge, and five months after starting demonstrated a working prototype to Navy engineers which was very well received. Within one year of that first order they were able to pay off their start-up debts and begin to draw a salary. We’ve been able to grow the business steadily since then while maintaining profitability and retaining 100% ownership. The company designs and manufactures control platforms, operates an application engineering and services group, and is very active in new technology development for to US NAVY We’re here today to discuss our hybrid controller technology and a unique and exciting new approach to hybrid control that we call Chameleon

3 DD(X) AFSS Designed and implemented leading-edge Autonomic Fire Suppression System (AFSS) Based on embedded smart-valve technology Distributed device-level control (LonTalk protocol) Successful Weapon Effect Test (WET) on ex-USS Peterson (first ever) Successful live-fire tests on ex-USS Shadwell Anticipate central role in DD(x) Flight I ADCS design Process improvement initiative underway to achieve CMMi Level 3 assessment (sponsored by Raytheon)

4 First Generation FAC-2000 MIL-SPEC Grade A Shock, MIL-SPEC Vibration
Programmable Digital Multi-Loop Controller User-Friendly, Hardened Integral Operator Interface Initially Installed in 1997 to Overhaul Legacy Controls Reactor Secondary Steam Plant Controls Catapult Accumulators Primary Boiler Controls Main Feed Pumps Distilling Plants Evaporators Five months after starting we demonstrated a working prototype to Navy engineers which was very well received, and within one year we were operating a successful business. Our first product…the FAC2000, initially installed in 1998, proved that we could deliver high performance control in a robust package that the NAVY needed We were soon replacing a vast array of legacy controls in applications including: Waste Heat Boilers Distilling Plants Steam Propulsion Propulsion Boilers USS John F Kennedy

5 Current Installed Base
Over 1500 Loops of Control Aircraft Carriers Amphibious Assault Amphibious Transport Destroyers Cruisers Frigates Combat Support Ships Submarine Supply Ships Although we’re relative new-comers to ISA and the industrial sector, we not new to the world of automation & control. Our products are currently being used in mission critical and severe applications through-out the US Navy. We currently have over 1500 loops of control installed and operational across the fleet Our equipment is used both to retrofit the existing Fleet and in new construction. We have equipment on nearly every ship class other than submarines. and nearly one in three surface ships uses a Fairmount Automation controller Most U.S. Navy ships have an expected service life of years. The same service period is expected of our equipment. In addition, we are currently working with one of the nations largest regional rail systems to retro-fit legacy rail car controls. USS Boone

6 Installed Applications
Propulsion Boilers Feed Pumps Distilling Plants Waste Heat Boilers Condensers Evaporators Oil and Fuel Heaters Steam Turbine Aux. Diesel Generator Aux. Force Draft Blowers Deaereating Feed Tanks Chilled Water Plants Catapult Accumulators Compressors Purifiers Shaft Speed Indication Our application experience comes from controlling a variety of machinery—primarily steam machinery— operating in the propulsion plants of Navy vessels. Namely power generation machinery and the machinery that drive the primary movers for the ship. Clearly these applications are mission-critical. One of the more common applications has been automatic boiler control, including combustion control, feed pump control, blowers and feed tanks. Another notable application is control of the steam accumulators in the catapult systems that launch aircraft from carrier flight. Again, the application is critical to the ship’s mission—the purpose of an aircraft carrier of course is to run flight operations. USS Ticonderoga

7 Chameleon: New Controller Platform
Point our the modular architecture Snap together modules Local HMI Hot Swap Active electronics on cover plate – optimal replacement unit

8 Key Characteristics MIL-SPEC qualified “out-of-the-box”
Eliminates need for costly, bulky, and heavy enclosures Distributed processor architecture enhances survivability Open connectivity to industry standard protocols and networks Flexible and modular architecture with versatile I/O suite Easy to assemble, install, and maintain Integrated user-interface with prominent displays and buttons Wireless device configuration and data retrieval


10 Chameleon PAC Installations

11 FFG-7 Class SSDG Aux. Control
Decentralized Control Architecture 5 Networked Chameleon Nodes 9 PCM-1, 6 NIM-1, 5 ACP-1 Installed on 10 Ships; Approved for Entire Class Control Loops Include Fuel Oil Transfer and Service Heaters Main Engine Lube Oil Purifier Heater, Start Air Cooler Main Engine Lube Oil Cooler, Lube Oil Pressure Hot Water Tank SSDG Waste Heat Temperature SSDG Jacket Water Temperature Networked to flat screen to provide plant-wide information and remote control USS Doyle

12 FFG-28 Installation Pictures

13 LHA-1 / LHD-1 Class SSTG Aux. Control
Decentralized Control Architecture 3 Networked Chameleon Nodes 5 PCM-1, 3 NIM-1, 3 ACP-1 Installed on 4 Ships; 2 more to begin in October Control Loops Include SSTG Hotwell Level SSTG Recirc Temperature SSTG Gland Seal Pressure Control Fully networked Plant-wide information accessible at any node via wireless infrared interface USS Peleliu

14 LHD-1 Installation Pictures

15 LPD-4 Class Chilled Water Control
Decentralized Control Architecture 5 Networked Chameleon Nodes 9 PCM-1, 5 NIM-1, 5 ACP-1, 2 UCM-2AMI Installed on 3 Ships Expanded system to be installed on LPD-9 in Q4 Control Loops Include Flow rate thru chiller pump with local A/M control Cooling water for condenser Monitor expansion tank level and pressure Monitor condenser outlet pressures Networked to flat screen to provide plant-wide information and remote control USS Cleveland

16 Automatic Burner Ignition System
Two Nodes (4 DAM-2, 2 PCM-1, 2 NIM-1, 2 ACP-1) Installed on USS IWO JIMA (LHD-7); LHD-2 next Burner light-off system for main propulsion boiler Monitors atomization pressure, windbox pressure, fuel-oil pressure, and port-use fan speed Controls burner fuel flow, ignition arm position, and ignition spark Coordinated control from burner front, EOS, or both Future expansion to include Full burner management system Integration with FAC2000-based Automatic Boiler Controls Fully automated throttle control from the bridge USS Iwo Jima

17 Manual Boiler Light-Off

18 Shaft-Speed Indication System
Two Nodes 2 PCM-1, 2 NIM-1, 6 ACP-1, 4 UCM-1, 2 NBM-1 Installed on USS PONCE (LPD-15); LCC-19 next Port and starboard shaft quadrature encoders inputs Calculates RPM and maintains shaft revolution count Provides redundant power supplies for remote RPM displays Interfaces with external display using NMEA protocol Implemented with our user-defined ASCII messaging Applicable to every ship in the Fleet USS Ponce

19 LPD-15 Installation Picture

20 Key Characteristics: Packaging
MIL-SPEC qualified “out-of-the-box” High Impact Shock: MIL-STD-901D (Grade A, Class I) Mechanical Vibration: MIL-STD-167B Electro-Magnetic Interference: MIL-STD-461E (Pending) Power Spikes: MIL-STD-1399 Designed for shipboard environments Operating Ambient Temperature Range: -40°C to 65°C Keypad & Housing: NEMA 4X, 6, and 13 Eliminates need for costly, bulky, and heavy enclosures Easy to assemble, install, and maintain Integrated user-interface with prominent displays and buttons

21 Key Characteristics: Packaging

22 Key Characteristics: Modular Design
Multi-Processor architecture enhances survivability Each module is self-contained controller Deterministic performance (sub 10ms) Facilitates future technology insertion Open connectivity to standard protocols and networks Versatile I/O suite All modules are hot-swappable Highly granular redundancy I/O connections Control execution Power sources Network connections

23 Key Characteristics: Modular Design

24 Key Characteristics: Design Flexibility
Local controller for OEM equipment Strainers Chillers Pumps Generators Valves Remote I/O drop Connectivity to central PLC Potential integration with Smart Carrier program Decentralized and highly-survivable ship-wide machinery control and monitoring system

25 MCMS Conventional I/O Drop
Enclosure to House PLC or VME-based control hardware Din-rail mounted terminal points Power supplies / conditioners Network media converters Assume 24” x 24” x 8.5” Require shock mounts Coily mounts C-Worthy mounts (adds 5.5” to depth) Angle spot weld studs mount to ship (adds 2” to depth) Signal densities I/O points typical, approximately 160 maximum Assume 100 points per enclosure for this example Total weight 140 lbs typical (including mounts) Assume 90 lbs per enclosure is achieved for this example

26 MCMS Chameleon I/O Drop
Integrated Package All power supply, media converters, terminal points, etc. Sample I/O drop configuration 2 power modules, 2 network modules, 8 I/O modules Dimensions: 24” x 24” x 6.5” Chameleon node 3-row mounting bars Angle or studs connect bars to ship Signal density 96 to 144 I/O points with currently available modules Assume 100 points on average for this example Total weight: lbs Chameleon nodes 20 lbs, Mounting bars 10.5 lbs, Other 10 lbs

27 MCMS Chameleon Mini-I/O Drop
Integrated Package All power supply, media converters, terminal points, etc. Sample mini-I/O drop configuration 1 power module, 1 network module, 2 I/O modules Dimensions: 16.5” x 11.5” x 6.5” Chameleon node 2-row mounting bars Angle or studs connect bars to ship Signal density 24, 30, or 36 I/O points with currently available modules Assume 25 points on average for this example Total weight: 16 lbs Chameleon node 7.5 lbs, Mounting bars 3.5 lbs, Other 5 lbs

28 CVN-21 MCMS I/O Drop Comparison
Assume example platform has 20,000 I/O points Conventional I/O Drop 200 drops required Volume: ft3 per drop, 1,067 ft3 total Weight: 90 lbs per drop, 18,000 lbs total Cost Estimate (Avg.): $25,000 per drop, $5.0MM total Chameleon I/O Drop Volume: 2.17 ft3 per drop, 433 ft3 total Weight: 40 lbs per drop, 8,100 lbs total Cost Estimate (Avg.): $15,500 per drop, $3.1MM total Chameleon mini-I/O Drop 800 drops required Volume: ft3 per drop, 571 ft3 total Weight: 16 lbs per drop, 12,800 lbs total Estimated Cost: $4,500 per drop, $3.6MM total

29 CVN-21 MCMS Example Plant
Example plant layout for I/O drop 100 points of I/O Ten pieces of machinery 100ft x 100ft plant All cabling runs to I/O drop Mix of analog and digital cables Assumed cable weights of 0.075lbs/ft and 0.1lbs/ft Estimated cable weight: 269lbs

30 CVN-21 MCMS Example Plant
Example plant layout for Mini I/O drop 100 points of I/O (4 mini drops) Ten pieces of machinery 100ft x 100ft plant Network cable runs to Mini I/O drops Assumed average power source within 25ft Assumed average I/O length is 28ft Assumed CAT5e network cable weight 0.065lbs/ft (LSC5OSW-4) Assumed I/O and power wire weights of between 0.075lbs/ft and 0.1lbs/ft Estimated cable weight: 85lbs

31 CVN-21 MCMS Mini I/O Benefits
Assume example platform has 200 plants similar to example plant (i.e. 20,000 points of I/O on platform) Total Weight Comparison I/O drop weight Cable: 53,800 lbs I/O Drops: 18,000 lbs Total: 71,800 lbs Mini I/O drop weight Cable: 17,000 lbs Mini I/O Drops: 12,800 lbs Total: 29,800 lbs Weight Savings: 42,000 lbs (over 18 tons or the 1.4 times the weight of one empty F/A-18F jet fighter!)

32 CVN-21 MCMS Mini I/O Benefits
Significant cabling reduction Cable cost savings Installation labor cost savings Design engineering cost savings (simplified drawings) Weight savings: 42,000 lbs Simplified troubleshooting Easier to isolate wiring problems Can operate systems in isolation Don’t need to bring up all systems at once Improved survivability Move towards decentralizing control Heartbeat control Mode shedding

33 Chameleon Modules AC Power Module (ACP-1, ACP-1PA)
DC Power Module (DCP-1) Process Control Module (PCM-1) Discrete Automation Module (DAM-1, DAM-2) Network Interface Modules (NIM-1, NIM-3, NIM-4, NIM-6) RS-485, RS-422, RS-232 Modbus LonTalk FairNET User-defined ASCII / Binary messaging User Configurable Modules (UCM-1, UCM-2, UCM-2NB, UCM-2AMI)

34 AC/DC Power Modules Single or Multi Power Source
Redundant Power with Automatic Switch-over Rugged packaging Spike Tolerance per MIL-STD 1399 Over-current Shut-off Input Circuit Fused ACP-1PA Standalone Power Source

35 Process Control Module (PCM-1)
Process and Motion Control Four Analog Inputs Current, Voltage, Resistance, RTD Four Analog Outputs Current, Voltage Two Digital Inputs On/Off, pulse counting Frequency meter, event timing Pulse width, quadrature decoding Two Digital Outputs On/Off, PWM, square-wave generator Four 4-digit numeric displays Eight 3-color LED indicators

36 Discrete Automation Module (DAM-2)
Discrete logic, sequence, batch Ten Digital Inputs Broad range of AC or DC signals Configured in software Eight Digital Outputs AC or DC Individually Soft-Configured Hybrid Mechanical / Solid-State Relays Dramatically improved endurance Drastically reduce conducted and radiated EMI produced when switching inductive loads by maintaining zero voltage crossing turn on and zero current crossing turn off Four Push-Buttons Eight 3-color LED indicators

37 Network Interface Modules
Network Media Available Today: NIM-1: RS-485, NIM-3: RS-422 NIM-4: RS-232, NIM-6: TP/FT10 Network Protocols Available Today: Modbus (Master/Slave, RTU/ASCII) LonTalk FairNET (FAC2000 Integration) OPC Server (ICAS Integration) Custom ASCII / Binary Protocols NMEA Implementation Adaptable to custom TCP/IP messaging Currently In Development NIM-2: Ethernet w/ 6-Port Switch NIM-5: Ethernet (TCP/IP, Ethernet/IP) NIM-7: ProfiBUS DP (Master/Slave)

38 User-Configurable Modules (UCM-X)
Custom modules with buttons, displays, etc. Use as junction box Available in full or half size

39 Development Roadmap Networking Modules in Development:
NIM-2: Ethernet with built-in 6-Port Switch NIM-5: Ethernet (support TCP/IP, Ethernet/IP, ProfiNET) NIM-7: ProfiBUS DP (Master/Slave) NRM-1: Multi-port RS-485 Repeater Module Wireless Access Point Module Joint Development Program with 3e Technologies (SBIR) FIPS Certified Wireless Security a/b/g, Zigbee Continue to Expand I/O Module Offering Touch-Screen Interface Module Motor Drive Module Battery Backup Module Direct connectivity to TSCE (DDS Protocol) Integrate C/C++ Programming with Function Blocks Plant-wide Configuration Management

40 PAC Programming: Design Pad G3
Easy to Use Graphical Programming Intuitive Function Block Diagrams Requires Little or No Training State-Transition Diagrams Clear and Concise Method of Programming Reduced Program Size and Complexity Organizes Complex Control into Easy to Program Nuggets Eliminates Multiple Use of Interlocks and Transition Logic Typical Using Ladder Logic Integrated Simulation Platform All signal values continuously displayed during simulation run Simplifies Diagnostics and Check-out by Highlighting Active States Wireless Device Configuration Chameleon’s distributed processor architecture enables high speed control execution even with complex control schemas. It’s capable of executing loop and logic control in the sub 10 millisecond range, enabling it to provide high performance control for a broad range of applications. Fast control response allows you to operate more safely closer to process limits, while providing tighter control. This means that you may be able to increase productivity and at the same time produce a higher quality product. It seamlessly integrates loop, logic and state control, and uses variables with user defined tag names for ease of programming and diagnostics. There are no compromises or limits to your ability to merge loop and logic control on one high performance package, and we provide programming and simulation tools such as state diagrams that are specifically designed to make the integration of loop and logic simple and easy to use

41 Design Pad G3 Demonstration

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