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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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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
North America; Europe, Middle East & Africa; Asia; China; Latin America;
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.
Partnerships and Acquisitions
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.
Strengths and Challenges
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
North America; Europe, Middle East & Africa; Asia; China; Latin America;
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.
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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.
Partnerships and Acquisitions
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
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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
Strengths and Challenges
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.
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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
North America; Europe, Middle East & Africa; Asia; China; Latin America;
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/
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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.
Partnerships and Acquisitions
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