EcoStruxure Hybrid DCS

Meeting the demands of
modern day production

EcoStruxure Hybrid DCS
schneider-electric.com
Contents
> Introduction
> Multi-engineering environment
> System operation
> Hybrid DCS libraries
Introducing
EcoStruxure Hybrid DCS
Introduction Engineering System Hybrid DCS

environment operation libraries
Life is On | Schneider Electric
Introduction
Design, engineer, and maintain your plant with a single system
EcoStruxure Hybrid DCS is a single automation system

EcoStruxure™ Architecture
to engineer, operate, and maintain your entire plant. The
system enables users to achieve operational profitability Apps,
from design engineering to meeting the demands Analytics &
Services
End-to-end Cybersecurity
Cloud and/or On Premise

of modern day production.
Positioned at the Edge Control layer of EcoStruxure Plant, it is

the next-generation process automation system for a digitized Edge
Control
and energy-aware plant. EcoStruxure
Hybrid DCS
The industry-leading EcoStruxure architecture is based on a

three-tiered technology stack, bringing energy, automation, Connected
and software together. The stack comprises connected Products
products, edge control, apps, analytics, and services.
EcoStruxure Hybrid DCS is positioned at the Edge Control

layer of the EcoStruxure Plant Architecture.

Maximize your operational profitability
Interconnect and manage automation architecture

This single automation system combines the management
of fieldbuses, instrumentation, intelligent devices,
control neworks, controllers, operator stations,
engineering stations, and alarm management, in a
common, single database.
EcoStruxure Hybrid DCS is an essential component of

EcoStruxure Plant, interconnecting and managing all
components of the automation architecture so plants
can maximize their operational profitability. EcoStruxure
Hybrid DCS safely supports standard fieldbuses,
instrumentation, and best-in-class, intelligent, connected
devices. At the heart of the system is a scalable and
powerful automation platform.

Tangible value to your bottom line

100% measurable* ROI within three months
EcoStruxure Hybrid DCS is the downtime to almost zero. Possible Business Results
only distributed control system Downtime costs the average
for hybrid industries that can plant 5% of production,** so let’s Efficiency Profitability
improvement improvement
measurably pay for itself within conservatively assume increased
three months of implementation. maintenance maturity can reduce Reduce
time-to-market $2.4 M
this to 2% unplanned downtime.
Reduce project execution time by 25%
For a plant running 40 hours per Reduce
Industrial production costs are
week, 50 weeks per year at a unplanned
$1.2 M
on average $20,000/hr, so a 25% downtime
cost of $20,000/hr, this increases
reduction in time-to-market on to 2%
profit by $1.2M per year. In Increase
a 3-month project would be
addition, maintenance staff operational $1.3 M
3 weeks (i.e., 3x40hrs) = $2.4M in visibility
could waste less time performing
extra production.
needless maintenance tasks, Reduce
Improve profitable reliability which could save the average energy use $1.8M
by 30 %
Moving from reactive to prescriptive plant up to $800K per year in
maintenance can reduce unplanned maintenance costs.*** *patent protected, **Statements by ARC,
***Data from Alinean

Improve operational profitability
Improve process visibility

Accessing data and turning it into actionable business
intelligence delivers enhanced process visibility, which
can result in 0.5 to 3% of revenue improvement a year
and 3 to 10% of potential margin impact. This can result
in over $1.3M of annual bottom-line impact.***
Improve energy utilization

Large water treatment plants or industrial facilities, for
example can use up to 1.2 M kWH of electricity per
year.**** At an energy cost of 5-cents per kWh, this is
$6.02 M per year. Improving process energy use can
yield savings of up to 30%, which translates to $1.8M
in annual cost savings.
***Data from Alinean **** Water Research Foundation report sec 4.1

Multi-engineering
environment

Improving efficiency, accelerating

startup, and reducing risk
Single database A productive engineering approach

EcoStruxure Hybrid DCS global database stores all EcoStruxure Hybrid DCS provides common
the configurations for the entire system. This single services like configuration, deployment, diagnostics,
database enables active services to share information communication, security, connectivity, user collabo-
across all automation system components as well as ration, and data sharing. These services enable
share real-time engineering data with all the users. you to build a single, unified model that
This centralized repository for the whole system makes logically represents your process, and a plant
maintenance easier. Infrastructure that represents the actual equipment.
This makes design and maintenance of the system
Configure-once philosophy
more efficient, more flexible, and less risky.
A single entry point for all configuration enables faster
The model also gives essential context to
system design and fewer errors. Asset information
your data, greatly assisting with diagnostics and
data is introduced only once and the design of system
troubleshooting. It also provides valuable system
follows the Control Instrumentation Diagram, making
documentation throughout the system lifecycle.
controls design, installation, and commissioning easier.

A single consistent representation

of your plant
Object model approach — The foundation of EcoStruxure Which industries can benefit
from the EcoStruxure Hybrid
Hybrid DCS is the Plant Model: the logical representation DCS platform?
of the physical equipment and processes being controlled,
supervised, managed within EcoStruxure Hybrid DCS. This • Mining, minerals, and metals
provides a single, consistent definition of your infrastructure • Water and wastewater
or plant, organized as reusable templates. The model enables
• Food and beverage
you to view your operations from multiple perspectives, including
of the equipment: control logic, graphical representation, • Chemical and specialty chemical
data acquisition, alarms, trends, documentation, system
• Power generation
security, access control, and external interfaces. Through
this hierarchical, object-based model, you can view, detect
and define abstract visulizations of real-world systems, their
relationships, and physical locations.

Flexible engineering
EcoStruxure Hybrid DCS is adaptable to different server architecture that can be adapted to the
business needs at every stage of the plant lifecycle. size and needs of the plant. EcoStruxure Hybrid
Thanks to its object-oriented model, application DCS enables concurrent engineering in the same
object templates that encapsulate and integrate system/application with consistency management.
all aspects of an automation object can be used The transparent check-in/check-out mechanism
unlimited times to reduce engineering and improve optimizes engineering design, and shares, in real
maintenance, without losing quality. This reduces time, all the work performed across the different
time and risk throughout the lifetime of your system. engineering workstations. This means there’s
no need to split the project in several pieces
Concurrent Engineering
and enforce a reconciliation which could lead to
Multiple design teams can work in parallel during
inefficiencies and loss of information.
the engineering phase, which reduces design time
and cost dramatically. EcoStruxure Hybrid DCS
engineering system is a scalable and flexible client/

Comprehensive change tracking,

embedded simulation
Change Management Saves you time and cost

EcoStruxure Hybrid DCS provides out-of-the-box EcoStruxure Hybrid DCS engineering benefits
engineering traceability and revision control by you in several ways:
recording any system configuration changes. This
• Centralized hardware and software configuration
feature helps to support the verification of changes to
is uniform throughout the platform, and the
comply with the requirements of regulated industries.
engineering system includes integrated field
Simulation device configuration
EcoStruxure Hybrid DCS provides embedded • A single, global database and configure-once
simulation capabilities that allow simulation of philosophy eliminates redundant entries and makes
the entire system at any time via any engineering data entered available throughout the system
workstation. This greatly reduces errors during
• Pre-configured, tested and validated object template
the design phase. It reduces time to market and
libraries simplify asset configuration
engineering costs while increasing the quality of
the final control system. • Reusing existing object templates simplifies
duplication of equipment

System operation

Get a complete picture of your

production process engineering
The ability to provide operators with clear process information
is crucial to driving production efficiency. EcoStruxure Hybrid
DCS provides a consistent control and operational interface
Historical data
with a real-time view of your process. The system delivers ng
ki
operators all the services and data they need to make timely Tr
ac
Operator logs
and accurate decisions.
Alarm views
Trending views
g
rin Faceplates associated with
to
o ni objects monitor the process
M
Simple efficient navigation
Predetermined environment
to monitor process

Improve navigation and monitoring
A predefined environment simplifies navigation

The menus and contextual sub-menus and banners
enable the operator to access the data easily.
Easily monitor the process

The Faceplate is how operators interact with assets.
Each Faceplate is embedded with:
• A user interface for an operator to monitor the assets

• Visibility into which missing interlocks are causing
problems
• Status and information about the assets
• Parameters associated with the assets (e.g. PID)
It is possible to open several Faceplates in parallel.

Information at your fingertips
Advanced diagnostics with Runtime Navigation Services (RTNS)

With EcoStruxure Hybrid DCS, the right person gets the right
information at the right time. Problems can be diagnosed and
solved faster. You can access any data in real time for any
asset or equipment in your system. This includes the control
device running in the controllers, all documentation, event
historian, asset management, and internet links.
The RTNS is a native service provided by EcoStruxure Hybrid

DCS Objects during runtime. These powerful diagnostic
services allow the user to access different points of view for
each asset, including monitoring control logic, documentation,
topological localization, alarms and trends. This innovative
service reduces commissioning time, as well as downtime, by
quickly identifying the root cause of any issues.

Trending views
Trends seamlessly combine real-time and historical data.

When users view a trend page, they can monitor the current
activity as it happens, and simply scroll back through time
to view the trend history. The distributed trending system
handles large amounts of asset data without compromising
performance or data integrity. Operators can choose from a
selection of pre-configured trend pages that provide clear
data representation, with customizable views for quick and
simple trend analysis.

Fast access to data reduces downtime
Alarm views Operator logs

An efficient alarm tool allows users to quickly The operator log enables a plant manager to track
identify faults within the system or process and take all the commands performed by an operator.
corrective action, thereby reducing plant downtime.
The following information is logged:
The EcoStruxure Hybrid DCS alarm system is fast > Change of process values
and reliable, providing you with detailed information > Bypass of interlock conditions
about the status of your plant. Alarms are displayed > User activities, like:
on dedicated alarm pages, with the most recent • Manual reset following a failure
alarms visible at all times in the alarm banner
• Consignment of a device; device simulation
on every page. Working in conjunction with the
• Change of command mode, Operator-to-
controller, alarms are time-stamped and accurate to
Program mode, or reverse
a millisecond. Alarms can be filtered according to
the application view, enabling the operator to easily
zoom into a sub-part of the application.

EcoStruxure Hybrid
DCS libraries

The building blocks for your control system

Integral library of tested, validated, and documented reusable objects jump-starts app development.
The components of the objects within the library are the

connection, control, and visualization facets, but these are
extended to also include historian reporting and other facets
of the DCS.
Weight
The DCS libraries are a set of lightweight blocks that are
constructed to meet the needs of the market, providing
best in class functionality with minimum code. They
can be customized for the site or individual device. The
options selected are readily visible in the code (no hidden
parameters). The result is a lighter program (needs fewer
controllers) and a clearer program that is easier to debug
in the field.

Expert support, easy customization
Support Customization
Schneider Electric EcoStruxure Hybrid DCS There is no perfect library for every customer. The
libraries are tested, validated and documented, DCS libraries are extensible between objects but
specifically designed to reduce engineering costs can also be customized within the blocks. This is
and time to market. These libraries allow engineers done by allowing the objects to be copied and
to focus on the process rather than control changed. The customized objects can still use
configuration. They are embedded with our offers many of the functionalities of the library blocks
but also used by our testing, delivery and support and are supported as stand-alone code objects
teams, who can demonstrate that they work well in each facet. Customization is expected. The
in actual situations. With this testing we can offer libraries should offer a platform on which this final
support for each block within the libraries. A team customized automation system can be delivered
is dedicated to their ongoing development and in the fastest possible time.
support. Most library components are open and
can be viewed as DFBs within the controller and
can be simply diagnosed by the engineers within
the project.

Integrating smart connected products and

software applications through libraries
Apps
Historian, Batch,
Management Plant Energy
Asset Management
Optimization Sequence, PID APC / Site Specific Plant Intelligence

Edge control
Equipment Flow Control/Duty/Standby Vertical Process Templates Load Shedding
Control Indicators, Motors, Valves Vertical Specific Devices Motor Control

Products
Network Ethernet MP, Modbus (TCP/Serial), 61850, Profibus, HART
Access Motors, Starters, Drives, Weighing Breakers, Meters, Filters
General Purpose Library
Edge Connected Software/Apps Vertical Library + Power Control +

Control Products Integration Custom Site Code Energy Management

Connecting devices
Libraries enable the integration of Schneider Electric and third party devices via different open
protocols, making their data available through the DCS control system.
Supported industrial networks to make key data available within Schneider Electric power
• Ethernet I/P the control system. For third party management
• Modbus (TCP and serial) devices, the interface is open for • Circuit Breakers (Masterpact
• Profibus integration partners to leverage & Compact)
• HART the interfaces and expose data • Protection Relays
from other devices. (SEPAM 20, 40, 80)
Using these networks, the
libraries are able to provide Schneider Electric motor • Power Meters (PM 9C ,700,
data from the available automation and drive management 800, 1200, 53xx, 82xx)
and electrical assets. Connecting • Motor Starters • Smart UPS (AP 9622)
the rich set of parameters and (TesysU & TesysT) • Harmonic Filter (Acusine)
readings available within your • Progressive Starters
Motor Control Center. For Schneider (Altistart 22, 48)
Electric devices, complete • Variable Speed Drives (Altivar
automation blocks are provided 31, 312, 12, 212, 32, 61, 71, 600,
900, 1200, 6xxx, 9xxx).

Library components
The core library is designed to provide the components you need for the core of
your automation process:
Analog Devices Process Templates

• Analog Input (direct, processed or multiple) • Flow Control
• Analog Output (actuators, control valves, • Pump Set Management
motorized valves, pulse width)
Automation Infrastructure
• Analog Control (PID, ramp, split range, ratio, • Sequence Management (ISA88 - sequencing)
ramp, lead-lag, 3-step)
• Process Management (ISA — equipment module
Digital Devices • Batch Integration (InBatch phase management)
• Digital Inputs (limits or other discrete sensors)
This functionality extends beyond the classical
• Motors (direct, dual direction, dual speed,
automation layer to integrate Smart Connected
variable speed)
Products and Software applications through the
• Valves (fail open, fail close, fail) libraries within Edge Control. This brings the IIoT
from concept to reality within your control system.

Specific libraries to suit your industry
To enable EcoStruxure Hybrid DCS to develop specialized

“Thanks to EcoStruxure Hybrid DCS and
applications, Schneider Electric has a wide range of libraries
its seamless integration with Schneider’s
for various industries. These include applications devoted to a electrical devices, including power meters,
specific industry, such as mining, cement, or water treatment; Premier now has energy metering at almost
or to a specific function, such as power management, energy every level of the plant, from an overall plant
management, and advanced process control. The libraries level right down to the device level.”
also help model specific equipment for the industries, such
Durban Bakery, Premier FMCG
as penstock for water, and provide templates for specific
processes, such as grinding or flotation for mining.

Industry-specific libraries
Water Library Mining Library Cement Library

> Process Templates > Process Templates > Process Templates
• Aeration • Ore Volume Control • Kiln Management
• Dual Media Filter (Belt Conveyor) • Gas Analysis
• Wet Grinding Mill • Fuel Selection
> Control Equipment
• Spiral Separation • Gear Lubrication
• Penstock
• Rotary Cyclone Separation
• Flow Measurement (Flume) > Control Modules
• Thickener
• Flow Measurement (Weir) • The Cement library uses a
• Rotary Dryer
dedicated control library
> Scheduling
> Control Equipment which provides functionality
• Time & Event Scheduler
• Belt Conveyor similar to the general purpose
library for automation.
> Scheduling
• Time & Event Scheduler

Software integration
As part of the Schneider Electric suite of automation, EcoStruxure

“The integration between EcoStruxure Control
Hybrid DCS enables access to the most comprehensive set of Expert and the supervision system is very
software offerings on the market. These offers start with historians impressive. It is simple to add new hardware.”
and batching systems but extend to asset management,

John Mackenzie, Senior Research
planning, supply chain, simulation, training, and other offers. Associate, Hazer Group
Ecostruxure Hybrid DCS and its libraries deliver all the data
and interfaces necessary to integrate seamslessly with typical
industrial software applications like:
• Wonderware Historian
• Wonderware inBatch
• Plant Asset Management

To learn more about how EcoStruxure Hybrid DCS can help you meet the demands of modern day
production, contact your local Schneider Electric representative or visit
schneider-electric.com
Schneider Electric
89 Boulevard Franklin Roosevelt 92500

Rueil Malmaison France
Phone: +33(0)1 41 29 70 00
998-20212775_GMA-US_A

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Meeting the demands of

modern day production

Introduction Engineering System Hybrid DCS