DCS Worldwide Profiles 09

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Distributed Control Systems Worldwide Outlook • Supplier Profiles

Copyright 2009 © ARC Advisory Group • ARCweb.com • For Internal Use Only • 5-1

Chapter 5

Supplier Profiles

The following pages provide profiles of the leading DCS suppliers world-wide. These profiles analyze the total business of each company as well as

the DCS-related portion. Information is provided regarding current model

numbers, associated components, communication protocols, and system-

level offerings. We‟ve also provided information on served markets and

alliances where appropriate. ARC derived this information from company

annual reports and in-depth discussions with senior company officials.


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5-2 • Copyright 2009 © ARC Advisory Group• ARCweb.com • For Internal Use Only

ABB

http://www.abb.com

DCS OfferingsSystem 800xA, Freelance 800F are current offerings. Prior generation sys-

tems include Symphony (Harmony and Melody); INFI 90; Contronic;

Master; MOD 300; Freelance 2000; SattLine; DCI System Six.

Regions

North America; Europe, Middle East & Africa; Asia; China; Latin America;

India

Description

Central to ABB‟s automation offerings is IndustrialIT. In ABB‟s view, the

primary market drivers behind the implementation of automation today

are increased productivity and flexibility, reduced lifecycle costs, safe-

guarding investments, energy efficiency and environmental and safety

management. These are also the primary drivers behind the IndustrialIT

philosophy.

Industrial IT is ABB‟s architecture for collaborative process automation. At

the core of all Industrial IT solutions is the System 800xA Extended Auto-

mation control system. Extending the core of System 800xA hardware andapplications are ABB and third party products that have been tested and

certified (Industrial IT Enabled) to verify proper operation with an 800xA

system.

A powerful object-oriented technology, called Aspect Objects, underlies all

of the Industrial IT offerings and resides at the core of System 800xA. Put

simply, Aspect Objects allows users to view any aspect of the automation

scheme, from a pump or a valve to a process unit or pressure transmitter, as

a software object. Each object in the system has a number of attached as-

pects that can range from integration to computerized maintenancemanagement systems (CMMS) and enterprise asset management (EAM)

systems to schematic drawings and trending information. Aspect Objects

provides the key real-time linkage between equipment and applications.

System 800xA provides these functions with a single window environment

for context-sensitive information access and navigation, and builds on a

http://www.abc.com/http://www.abc.com/


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common environment for engineering, operations, information manage-

ment, and asset optimization. System 800xA also provides a common

operator environment for ABB‟s entire portfolio of safety and process con-

trol systems, providing access to information across the enterprise as well

as context-sensitive decision and action tools that allow the right users

access to the right information at the right time from any point within the

system.

A key strength of System 800xA is its ability to extend its reach beyond the

traditional functions of the DCS to include functions such as collaborative

production management, safety and critical control, advanced control, in-

formation management, smart instrumentation, smart drives and motor

control centers, asset management, enterprise connectivity and documenta-

tion management capabilities. System 800xA was built from the ground up

as an integration platform and its architecture, together with the AspectObject technology, provides the foundation for integrating ABB and third-

party hardware and software.

In early 2009, ABB released the latest version of its Industrial IT Extended

Automation System 800xA with SIL3 integrated safety. This latest release

completes ABB‟s portfolio of SIL-certified safety systems and provides a

diverse architecture that supports both dual and quad configurations.


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In addition to SIL3, ABB also released its IEC61850 communication module

supporting the IEC61850 standard for communications with medium and

high voltage switchgear and protection equipment. This enables ABB to

deliver a seamlessly integrated automation and electrical solutions provid-

ing interoperability between IEDs (intelligent electrical devices) and thus

reducing operational and engineering costs. Today, ABB can integrate the

process control, process electrification, and power distribution and man-

agement portions of a plant with System 800xA, so information is available

to all areas. The IEC61850 standard is a key component of their strategy.

This strategy is particularly interesting to industries that are heavy electric-

al users such as oil & gas, utilities, pulp & paper, and metals that view

electricity as a raw material.

ABB has also released a more powerful AC800M controller, which provides

significant CPU performance and software execution improvements. Thiswill enable System 800xA to deliver improved productivity with less cost

and in a smaller footprint. Process Graphics II was also released in 2008

and provides a significant boost in engineering efficiency through the addi-

tion of standard Microsoft WPF features and increased run-time

performance.

New AC800M function code libraries for the Harmony and MOD300 sys-

tems enables ABB to provide an evolution path to System 800xA controllers

as well as operator graphics. With the release of the new control libraries,

any Harmony of MOD300 system can be expanded using AC800M control-lers while preserving familiar control configuration, faceplates and alarms.

All of these features are designed to increase flexibility and efficiency while

reducing the risk of unnecessary downtime and providing cost efficiencies.

This is consistent with ABB's approach of equating Industrial IT and 800xA

to key end user business value propositions, specifically reduction of total

cost of ownership, increasing productivity, and reducing risk/enhancing

security. The ability to evolve the installed based to the most current Sys-

tem 800xA offering enables ABB to support their customers throughout the

product lifecycle while making new features and applications available tousers of any ABB system. This is a key factor in helping reduce risk and

increase productivity in today‟s plants.

Industrial IT Enabled Applications

In addition to ABB‟s new System 800xA features, several integrated appli-

cations have been Industrial IT Enabled over the past few years. These


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applications include ABB‟s cpmPlus Enterprise Connectivity, Matrikon‟s

AlarmInsight for System 800xA, Intergraph‟s Smart Plant Instrumentation,

and ABB‟s 800xA Evolution for Honeywell System Migration (HSM).

The cpmPlus Enterprise Connectivity solution (ECS) provides a stream-

lined, single point interface for vertical integration that is suitable forenterprises of all levels of complexity. ECS provides a unified framework

for dealing with transactional and event-driven systems in a common envi-

ronment. It provides a single, highly flexible and configurable interface,

which results in a higher degree of reliable information flowing between

manufacturing and business systems and lower engineering and interface

maintenance costs.

Matrikon‟s AlarmInsight for System 800xA provides a configurable inter-

face between Matrikon‟s ProcessGuard and ABB‟s System 800xA. This

integration allows 800xA users to view any ProcessGuard report or Alarm

MOCCA report, so users can access Alarm history, Alarm performance

KPIs and operator assistance documentation through their existing 800xA

displays. AlarmInsight provides context-sensitive access to any available

alarm information; turning data into actionable information.

The Intergraph Smart Plant Instrumentation (SPI) integration with System

800xA provides automatic configuration of the control system; updates to

the control system during design changes; documentation of control system

configuration; consistent as-built documentation during plant handover;and improved decision-making during critical maintenance and operations

events. The bi-directional synchronization between SPI and 800xA enables

efficient engineering and maintenance through the entire lifecycle of the

control system.

The 800xA Evolution for HSM connectivity package enables supervision

and operation of objects from a Honeywell TDC3000 from System 800xA. It

provides integrated alarm and events, standard 800xA graphical elements

and browsable OPC items. The single-window environment of 800xA pro-

vides visibility for all control data (from 800xA and TDC3000) to theoperator to ensure that the right information is provided in the right con-

text to support accurate decisions and actions.

800xA Controllers Receive Cyber Security Certification

In September of 2007, ABB announced that its System 800xA Extended Au-

tomation AC 800M controller achieved Mu Security‟s Industrial Control


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(MUSIC) Foundation-level Certification. MUSIC certification means that

AC 800M meets industry-defined best practices for safety, reliability, and

security. During the evaluation process, the AC 800M met or exceeded the

requirements of MUSIC‟s multi-faceted security and stress tests.

MUSIC Foundation and Advanced certifications both ensure critical infra-structure and process control-focused organizations verify a diverse range

of network equipment and application protocols to meet industry-defined

best practices for safety, reliability, and security testing. For the chemical

industry, this means that MUSIC Certification and product safety ben-

chmarking, using the Mu-4000 appliance, minimizes process control

product safety issues and minimizes costly downtime due to implementa-

tion flaws. The MUSIC program also provides a migration path to open

industrial control systems security specifications currently under develop-

ment by government and industry groups,including ISA Security Compliance Institute

(ISCI) and ISA SP99.

Earlier in 2007, ABB announced that the Sys-

tem 800xA Extended Automation AC 800M

controller achieved Achilles Controller Level 1

cyber security certification. Wurldtech Securi-

ty Technologies, a leading provider of security

products and services for the industrial auto-

mation industry, introduced its AchillesController Certification Program several years ago.

The Achilles testing process is rigorous. According to Wurldtech, the ma-

jority of controllers submitted failed Level 1 Certification testing, and a

substantial number have still not passed on retest. AC800M passed each of

the over 30 million individual tests required to achieve Achilles Level 1

Certification.

Wurldtech and its partners developed the Achilles Certification Program to

provide a benchmark for certifying secure industrial controllers. The certi-fication process presents device manufacturers with an independently

verified result from which to communicate their product security to cus-

tomers, while providing operators of control systems the most complete,

accurate, and trustworthy information currently possible on the security of

their deployed products. Achilles Level 1 Certification verifies the security,


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reliability, and robustness of a device's implementation of OSI layers 2 – 4,

including Ethernet, ARP, IP, ICMP, TCP, and UDP.

System 800xA AC 800M controller is one of the first controllers in the in-

dustry to have achieved both Foundation-level MUSIC and Achilles Level 1

security certification.

Automation Sentinel

In March of 2007, ABB announced the release of its Automation Sentinel

program for ABB control system software management. Designed to help

customers actively manage their lifecycle costs, Automation Sentinel ex-

tends support for, and the value of, existing ABB control software

investments. Automation Sentinel combines comprehensive technical and

online support with a planned evolution path to latest-generation functio-

nality for earlier control system software versions. When evolving to

System 800xA, program subscribers do not incur additional license fees for

upgrades to functional equivalent System 800xA software. Automation

Sentinel program subscribers automatically receive all available updates

and enhancements to their current System 800xA software. In addition,

they have the option to stay on that version for an extended period up to

seven years. The Automation Sentinel program provides not only software

updates, but also extended version support, comprehensive evolution

planning, on-line access to patches and downloads, and access to technical

specialists for software installation and troubleshooting support.

Load-Evaluate-Go as a Path to High Availability Control

The Load-Evaluate-Go feature sprang from ABB‟s relationship with Dow

and is a key requirement for Dow applications. Load-

Evaluate-Go enables users to modify, download, and eva-

luate a “revised” application without interfering with the

running or “current” application. The “revised” applica-

tion can then be put on line, further modified, or

discarded. Load-Evaluate-Go provides many end user

benefits in the area of reducing risk. Aside from reducing

the overall risk of unplanned downtime, Load-Evaluate-Go reduces the risk of applying erroneous application

changes to the process during application changes in run-

ning processes.

System 800xA supports on-line version upgrades. With

System 800xA AC800M controllers in a redundant configu-Load-Evaluate-Go Workflow


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ration, online upgrades of the controller‟s firmware is accomplished by

loading the new firmware into the backup controller, evaluating various

parameters, and then switching it to be the primary controller. The second,

now the backup controller, will then have its firmware upgraded and re-

dundancy will be re-established. This is particularly important in the

chemical industry, where process plants often have many process streams

plus a “common” for process services that never shuts down to facilitate

such upgrades.

System 800xA supports Load, Evaluate, Go for application modifications in

System 800xA. Load Evaluate Go allows you to “load” a modified control

application to System 800xA‟s AC800M controller without replacing the on-

line, running control application. Both application versions will then be

executed in parallel using the same controller inputs. However, only one

application's outputs will be used to control the process. With both appli-cations running in parallel, you can compare the two versions and

“evaluate” the new application using actual process inputs without inter-

fering with the on-line application. The evaluation is done by looking at

the “evaluation environment,” which shows key operating parameters,

alarms and events, and even graphics. After the evaluation is complete, the

user may choose to accept the new application as the online version, by se-

lecting the “Go” command, or reject the new application, which removes it

from the controller. For added security, “Administrate” permission is re-

quired to enable and use Load Evaluate Go sessions in addition to the re-

authentication features mentioned previously.

Freelance 800F System

ABB has also fully reintroduced the smaller Freelance control system to the

marketplace for North America and the rest of the world. Hartmann &

Braun originally developed Freelance to address the requirements of the

small- to medium-size applications in the hybrid industries, including fine

chemicals. It provides a good counterpart to the more highly scalable and

fully functional 800xA system. Freelance features a new HMI and a new

compact controller in the form of the 700 series. This latest version of Freel-

ance goes a long way toward addressing a very important segment of the

market for ABB.

Partnerships and Acquisitions

ABB recently made news in the oil & gas world when it signed an agree-

ment to acquire the business of Ber-Mac Electrical and Instrumentation Ltd.


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of Calgary, Canada. Ber-Mac specializes in industrial automation, electric-

al, instrumentation design, process optimization, panel fabrication, and

field services. It is particularly strong in the oil & gas industry. Established

in 1980, the company has enjoyed steady growth in recent years and earned

revenues of ca. $100 million in 2007.

Key Industries

Cement & Glass; Chemical; Chemical Fine; Chemical & Petrochemicals;

CPG; Electrical; Food & Beverage; Life Sciences; Metals; Mining; Oil & Gas;

Oil & Gas Pipelines; Oil & Gas Production; Oil & Gas Refining; Plastic &

Rubber; Pharmaceutical; Power; Power Generation; Power T & D; Printing

& Publishing; Pulp & Paper; Textiles; Water & Wastewater.

Strengths and Challenges

ABB‟s positioning of Industrial IT around the three primary domains of

reduced cost of ownership, increased productivity, and reduced risk is a

good fit with this increased focus on business value. ABB also has the ad-

vanced capabilities in products, services, and vertical industries to help end

users realize the business value and increased performance potential of au-

tomation. In terms of offering a high degree of functionality and a wide

array of advanced applications, ABB is very strong and has a lot to offer.

The future success of ABB depends largely on its ability to successfully

provide its customers with sustained and measurable benefits from auto-

mation that provide a path to continuous improvement for businessperformance and profitability.

In the realm of reduced cost of ownership, ABB has made great steps for-

ward evolving its installed base to the latest version of System 800xA,

providing performance improvements through its solutions for enhanced

OEE, and implementing an ISA 95-based approach to production manage-

ment and enterprise integration. No other supplier had been able to

rationalize such as large installed base of diverse process automation sys-

tems under a common framework as ABB. Preserving installed base will

remain perhaps the biggest ongoing challenge for ABB moving forward.

ABB‟s comprehensive lifecycle support policy is designed to protect cus-

tomer‟s intellectual investment beyond the lifecycle of the underlying

hardware and software platform products. The Automation Sentinel soft-

ware subscription service provides not only software updates, but extended

version support, comprehensive evolution planning, on-line access to


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patches and downloads, and access to technical support specialists for

software installation and troubleshooting support.

ABB‟s solutions for improving productivity are also formidable. As far as

providing information in context and enabling a knowledge workforce, the

800xA system is extremely powerful and strongly corresponds to the ARCcollaborative process automation system framework. The company also

provides an integrated approach to maintenance and plant asset manage-

ment that can provide true bottom line results by reducing maintenance

costs and eliminating unnecessary maintenance.

One of ABB‟s primary challenges, however, lies in making these solutions

easier to implement and to use for their customers. The high degree of

functionality offered by 800xA and Industrial IT and the wide range of asset

management services offered by the company also require a significant

component of implementation services, training, and vertical industry ex-

pertise, which ABB provides. A consultative selling approach is also

required where, ideally, ABB is involved from the front-end engineering

and design through project execution and the operational phase, which

ABB also provides and must continue to strengthen and sustain. ABB‟s has

leveraged their global project execution capability into a strong Main Au-

tomation Contractor (MAC) offering. This approach can deliver significant

savings during engineering and in overall project cost.

Integrated safety and high availability control are both key concerns for endusers today, and ABB is a leader in this regard with its 800xA High Integri-

ty platform. ABB also takes a leading approach to security with its Load-

Evaluate-Go functionality, audit trail, and other features. As with the com-

pany‟s other offerings, however, a sophisticated approach to security, high

availability control, and risk mitigation requires a sophisticated approach to

the end user in the form of a consultative sale and an ability to effectively

articulate the benefits. Industrial IT can help end users achieve a sustained

economic benefit from automation. ABB must continue to build on its ser-

vices and solutions expertise and increasingly focus on ease of use to help

end users realize that vision.


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Emerson Process Management

http://www.emersonprocess.com

DCS OfferingsDeltaV and Ovation are current offerings. Previous offerings include RS3;

PROVOX; WDPF II, RMV9000

Regions


India

Description

Emerson‟s Process Management business is organized around the four

main areas of Systems and Solutions, Asset Optimization, Measurement

and Analytical, and Final Control Elements. Emerson‟s Process Systems

and Solutions division includes their control systems platforms and global

product support services, project planning and execution and optimization

services. The Asset Optimization division includes the AMS Suite software

and comprehensive asset optimi-

zation services. The Measurement

and Analytical division includes

Rosemount, Micro Motion, Rose-

mount Analytical, Daniel, Mobrey,and Saab Rosemount. Final Con-

trol Elements includes the Fisher

Valves business, Fisher Regulators,

and Valve Automation.

Emerson utilizes industry stan-

dards like HART and Foundation

Fieldbus to integrate their intelli-

gent field devices, control platforms, and asset software into a digital plant

architecture, called PlantWeb. Emerson offers two primary digital automa-tion platforms: Ovation, targeted to the power and water market; and

DeltaV, targeted to the industrial process control market, including batch

applications.

DeltaV Architecture

http://www.emersonprocess.com/http://www.emersonprocess.com/


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DeltaV

Emerson originally introduced the DeltaV digital automation system for

small and hybrid market opportunities. More recently, however, the sys-

tem has fulfilled the promise of being fully scalable for large applications.

DeltaV system hardware consists of Intel processor-based PC workstations

running Windows Vista and/or XP and Windows Server software. The

controller features a 500-channel control module running on a Motorola

microprocessor, Foundation Fieldbus and HART protocol interfaces for

smart field devices, and modular plug-in I/O in a compact, field-mountable

package.

Version 7.4 of DeltaV was released at the beginning of 2005. This release

added a new engineering productivity tool with integration of the INtools

instrument design software from Intergraph. The DeltaV system and IN-

tools now share common data structures and seamlessly exchange datausing XML and Microsoft .NET technology. This enables the reuse of in-

strumentation information during instrumentation design, reducing

engineering effort and speeding up project execution. INtools has also been

enhanced to be "DeltaV-aware" and is embedded directly into the DeltaV

system. Intergraph has also been included as a partner in the Emerson

Process Management Alliance Program -- a global, business-to-business

network connecting third party suppliers and their products directly to the

Emerson sales and project execution channel for use with DeltaV projects.

DeltaV Version 7.4 also offers many fieldbus enhancements. The number ofVirtual Communications Relationships among Foundation Fieldbus devices

has been increased to 50, significantly increasing communications power

for customers who gain the ability to address more complex devices and

expand possibilities for more intricate control relationships. Enhancements

to DeltaV operations software also permit faster access to Foundation

Fieldbus parameters, enabling AMS Device Manager diagnostic screens to

populate data much faster. This reduces the time required for customers to

commission or troubleshoot fieldbus devices.

The DeltaV Continuous Historian stores the wealth of information availablein the intelligent field devices. The status of a parameter configured for his-

tory collection is automatically stored along with its value. Status and

value are visible through a new Excel based analysis and reporting tool.

The new release also includes an OPC Historical Data Access (OPC HDA)

server for use with the DeltaV Continuous Historian, enabling integration

of a variety of third party analysis tools.


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DeltaV Version 8.3, introduced in August 2005, marked the initial release of

DeltaV SIS, part of Emerson‟s smart SIS solution built upon PlantWeb tech-

nologies. These technologies provide continuous diagnostics and testing

across the complete safety instrumented function, including sensors and

final control elements. The DeltaV SIS system earned formal TÜV certifica-

tion in July 2005. The version 8.3 release also included remote I/O. System

security and maintenance throughout the lifecycle are enhanced by a confi-

gurable Guardian Portal dashboard website that provides automated, up-

to- date access to Knowledgebase Articles, Technical Support calls, and sys-

tem lifecycle details and customized semi-annual system analysis reports

outlining specific recommendations for system maintenance.

Emerson Process Management released version 8.4 of DeltaV system soft-

ware in 2006. Version 8.4 includes enhancements to help users prevent

abnormal situations. DeltaV digital automation systems are a core compo-nent of Emerson‟s open, standards-based PlantWeb digital plant

architecture.

With the new software release, standard HART device status information

can now be used by predictive diagnostics that generate PlantWeb Alerts.

The unique alerts are categorized and targeted to specific departments (Op-

erations, Maintenance, etc.) and provide specific guidance help users take

corrective actions that can head off abnormal situations in the plant. In an

additional enhancement, conditional alarming has been extended to

FOUNDATION fieldbus devices, enabling the devices to deliver criticalpredictive alarms for immediate attention by operations staff to avoid un-

planned downtime.

Key Enhancements to Version 10.3

Version 10.3 of the DeltaV system includes some key functional enhance-

ments, such as incorporation of the Microsoft Vista operating system and

larger DeltaV MX Controllers. Emerson also limits major revision releases

to every 18 months, and end users can count on there being only three revi-

sions to every major version release (which is why 10.3 will be the last

major revision of version 10 of DeltaV). Another strategy the company em-ploys is to keep service pack releases limited to hot fixes and updates.

Version 10.3 began shipments in late 2008. In addition to the Vista compa-

tibility, the larger DeltaV MX Controllers deliver 2.5 times the performance

and twice the memory of previous controllers. The new MX controllers are

primarily targeted at large continuous and batch applications and as a re-


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placement for PROVOX controllers with the same form factor as current

DeltaV controllers. The DeltaV workstation count also increases from 60 to

65.

Version 10.3 also includes a redundant Profibus DP card, which is a drop-in

replacement for the existing Profibus card and includes features such asautosense of redundant pairs, requires no added configuration, and fea-

tures a Profibus DP V1 pass-through. Version 10.3 also includes increased

secure communications bandwidth for DeltaV Safety Instrumented Systems

(SIS). New controller function blocks such as the DeltaV SIS, analog voter,

discrete voter, cause and effect matrix, state transition, and step sequencer

are also available in the 10.3 release.

DeltaV Smart Switch Provides Built In Security Features

The DeltaV Smart Switch is a major aspect of the 10.3 release and embodies

Emerson‟s strategy of driving increased ease-of-use into its products. Cy-

ber security is not normally something that would be equated with ease of

use, but the new switch, made in partnership with Hirschmann, has many

features that make security easier. This includes an “Auto Lockdown” port

security function that requires no configuration. This allows a user to au-

tomatically lock and unlock the port access of all the switches in the

network. This lockdown will disable all unused network connections

(ports) on the switch. One of the biggest security vulnerabilities in a control

system is that network devices, such as Ethernet-based network switches,

are located in unsecure locations out in the process and thus easily accessi-ble to everyone. Locking down switch ports will prevent accidental

connection, and virtually prevent the deliberate connection of an unautho-

rized device to the switch.

Integrated Wireless Functionality

No discussion of Version 10.3 would be complete without a discussion of

the integrated wireless functionality in the DeltaV system. In the new re-

lease, the 1420 gateway functions as a node on the DeltaV control network

and can be auto-sensed and auto-configured in the DeltaV Explorer. Wire-

less I/O from the 1420 WirelessHART device appears as native I/O in theDeltaV system. HART alerts from WirelessHART devices can also be

passed directly through to the AMS Suite Intelligent Device Manager, eli-

minating the need for an additional Ethernet network.


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Making FOUNDATION Fieldbus Easier to Use

ARC has been saying that suppliers need to do more to make fieldbus easi-

er to use for some time now. Emerson is taking steps to make that happen

with easier FF device commissioning and replacement. The new automated

process eliminates the human-software interaction and essentially enables

“commissioning with a wrench,” eliminating the need to decommission

devices, put them in standby states, and so on. Emerson will also be offer-

ing FF segment downloading, where multiple segments can be downloaded

simultaneously, reducing the time needed for FF segment startup and

shutdown.

Fieldbus devices mounted on OEM skids can greatly reduce plant startup

times. Emerson is striving for faster commissioning of OEM skids with FF

devices by providing users with the option to retain the commissioning

state of FF devices upon import of configuration. New fieldbus multip-lexed function blocks will also be introduced, specifically to deal with

multiport devices. In DeltaV 10.3, Emerson has improved the overall confi-

guration experience for FF devices so only the applicable engineering units

and channel selection are shown.

Ovation

Emerson offers its Ovation expert control system primarily for power gen-

eration and water/wastewater applications. There are currently over 3,000

Ovation systems in operation around the world. In the US, Ovation sys-

tems are installed in hundreds of power generation facilities, with acombined generation capacity of over 300,000 Megawatts, or approximately

40 percent of average US peak demand. In nuclear power, Emerson has a

long-standing agreement with Westinghouse Electric to supply Ovation

controls for Westinghouse plant modernization projects as well as its new

AP-1000 advanced nuclear plant. In water and wastewater applications,

Ovation is utilized for process control and monitoring at major metropoli-

tan systems including New York City, Chicago, Los Angeles, Washington,

San Diego, Seattle, Detroit, Philadelphia, and Pittsburgh.

Ovation is designed to provide a flexible and easy-to-upgrade platform formission-critical control and is based on widely adopted computer industry

standards. It features fully redundant PC-based controllers, an unaltered

Fast Ethernet network, and wide range of standard and specialized I/O

modules. Since its introduction in 1997, Ovation has continuously evolved

to incorporate new technologies and capabilities designed to match the


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unique operational needs of the power generation and water/wastewater

industries.

Ovation incorporates an array of embedded software capabilities required

in power generation control applications, including fully coordinated boi-

ler/turbine control, emissions monitoring and optimization, economicdispatch and fleet management. It also includes native HART, Foundation

fieldbus, Profibus, and DeviceNet connectivity as well as seamless interfac-

ing to wireless field devices. Ovation offers connectivity to a wide range of

third-party I/O, PLCs, and other control devices as well as providing high-

speed interfaces to General Electric, Mitsubishi, and Toshiba turbine con-

trollers. It also includes wide area SCADA capabilities necessary for the

water, wastewater, district heating, and renewable energy applications such

as wind farms, solar fields, and hydroelectric stations.

Recent Ovation Upgrades and Enhancements

Recent upgrades to the Ovation system include the Scenario Virtual Engi-

neer, which combines simulation, virtual technology, and Ovation within a

single desktop computer. Scenario Virtual Engineer provides users with

the necessary tools to easily build, test, verify, and download process

graphics, control logic, and process point databases without affecting plant

operation. The Virtual Engineer consists of a single PC workstation loaded

with complete Ovation engineering, operator, and database server software

as well as the Ovation Developer Studio configuration and simulation tools.

Because this workstation supports virtual controller technology, up to 20Ovation controllers can be virtually duplicated within this one Windows-

based workstation.

Emerson has also integrated the Bristol ControlWave remote terminal unit

(RTU) technology into the Ovation SCADA platform. Traditionally, SCA-

DA systems poll RTUs for information either at specified time intervals or

on demand. With the tight integration of the ControlWave RTU to the Ova-

tion SCADA platform, users now have a configurable polling mechanism.

This allows operators the option of having the RTUs send data directly to

the SCADA server or central Ovation control system only when valueschange. This “report by exception” messaging scheme not only optimizes

bandwidth but also provides real-time alarming of remote sites.

The Ovation Security Center consists of a suite of security packages and

services that have the ability to enhance and manage the cyber security of

Ovation systems without disrupting the controlled process. These security


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products allow operators to detect vulnerabilities in operating systems, con-

figurations, patches, and other system software. It addresses all network

devices, including servers, workstations, laptops, switches, and routers

while helping users comply with the North American Electric Reliability

Corporation (NERC) Critical Infrastructure Protection (CIP) standards.

The Ovation Alarm Analysis tool performs statistical analysis by leveraging

the information stored in the Ovation historian. The alarm analysis tool can

run on any laptop or desktop computer and data can be imported manual-

ly. An excessive volume of alarms can make it difficult for operators to

distinguish between critical events that require intervention, and nuisance

alarms or non-critical alarms. Emerson‟s Alarm Analysis tool examines

alarm data collected by the Ovation historian, providing the information

necessary to minimize unnecessary alarms and allow plant operators to

more effectively address real, high-priority issues and focus on actionableitems.

Ovation System Transitions for Legacy ABB and Siemens Systems

Emerson provides system transition programs for a number of legacy DCS

systems. These allow users to move to a full-function Ovation system with

little plant disruption while retaining significant elements of their current

infrastructure investment. Ovation transitions are available for ABB-Bailey

Symphony/Harmony, INFI 90 and Network 90 systems, as well as Siemens

Teleperm XP systems.

Emerson/Mitsubishi Alliance for Turbine Retrofit Projects

Emerson Process Management and Mitsubishi Power Systems Americas,

Inc. have formed an alliance that combines Emerson's turbine control exper-

tise and Ovation technology with Mitsubishi's experience in gas and steam

turbine design, manufacture, and service. The alliance applies to North and

South American turbine retrofit projects for Siemens-Westinghouse W251,

W501D5, W501D5A, and W501F gas turbines as well as all vintages of Sie-

mens-Westinghouse steam turbines.

Emerson Power & Water Extends Contract with Westinghouse NuclearIn 2007, Westinghouse Electric and Emerson Process Management an-

nounced a 10-year extension to an existing agreement in which Emerson

will provide key technology for automation of nuclear power plants that

utilize the important Westinghouse AP1000 design. The AP1000™ is the

only Generation III+ design for nuclear power plants to have received de-

sign certification from the Nuclear Regulatory Commission. Westinghouse


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will use Emerson‟s Ovation system to control power generation processes,

provide operations and maintenance interface, and collect and distribute

plant-wide information for process and power generation management.

Emerson Develops Comprehensive Migration Program

Emerson has a three-tiered approach to delivering migration solutions thatstarts with its domain expertise and high level consulting capabilities. The

company has considerable domain expertise migrating its installed base of

RS3 and PROVOX systems, and Emerson has made significant investments

in building deep domain expertise in competitor systems. The company

has hired several high-level migration consultants, most with 20-30 years

experience in Bailey Infi 90, Honeywell TDC 2000 and TDC 3000, and other

competitor systems. These high-level consultants work closely with the

customers to develop migration strategies based on unique requirements.

Once the requirements are determined, the transition or migration products

and services come into play. These include a range of solutions designed to

migrate the user‟s system one component level at a time, from the wiring

and I/O to controllers, HMI, and other applications that can be applied in a

flexible fashion and work seamlessly with the legacy system. Emerson ser-

vice people and Emerson Local Business Partners (LBPs) then execute the

project. In many cases, the LBPs act more like systems integrators or engi-

neering firms, bringing a lot of expertise to the table. Emerson augments

this execution capability with long-term system plans, field audits, and a

broad scope of after-sales services.

All of this is done with an eye toward

maximizing the end user‟s existing in-

vestment, reducing overall transition

costs as much as possible, eliminating

downtime during transition, and leverag-

ing the technology available in the

DeltaV system and PlantWeb architec-

ture. This includes Emerson‟s

considerable capabilities in plant assetmanagement (PAM), fieldbus, advanced

control capabilities, and expertise in

batch control.

Emerson has five primary methods of

transition from their own legacy systems

PlantWeb Migration Options Target Every MajorFacet of the Process Automation System


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as well as competitor legacy systems that allow for a flexible migration

path. Each method targets a layer of the system, from the field wiring and

I/O through the controller layer, and finally the workstation, data historian,

and advanced application domains. This allows end users a phased ap-

proach that will preserve the assets that are still functional.

DeltaV Connect resides at the application workstation layer, and allows end

users to add DeltaV workstations to existing control networks of competi-

tors‟ systems. Likewise, DeltaV Operate allows users of Emerson systems

to add DeltaV workstations. These solutions preserve the end user‟s in-

vestment in legacy controllers, I/O, and wiring.

FlexConnect is a method of connecting multi-conductor cables to the exist-

ing termination panels and auto-marshalling the signals to DeltaV I/O.

The existing I/O signals can be controlled and monitored by the DeltaV

system through a pre-engineered marshalling solution. FlexConnect is

available for a wide range of systems, including Emerson‟s own RS3 and

PROVOX systems, as well as systems from ABB, Honeywell, Invensys,

Siemens, and Yokogawa. FlexConnect can reduce downtime by up to 75

percent versus rewiring. Documentation costs are also reduced because the

end user does not have to change loop sheets.

Emerson also offers I/O Bus Interfaces that allow end users to connect di-

rectly to legacy I/O subsystems. These are available for several competitor

systems as well as Emerson PROVOX and RS3 systems. The DeltaV Serial,Virtual Interface Module, Profibus DP, or DeviceNet Interfaces provide the

connection between the DeltaV system and I/O devices. Using these inter-

faces, plant operators have access to the legacy control system data via

DeltaV operator consoles.

Emerson‟s migration program also includes expert platform-specific and

industry-specific consulting services, aimed at helping customers identify

areas where new technologies, such as advanced control and asset man-

agement, can improve operational performance. The purpose of a

consulting engagement is to ensure the objectives of a modernizationproject match the customer‟s business drivers and that the project is finan-

cially justifiable. The consulting engagement includes the early stages of

project planning, providing various migration and conversion options with

associated cost estimates.


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To round off this impressive portfolio, Emerson has enhanced its project

services capability by developing sophisticated conversion utilities for sev-

eral competitors‟ systems as well as continuing to improve utilities for

PROVOX and RS3 systems. Control database, displays, DeltaV Operate,

and DeltaV Connect conversions are made easier, more efficient and accu-

rate. Services based on tools minimize the risk of translation errors and

give customers a high level of confidence that Emerson experts will deliver

a fully functional system modernization project while minimizing project

time, project cost, and disruptions to operations.


In January of 2008, Emerson acquired The Automation Group (TAG). TAG

provides process automation/control system engineering, instrument, and

electrical design, project management services to the refining, petrochemi-

cal, chemical and coal power industries. The company is headquartered inHouston, Texas, and has branches in Corpus Christi, Texas; Bloomington,

Minnesota; Concord, California; and Baton Rouge, Louisiana. TAG sup-

ports all of the leading process automation systems and will continue to do

so. TAG's expertise covers a wide range of process automation technolo-

gies. These include distributed control systems (DCSs), safety shutdown

systems, programmable logic controllers (PLCs), human machine interfaces

(HMIs), supervisory control and data acquisition (SCADA), process analyz-

ers, control networks, control room design and system documentation.

Key Industries

Cement & Glass; Chemical; Chemical Fine; Chemical & Petrochemicals;

Food & Beverage; Lifesciences; Metals; Mining; Oil & Gas; Oil & Gas Pipe-

lines; Oil & Gas Production; Oil & Gas Refining; Pharmaceutical; Power;

Power Generation; Power T & D; Printing & Publishing; Pulp & Paper; Tex-

tiles; Water & Wastewater.


Emerson‟s key strength has always been its leading position in the field de-

vice and control valve market. With the DeltaV systems, it is able tointegrate its strong field offerings with its AMS software and the DeltaV

control system through Foundation Fieldbus to significantly reduce main-

tenance costs and process variability. Emerson has also considerably

strengthened its position in the APC market through the acquisition of

MDC.


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Emerson must continue to penetrate new markets successfully with DeltaV

to maintain its high level of growth. Emerson has also made great strides in

providing a migration path away from legacy systems, such as PROVOX

and RS3, to PlantWeb and DeltaV. In ARC‟s view, Emerson has developed

a strong migration and transition path for both its own systems and many

of its competitors. Emerson‟s focus on migration pro ject services is a key

strength. By tailoring specific service offerings to meet the demands of hot

cutovers, maintenance turnarounds, and particularly the consulting and

FEED stages of projects, Emerson demonstrates capabilities far beyond the

standard products and applications offerings. Engaging in early stages of

projects creates more business opportunities for Emerson and, more impor-

tantly, creates more opportunities for the end user to take advantage of the

business value provided by Emerson‟s offerings.


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GE Fanuc Intelligent Platforms

http://www.gefanuc.com/

DCS Offerings

GE Fanuc Process Solutions

Regions


India

Description

GE Fanuc has combined its long-time expertise in real-time control applica-

tions with its production management and HMI capabilities to produce a

process automation system, which the company has dubbed ProficyProcess Systems. Proficy Process Systems play well against many of GE

Fanuc‟s strengths to produce a cost-effective, standards-based, collaborative

production environment that addresses the requirements of hybrid manu-

facturers. Proficy Process Systems are more than just GE Fanuc‟s answer to

a collaborative production system. GE Fanuc‟s capabilities in areas such as

condition monitoring, advanced process control, environmental monitor-

ing, and even wireless technology all provide promising synergies that the

company is developing to become a true global player in process automa-

tion.

The company‟s name change to GE Fanuc Intelligent Platforms in late 2007 ,

reflects its expanding reach into process and hybrid automation. Tying to-

gether the company‟s business of GE Fanuc Automation, CNC, and

Embedded Systems, the name change is intended to accurately represent to

their customers and the marketplace who they are and what they do.

GE Fanuc Intelligent Platforms launched the Proficy Process System to pro-

vide a fully integrated system that provides customers with improved

quality and reliability; increased throughput, performance, and efficiency;

and reduced total cost of ownership. GE Fanuc‟s Proficy software technol-

ogies empower users with visibility, analytics, and connectivity throughout

their enterprise. The HMI/SCADA and Historian technologies, coupled

with Batch and a complete Production Management suite, allows customers

to finally close the gap between automation and information. All of this

exists within an open communications framework based on industry stan-

http://www.gefanuc.com/http://www.gefanuc.com/


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dards to facilitate the sharing of data throughout a manufacturing organiza-

tion.

PACSystems Provide a Single Platform for Process, Discrete, and Motion

Applications

The foundation for Proficy Process Systems is the single, open control plat-form in the form of PACSystems controllers. These are multi-disciplined

controllers that allow end users to run process, discrete, and motion appli-

cations in the same controller simultaneously. Whether the end user has a

process control application that requires function block programming, or

high speed packaging application that requires ladder logic, both applica-

tions can be run in the controller at the same time.

Being able to use the same controller across an entire plant or facility can

lower the end user‟s total cost of ownership by reducing training time,

maintenance, spare parts, and increasing uptime and availability. PACSys-

tems controllers are VME64-based, and support all standard VME-based

modules, yet operate at four times the bandwidth of standard VME.

PACSystems controllers are available in two configurations – the RX7i and

RX3i. The PACSystems RX3i is an integrated programmable automation

controller (PAC) solution that can address applications in the discrete and

hybrid domains. The PACSystems RX7 offers more power, memory, and

bandwidth to han-

dle mid- to high-endapplications.

Another key feature

that makes PACSys-

tems different is a

common engine

used in both the

RX7i and RX3i,

providing consistent

deterministic con-

trol. Bothcontrollers are ca-

pable of running

process, discrete,

and motion applica-

tions. Programs

created in one can easily be moved to another. The end user can start with

Ethernet

Fieldbus & I/O

Devices and

Instrumentation

PACSystems Controller

Engineering Workstations

Open Fieldbus – Foundation Fieldbus – Profibus

–Hart

– AS-I Interface – Ethernet

I/O – Genius – PACSystems I/O – VersaMax I/O

A p p l i c a t i o n

C o n t r o l l e r

F i e l d b u

s &

I / O

Historian,

Change Management

Operator

Consoles

Proficy Process Systems Architectural View


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an RX3i and, as the system grows and expands, switch to an RX7i without

having to reprogram the system.

Support of Third-Party I/O and Controllers

Proficy Process Systems supports a range of I/O offered by GE Fanuc, in-

cluding PACSystems I/O, VersaMax I/O, and Genius I/O. Because of thesystem‟s strong roots in the HMI marketplace, Proficy Process Systems c an

easily interface to most suppliers‟ I/O and controllers. GE Fanuc has also

been a strong advocate of OPC and has one of the strongest OPC offerings

in the process automation market today.

HMI Environment

The Proficy Process Systems‟ Operator Console provides a user-friendly

environment for process operations and information access. In addition to

state-of-the-art graphical components for process monitoring and control,

the Operator Console also includes alarm monitoring and management

tools for process and system diagnostics and troubleshooting.

Proficy Process Systems offers a choice of visualization technology for host-

ing the Operator Console technology in the form of iFIX or CIMPLICITY.

In 2007, GE Fanuc announced the availability of Proficy HMI iFIX 4.5, pro-

viding monitoring, control and data management for companies

worldwide. This new version of the visualization product addresses a wide

range of customer-identified needs, including advanced reliability to im-

proved ease of use, while adding more power and flexibility.

iFIX 4.5 supports operation on the Microsoft Windows Vista operating sys-

tem. The software automatically adopts the latest operating system look

and feel throughout all of its applications and dialogs. In addition to inte-

gration with its award-winning Proficy Change Management and Microsoft

Windows Vista support, other major enhancements in iFIX 4.5 include dy-

namo versioning, multiple display instances, support for up to 200 clients

connected to one HMI node, and improved OPC functionality and certifica-

tion.

CIMPLICITY is based on open, distributed client/server architecture and

provides plant wide data collection, distribution, and visualization to users

across extended enterprises. The product is scalable and supports both

symmetric multiprocessing architectures and multi-user systems. CIM-

PLICITY clients are Internet-enabled and provide platform independent

visualization to wireless Windows CE-based operator interface devices.


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CIMPLICITY connects to enterprise-level systems to distribute production

requirements to the shop floor and feed back production results.

Global Namespace Allows Points to be Referenced throughout System

One intriguing thing about Proficy Process Systems is the ability to do plant

wide control in a single namespace environment. Process control and PIDfunctionality is available in the same programming and configuration envi-

ronment as discrete and motion control functionality. GE Fanuc‟s approach

of a global namespace, combined with a system that is designed to provide

scalability from very small systems to larger systems in an environment

that is totally network-neutral and offered at a value price point, is a com-

petitive advantage for the company.

Global Namespace provides

real-time data broadcasted from

the controllers and received by

each console, including process

data and process alarms. Proficy

Process Systems alarms, for ex-

ample, are generated directly in

the controller and sent to the

consoles through the Global

Namespace. Because each con-

sole receives the data and alarm

information independently,there is inherent redundancy in

the architecture. When used to

create control logic, the Logic

Developer also generates a

global namespace. Once the point is created in the logic, it becomes part of

the Global Namespace and is available throughout the system, including in

graphics or by the Historian.

Ethernet Global Data Provides Standard Control Network

The Global Namespace, along with Ethernet Global Data (EGD) and Ether-net, provides for common data communications for the system. Ethernet

Global Data is a technology that was developed by GE Energy and GE Fa-

nuc to enable high speed, reliable communications between computer

systems and controllers. Information is broadcasted on the Ethernet and

received by all interested recipients. EGD server can be local to the Engi-

neering Workstation, or it can be in a remote machine. This “configure

Historian

Global

Namespace

Global Namespace Provides Real-Time Data Broadcasted

from the Controllers & Received by Each Console, IncludingProcess Data & Process Alarms


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once” aspect of the Proficy Process System greatly simplifies creating, main-

taining, and operating the system and GE Fanuc claims it can cut

development times by as much as 40 percent over traditional systems.

Continuous Control Programming via Function Block Diagramming

Within the Engineering Workstation, the Process System Logic Developer isused to configure control strategies. It provides a flexible choice of lan-

guages for programming the controllers. In addition to Function Block

Diagrams, the Logic Developer also supports IEC languages such as struc-

tured text (ST) and standard ladder logic for high-speed discrete

applications like packaging. End users can create and define their own

function blocks using structured text, ladder logic, or function blocks. This

allows users to take specific knowledge and embed it as a reusable compo-

nent in the system. This feature is particularly valuable to integrators and

OEMs because it allows them to lock their intellectual property in functionblocks that their customers can easily use. Proficy Process Systems also

provides an Advanced PID block, which consists of both feedback control

and feedforward control. It supports adaptive tuning in which users can

change the setpoint into the PID.

Historian

Proficy Process Systems offers a scalable historian that grows with the sys-

tem. The historian is designed specifically for handling process data and

provides high performance storage and retrieval with sub-second collection

and millisecond time stamp-ing through the Global

Namespace. The historian

has the ability to handle

20,000 events per second for

both read and write. An

EGD OPC Server feeds data

into the historian through the

Historian OPC Collector.

The historian offers functions

such as trending and a Mi-

crosoft Excel add-in that

allows users to easily extract historical data to an Excel spreadsheet for de-

tailed analysis.

Control Memory Exchange Allows Data in One Controller to

be Exchanged & Shared with Another Controller at HighSpeeds


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Control Memory Exchange

Proficy Process Systems features Control Memory Exchange, a technology

that GE Fanuc incorporated from its Embedded Systems business. Through

high-speed fiber optics, Control Memory Exchange allows data in one con-

troller to be exchanged and shared with another controller at a rate of over

two gigabaud. Essentially, it provides “Shared Memory on a Wire” for tru-

ly distributed control. This allows end users to synchronize controllers for

distributed control, or reflect the memory state of one controller to another

for redundant operations.

This provides the end user with several key benefits. It allows the end user

to move large amounts of data in one command, in real time, and to coor-

dinate control between processors. It also provides users with the freedom

to design distributed control systems that are easier to build and maintain.

No message protocol is required, allowing the user to simply write or readdata between controllers. Control Memory Exchange is also a good solu-

tion for applications that require redundant controllers. Users can reflect

the entire data state from one controller to another, also known as Reflec-

tive Memory Exchange. Should a problem arise in the primary controller,

the secondary controller can instantly take over with the full and current

state of the process.

Target Industries

GE Fanuc Intelligent Platforms is specifically targeting a range of industries

for Proficy Process Systems. Aside from the pharmaceutical, food & beve-rage, and consumer products industries, GE Fanuc is also targeting sectors

such as ethanol, power, water & wastewater, and oil & gas. In ARC‟s view,

these sectors play best against GE Fanuc‟s strengths in batch and h ybrid

control. GE Fanuc also has considerable expertise in specific applications,

including blending, fermentation, and LNG regasification.

GE Fanuc Intelligent Platforms took advantage of many of GE‟s recent ac-

quisitions to develop Proficy Process Systems. This includes an optional

advanced multivariable control capability from GE Energy (via the Conti-

nental Controls advanced process control software acquisition). GE Fanuc jointly developed the Global Namespace, which is core to the Proficy

Process System, with the Turbine Control group. Some of the key visuali-

zation (iFIX) and batch (Proficy Batch ) technology derives from the

Intellution acquisition, while elements of the Production Manage-

ment/MES (Historian, Plant Applications) technology come from the

Mountain Systems acquisition.


28/83



Proficy Process Systems is available now, and GE Fanuc is going to contin-

ue to drive functionality into regular new releases of the platform. The

company is currently working on the 1.5 version release of the Proficy

Process Systems product, which is due in Q2. This will add the capabilities

for dynamic modifications to the EGD Global Namespace, update the sys-

tem for iFIX 4.5, and provide Batch 5.1 on the installation DVD.


GE Fanuc Intelligent Platforms recently acquired the assets of the MTL

Open Systems Technology (MOST) product lines, including the MTL8000

general purpose I/O, intrinsically safe I/O, SafetyNet system, and process

control technologies. With the addition of a line of redundant-capable,

SIL2-certified controllers and intrinsically safe I/O to its Process Solutions,

GE Fanuc is now able to fully address the safety system needs of key

process industries including oil & gas, chemical & petrochemical, water &wastewater, natural gas, and pulp & paper. Allowing the I/O to be

mounted directly in Division 2/Zone 2 or Division 2/Zone 1 hazardous

areas provides a cost-effective intrinsic safety solution.

The MTL8000 I/O and its proven technologies are deployed around the

world by process system OEMs, system integrators, and end users to solve

their most demanding process control applications. It is built to withstand

the extremes of temperature and vibration, as well as the hazardous and

corrosive gases, that rule out the use of conventional I/O in unfriendly en-

vironments. Included in this product line is a comprehensive solution for

safety-related applications, including: process shut down (PSD), emergency

shut down (ESD) systems, and burner management systems (BMS). It is a

SIL2 safety system in compliance with IEC 61508, and is built on the same

platform that is already widely used in process control applications.

This is an excellent fit for GE Fanuc, which will now have a full line of SIL

2- compliant and intrinsically safe open control platform products. MOST

offers a totally open control environment that can address SIL 2 and intrin-

sically safe requirements. They have a good installed base in the same

process industry segments that GE Fanuc is targeting with its Proficy

Process Systems offering. These include the oil & gas and water & waste-

water industries.

MOST has had a lot of success in applications where a pure PLC platform

provides too little functionality and a full-blown DCS too much (a space

that GE Fanuc fully addresses with its PAC Systems). The MOST offering


29/83



essentially provides a blank slate to which GE Fanuc can apply its own ap-

plication expertise and further develop GE Fanuc‟s adherence to ARC‟s

Collaborative Production Systems (CPS) model.

Key IndustriesCement & Glass; Chemical; Chemical Fine; Chemical & Petrochemicals;

CPG; Food & Beverage; Life Sciences; Metals; Mining; Oil & Gas Pipelines,

Production, and Refining; Pharmaceutical; Power; Power Generation; Pulp

& Paper; Water & Wastewater


In ARC‟s view, GE Fanuc is in a good position to take advantage of the

many opportunities that the process automation marketplace now offers.

Of course, the company has a long road ahead in a market that is already

saturated with players both big and small, but GE Fanuc‟s‟ capability forplant wide control, combined with a value price point and network-neutral

stance, should appeal to many process manufacturers.

GE Fanuc may be a new entrant into the marketplace for process automa-

tion systems, but it already has a strong presence in several markets that

serve the process industries that will give it an advantage when it comes to

getting new business and expanding its footprint at existing customer in-

stallations. Intellution has a huge installed base among the process and

hybrid industries, as do the company‟s batch solutions and PLCs. GE Fa-

nuc also has the advantage of being free to pursue these opportunities

without having to migrate an existing base of process automation system

customers.

ARC has said for some time that the hybrid industries in particular are ripe

for innovation and change. A key enabler for this is the adoption of a Col-

laborative Production System framework where all types of control from

continuous process to batch, discrete, and motion control can exist in and

be configured through a single, open environment. More importantly,

these domains of control must also exist in an environment that has stan-dards-based and transparent access to data from the operations

management domain. Building an open control platform is one thing, but

placing it in context with an open and collaborative environment for opera-

tions management is where the real power is. It provides a totally open

window into the entire manufacturing enterprise that lays the groundwork

for real optimization of manufacturing processes.


30/83



What‟s interesting about GE Fanuc‟s approach, however, is the company‟s

acceptance of the fact that we live in an open world. Through their back-

ground in providing solutions that often coexist with other suppliers ‟

hardware and applications, GE Fanuc has a lot of expertise that it can leve-

rage to provide an open and neutral environment.

GE Fanuc‟s level of openness also plays well with its OEM and system inte-

grator partners. Most automation suppliers today are focused on building

their own service capabilities, but GE Fanuc has a lot of strength it can draw

from through its existing network of partners. The company will have to be

careful to take the right approach developing its own internal service capa-

bilities while cultivating relationships with partners.

Despite these advantages, the company realizes that it has a long road

ahead and its work is just beginning. There is already a lot of competition

in the process automation marketplace and GE Fanuc is not the only new

entrant into this market. The company will really have to play to its

strengths and not try to cast itself in the mold of the traditional large DCS

suppliers. The key industries that GE Fanuc is targeting are those that are

typically underserved by adopting a combination of PLC and HMI technol-

ogies, but for whom the functionality of a full-scale DCS that would

normally be used in the refining or petrochemical industries might be over-

kill. Offering these industries the specific functionality they require, along

with a CPS-based approach to batch and operations management, should

serve the company very well.

GE Fanuc must also continue to drive synergies with the other businesses

in GE Infrastructure and Industrial to expand functionality of Proficy

Process Systems. Many possibilities exist with the Bently Nevada, Conti-

nental Controls, and other GE businesses that have a hand in automation

and production management


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Honeywell Process Solutions

http://hpsweb.honeywell.com

DCS Offerings

Experion Process Knowledge System (PKS); TPS; PlantScape; TDC3000

Regions


India

Description

Honeywell has the largest contiguous installed base of any single process

automation system, with the TDC2000, TDC3000, TPS, and Experion PKS

systems. The system is contiguous because Honeywell has taken an evolu-

tionary approach since the inception of the DCS in 1974, with incremental

changes over time that have kept the system up to date with current tech-

nology trends.

Honeywell‟s latest evolution in its system platform is Experion PKS, first

introduced in 2002. The goal of Experion is to provide Honeywell custom-

ers with single, scalable open system architecture while preserving their

investment in their

installed base of

TDC, TPS, Alcont,PlantScape, and

other Honeywell

control systems.

PKS is a significant

evolutionary step

for several reasons.

From an application

perspective, Expe-

rion leverages

Honeywell‟s

strengths in numer-

ous areas such as

collaborative pro-

duction

management

(CPM), advancedEx erion PKS Architecture

http://hpsweb.honeywell.com/http://hpsweb.honeywell.com/


32/83



control and optimization, and vertical industry solutions capabilities. This

evolution extends into integrated solutions for capturing and automating

the knowledge from a transitioning workforce, delivering on their com-

mitment to improving plant safety and efficiency.

Experion PKS was the first system from Honeywell to embed domain ex-pertise and related functionality from its advanced control and

optimization business in a significant way. It also was the first platform

from Honeywell to rely on an industrial Ethernet-based network with Fault

Tolerant Ethernet (FTE), and was the first to incorporate a unified approach

to fieldbus and bundled plant asset management (PAM) applications with

the inclusion of Asset Manager. The system also took a unified approach to

safety with the Safety Manager platform, which Honeywell claims is the

first safety instrumented system (SIS) to earn certification from TUV Rhi-

neland for Safety Integrity Level (SIL) 3 applications (IEC 61508 and 61511standards). Honeywell provides integrated MES solutions with POMSnet

production management functionality for the pharmaceutical industries,

Business FLEX® production management applications for the process in-

dustries, and OptiVision for the pulp & paper industry.

With the new Series C I/O and controller, Experion release R300 took con-

trol hardware one step further into the future, while also protecting

customers‟ current installed investments. For some time, ARC has been

saying that it is becoming increasingly difficult for suppliers to add value to

their control hardware. The influx of commercial off the shelf (COTS) com-ponents has drastically reduced the price of proprietary control hardware,

which at the base level, is usually little more than standard commercial

components packaged in a configuration that is acceptable for hazardous

industrial environments.

Honeywell, however, has taken a unique approach to the philosophy of

control hardware with a new design that rethinks the role of hardware and

its future in the plant. Series C incorporates a vertically designed cabinet

architecture. Instead of racks of controllers and I/O mounted horizontally

one immediately next to the other, each Series C module sits on its ownmodular and removable terminal, with modules mounted vertically on top

of one another in an angled fashion, allowing for convection air currents

between modules. The new design actually allows for a smaller footprint,

and better thermal management. This eliminates the need for a common

backplane, thus also eliminating the corresponding single point of failure.


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Honeywell extends the capacity of the control system to improve plant effi-

ciency with its second-generation wireless solution, OneWireless. The

OneWireless network is a universal and multi-functional mesh network

that supports multiple wireless-enabled applications simultaneously to op-

timize plant efficiency, improve safety and reliability, and help ensure

regulatory compliance. The breakthrough value of the solution lies in the

ability to integrate valuable data into existing control systems and ad-

vanced applications, while also sharing that data with other networked

applications.

Experion PKS Release 310

The newest version of Experion PKS is version R310. Key enhancements

include integration of Honeywell‟s Safety Manager safety system pla tform,

a new option that allows users to “shelve” non critical alarms (a develop-

ment related to Honeywell‟s involvement in the Abnormal SituationManagement Consortium), a set of power and turbine control function

blocks, and the new Batch Manager that drives batch control directly into

the controller.

The new Peer Control Data Interface (PCDI) provides a direct interface to

Modbus TCP control devices, such as RTUs, which are accessed through

the Tofino firewall. Honeywell has an agreement with MTL to sell the To-

fino in addition to its own Experion PKS Control Firewall. Other new

features include Series C Digital Input Sequence of Events (DISOE) and in-

tegration with Rockwell Automation PowerFlex drives. To expand on itsintegrated safety capabilities with Experion PKS and Safety Manager, Ho-

neywell is also offering integrated fire and gas detection capabilities. By

2010, Honeywell expects to have incorporated Windows Vista and Win-

dows 2008 Server capabilities. Class-based recipes for Batch Manager.

Series C Profibus will also be supported.

There is also a lot more activity around Honeywell‟s migration solutions.

Honeywell has always provided its end users with a consistent migration

path for its own control systems. Honeywell has no end-of-life date for ei-

ther the TDC platform or the C200 controllers, and is even enhancing theC200 offering. Honeywell has now turned its attention to many of its com-

petitors, offering a growing set of migration solutions, from panel-boards

that can interface directly from competitor‟s I/O to Honeywell controllers,

to things like automated graphics conversion tools and a full set of services.

Honeywell is taking a risk-mitigation approach to migration that empha-


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sizes reduced downtime and, when possible, hot cutover with zero down-

time.

Honeywell Controllers Achieve MUSIC Certification

Honeywell announced that its Experion Process Knowledge System (PKS)

C300 Process Controller has achieved the new Mu Security Industrial Con-trol Certification (MUSIC). The MUSIC certification is designed specifically

for IP-based controllers and is closely aligned with the emerging ISA-SP99

security standards. It enables organizations that rely on critical infrastruc-

ture or process control to ensure their network equipment and applications

meet industry-defined benchmarks for safety, robustness, resiliency, and

conformance. Mu Security utilized its Mu-4000 security analyzer to test the

C300 controllers with about 60,000 communication variations in an attempt

to crash the system.

Honeywell Expands Batch Capabilities

Honeywell‟s Experion batch control solution has three major components:

Experion Batch Manager, Procedure Analyst, and POMSnet. Batch Manag-

er resides in a controller to provide more security and speed of execution

than a conventional batch control package, where it may reside in a

workstation or server. Batch Manager includes a Recipe Control Module

(RCM), a Unit Control Module (UCM), and a Phase Function Block. The

RCM stores formula variables in phases and retrieves batch record values

during phase execution. The UCM represents plant equipment. It executes

phases and can manage simple queues in RCMs. The Phase Function Blockinitiates Phase (Sequential Control Module (SCM)) execution and sends and

receives recipe and report values to and from the Phase. Batch applications

that require high availability or have short cycle times are ideal candidates

for Batch Manager.

Procedure Analyst provides integrated batch information, including batch

and continuous control history, alarm and event history, query, trends, and

reports. It can interface directly with Batch Manager in a controller display-

ing information on running or completed batches. POMSnet provides the

higher level production management and MES functionality, such as recipe,procedures, and electronic batch record documents control; and integration

of HMIs, unit graphics, and instructions.

Honeywell calls this combination of integrated batch control application

working in the Experion environment their Manufacturing Control System

(MCS). It integrates MES and process control that leverages ISA-88 stan-


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dards to provide a single environment for manufacturing operations and

automation with seamless transactions between systems and personnel.


Honeywell acquired Tridium in 2005. Tridium‟s Niagara Framework

is anopen software platform that integrates diverse systems and devices from

different manufacturers, regardless of communication protocol. It is easily

managed and controlled in real time using a standard web browser inter-

face. Current applications include energy management, building

automation, telecommunications, security, lighting control, maintenance,

and total facilities management. Tridium‟s Niagara Framework is the basis

of Honeywell„s ComfortPoint control system, and Honeywell‟s acqu

Documents

DCS Worldwide Profiles 09